Crusader 5.0L MPI / 5.7L MPI / 6.0L MPI / 8.1L MPI / 8.1L MPI (HO) engines Owner's Operation and Maintenance Manual

OWNER’S OPERATION and MAINTENANCE MANUAL A Division of

Welcome to the growing family of Crusader Marine Engines owners. We are delighted you have chosen Crusader power for your boat and wish you many years of enjoyment. When you chose Crusader, you selected the utmost in premium power for your boating application. Crusader is the world’s largest manufacturer of gasoline marine inboards, and the clear-cut leader in cutting edge technology. Over the years, Pleasurecraft Engine Group, through Crusader and PCM, has introduced many breakthrough innovations that quickly became industry standards. The pyramidal exhaust system, light-weight transmissions, computerized engine control, micro adjustable all stainless steel mounts, and the Fuel Control Cell (FCC) are all Pleasurecraft innovations. No matter which Crusader model you purchased, you can be sure it is equipped with the latest in modern technology for added performance and durability. READ THIS MANUAL THOROUGHLY Before starting your engine(s), READ THIS MANUAL CAREFULLY AND COMPLETELY. If you do not understand any portion of the manual, contact your Dealer for clarification or assistance. Ask your Dealer for a demonstration of actual starting and operating procedures. The descriptions and specifications contained in this manual were in effect at the time of printing. Crusader Marine Engines’ policy of continued improvement reserves the right to change specifications or design without notice and without obligation. This manual will cover the following year of manufacture Crusader engines: Year Model 2009 5.0L MPI 2009 5.7L MPI 2009 6.0L MPI 2009 8.1L MPI 2009 8.1L MPI (HO) Part Number - L510001-09 Printed 12/08

Part Number - L510001-09 Printed 12/08 WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. PROPOSITION 65

1 L510001-09 SERVICE AND WARRANTY .................................................................................................... 4-19 Safety Information ...................................................................................................................... 4 Replacement Parts ........................................................................................................................... 4 Safety Warnings ......................................................................................................................... 4 Crusader Marine Engines’ Commitment to You ................................................................................. 5 Owner Warranty Registration (Warranty Registration Card is located at the back of this manual) ................ 5 Engine Operation and Care .......................................................................................................... 6 Maintenance Records ................................................................................................................. 6 Local Repair Service ................................................................................................................... 6 Service Away From Home ............................................................................................................ 6 Replacement Parts Inquiries ......................................................................................................... 7 Replacement Service Parts .......................................................................................................... 7 Applicable Limited Warranty ......................................................................................................... 7 Crusader Marine Engines Two-Year Limited Warranty (For Engines Sold and Used in the United States and Canada) ........................................................... 8 Items Not Covered Under the Limited Warranty ............................................................................... 10 Things You Should Know About The Warranty ................................................................................ 11 California Emission Control Warranty Statement ............................................................................. 12 General Emissions Warranty Coverage ......................................................................................... 13 Marine Transmissions ................................................................................................................ 15 Resolving a Service Problem ...................................................................................................... 16 Dealer’s Responsibilities ............................................................................................................ 17 Transferable Warranty ................................................................................................................ 18 Direct Sale By Owner ................................................................................................................ 18 Notes ..................................................................................................................................... 19 BOATING RESPONSIBILITY ................................................................................................. 20-22 Carbon Monoxide Hazard ........................................................................................................... 20 Safe Boating Suggestions .......................................................................................................... 21 Water Wisdom .......................................................................................................................... 21 Operation and Maintenance ........................................................................................................ 21 Rules of the Road ..................................................................................................................... 22 ENGINE IDENTIFICATION .................................................................................................... 23-24 Engine Identification .................................................................................................................. 23 Owner Identification and Registration Information ............................................................................ 23 Engine Model Identification / Advisory ........................................................................................... 24 ELECTRONIC FUEL INJECTION INFORMATION .......................................................................... 25 Electronic Fuel Injection System .................................................................................................. 25 TABLE OF CONTENTS

2 L510001-09 TABLE OF CONTENTS OPERATING INSTRUCTIONS ............................................................................................... 26-34 Instrumentation ........................................................................................................................ 26 Engine Alarm System ................................................................................................................ 26 Remote Controls ...................................................................................................................... 27 Starting Engine (Fuel Injected Engines) ........................................................................................ 28 Shifting Transmission ................................................................................................................ 29 Stopping Engine ....................................................................................................................... 30 Freezing Temperature Operation ................................................................................................. 30 Operation in High Debris Areas ................................................................................................... 30 Electronic Twin-Engine Synchronization and Cruise .................................................................... 30-34 Determining the Master/Slave Engine Positions ......................................................................... 30-31 Crusader Sync/Cruise Panel Functions ......................................................................................... 31 Normal Operation ..................................................................................................................... 32 Entering Sync Mode .................................................................................................................. 32 Entering Cruise Mode ................................................................................................................ 32 Adjusting Cruise Speed .............................................................................................................. 32 Cancelling the Cruise Set Point ................................................................................................... 33 Resume Mode .......................................................................................................................... 33 Exiting Sync/Cruise Mode .......................................................................................................... 33 Crusader Sync/Cruise Functions vs. Throttle Positions .................................................................... 33 Crusader Sync/Cruise - Possible Operator Concerns ....................................................................... 34 CONDITIONS AFFECTING OPERATION ................................................................................. 35-36 Trim and Weight Distribution ....................................................................................................... 35 Boat Bottom ............................................................................................................................. 35 Propeller Selection .................................................................................................................... 36 ENGINE BREAK-IN PERIOD ..................................................................................................... 37 25-HOUR ENGINE INSPECTION ................................................................................................ 38 FUEL REQUIREMENTS ............................................................................................................ 39 Gasoline Requirements .............................................................................................................. 39 Gasoline Containing Alcohol ....................................................................................................... 39 OIL REQUIREMENTS ............................................................................................................... 40 Engine Oil Recommendations ..................................................................................................... 40 Transmission and “V”-Drive Oil Requirements ................................................................................ 40 ENGINE MAINTENANCE ...................................................................................................... 41-69 Engine Maintenance .................................................................................................................. 41 Checking Fluid Levels ........................................................................................................... 41-42 Lubrication .............................................................................................................................. 43 Electrical System Relay and Fuse Block ........................................................................................ 44 Electrical System Fuses ............................................................................................................. 44 Boat’s Ignition Fuse ................................................................................................................... 44 Electrical System Wiring and Connectors ...................................................................................... 44 Battery .................................................................................................................................... 45 Fresh Water Cooling System Sacriﬁcial Zinc Anode ......................................................................... 46

3 L510001-09 TABLE OF CONTENTS Checking Coolant Level ............................................................................................................. 47 Flushing Cooling System - Sea-Water Section ................................................................................ 48 Testing Coolant For Alkalinity ...................................................................................................... 49 Draining Fresh-Water Cooling System .......................................................................................... 49 Filling Fresh-Water Cooling System .............................................................................................. 50 Cleaning Sea-Water Section of Heat Exchanger (Fresh-Water Cooled Applications Only) ....................... 51 Fuel System Description ............................................................................................................ 52 Fuel Control Cell (FCC) Fuel System ............................................................................................ 52 Servicing the FCC ..................................................................................................................... 53 FCC Service Instructions (Clamp-On Canister) ............................................................................... 54 Primary Fuel Filter ..................................................................................................................... 55 Priming Fuel System ................................................................................................................. 56 Flame Arrestor ......................................................................................................................... 57 Accessory Drive Belt ............................................................................................................. 58-60 Changing Oils .......................................................................................................................... 61 Engine Alignment ................................................................................................................. 62-64 Engine Maintenance Log ............................................................................................................ 65 Maintenance Schedule .......................................................................................................... 66-67 Visual Inspection ...................................................................................................................... 68 Engine Fluid Capacities ............................................................................................................. 68 Transmission Fluid Capacities ..................................................................................................... 68 Filter Requirements ................................................................................................................... 69 On-Board Parts Kits .............................................................................................................. 69-71 ENGINE SPECIFICATIONS ................................................................................................... 72-74 OUT-OF-SEASON STORAGE ................................................................................................ 75-78 Engine Storage ........................................................................................................................ 75 Draining Instructions .................................................................................................................. 76 Battery Storage ........................................................................................................................ 76 Out-Of-Season Engine Warm-Up ................................................................................................. 77 Recommissioning After Storage .............................................................................................. 77-78 TROUBLESHOOTING .......................................................................................................... 79-81 WATER FLOW DIAGRAMS ................................................................................................... 82-85 INSTRUMENTATION WIRING DIAGRAM ..................................................................................... 86 LITERATURE .......................................................................................................................... 87 FORMS .............................................................................................................................. 88-93 CRUSADER OWNERSHIP CHANGE NOTICE .............................................................................. 88 CRUSADER WARRANTY TRANSFER APPLICATION (PORT OR SINGLE ENGINE) ........................... 89 CRUSADER WARRANTY TRANSFER APPLICATION (STARBOARD ENGINE) .................................. 91 NOTES ................................................................................................................................... 93 CRUSADER WARRANTY / REGISTRATION FORM

4 L510001-09 SERVICE and WARRANTY - 1 SAFETY INFORMATION “Safety Warnings” and additional information or instructions are used to alert the installer/operator of possible safety hazards in performing certain service or maintenance procedures incorrectly or carelessly. DANGERS and WARNINGS are accompanied by the international HAZARD symbol: These “Safety Warnings” alone cannot eliminate the hazards that they signal. Strict compliance with these warning instructions while performing service and maintenance procedures, plus “common sense” operation, are major accident prevention measures. REPLACEMENT PARTS Use of replacement parts (i.e. automotive, after-market, etc.) in the electrical, ignition and fuel systems, which are not U.S. Coast Guard approved, could cause a ﬁre or explosion hazard and should be avoided. Always request that genuine Crusader Marine Engines replacement parts be used in any repairs or maintenance being performed on your engine(s). DANGER Electrical, ignition and fuel system components are designed and manufactured to comply with U.S. Coast Guard rules and regulations to minimize the possibility of ﬁre or explosion hazard. DANGER Signals serious damage, failure or breakdown of equipment; severe injury or high probability of death to the user if proper precautions are not taken. This signal word is applied in extreme situations SAFETY WARNINGS WARNING Indicates a potential hazard which could result in personal injury. CAUTION Indicates a hazard which could result in damage to equipment. WARRANTY NOTICE: Indicates a possible warranty exclusion. IMPORTANT: or IMPORTANT: Used to provide information to perform a procedure more easily.

5 L510001-09 SERVICE and WARRANTY - 1 OWNER’S SERVICE AND WARRANTY INFORMATION CRUSADER MARINE ENGINES’ COMMITMENT TO YOU Crusader Marine Engines is committed to assuring your satisfaction with your new Crusader engine. Your Dealer also wants you to be completely satisfied, and invites you to return for all your servicing needs, both during and after the warranty period. OWNER WARRANTY REGISTRATION It is important that your selling dealer fill out the “Warranty Registration Card” completely and mail it to the factory immediately upon the purchase of the new product. It identifies the name and address of the original purchaser, product model(s) and serial number(s), and the selling dealer’s name and address. The dealer is also certifying that you are the original purchaser of the product. Upon receipt of the “Warranty Registration Card” at the factory, you will be issued an “Owner Warranty Registration Card.” The “Owner Registration Card” is your only valid registration identification, and must be presented to the servicing dealer, should warranty service be required. If your “Owner Registration Card” is not received within 30 days from the date of purchase, please contact your boat dealer or engine seller. The product warranty is not effective until the Product is registered at the factory. Mail registration information to: NOTE: OWNERS WARRANTY REGISTRATION CARD IS LOCATED AT THE BACK OF THIS MANUAL. NOTICE: Registration lists must be maintained by the factory and dealer on marine products sold in the United States and some foreign countries, should notification under FEDERAL BOAT SAFETY ACT be required. It is our desire to have all products registered at the factory, should it ever be necessary to contact you. Make sure your Dealer/Distributor fills out the registration card immediately and sends the card to the factory. Crusader Marine Engines P.O. Drawer 369 Little Mountain, SC 29075

6 L510001-09 SERVICE and WARRANTY - 1 ENGINE OPERATION AND CARE Considering the investment that you have made in your new Crusader engine(s), we know you will want to operate and maintain it properly. We urge you to follow the maintenance instructions contained in your engine’s “Operation and Maintenance Manual.” If you have any questions on how to keep your engine in good working condition, see your selling dealer, the place where many owners choose to have their maintenance work done. Your Crusader Premier dealer can be relied on to use proper parts and practices. MAINTENANCE RECORDS It is recommended that receipts covering the performance of regular maintenance be retained. Damage to your engine, caused by lack of maintenance, is not covered under your warranty. Receipts can be very important if a question arises as to whether a malfunction is caused by lack of maintenance or a defect in material or workmanship. An “Engine Maintenance Log” is provided in the MAINTENANCE SCHEDULE section of the OPERATION AND MAINTENANCE MANUAL for your convenience in recording the service performed. LOCAL REPAIR SERVICE To obtain service or make a claim under your warranty, contact your selling dealer. They have trained technicians, knowledge and special tools and equipment to properly service your engine, if the need arises. They know you and your boat the best. SERVICE AWAY FROM HOME If you are away from home and your local dealer, and the need for service arises, contact the Crusader Captain’s Club™ Concierge using your exclusive Captain’s Club toll-free number. The Club Concierge is there to support your local dealer or locate the closest Crusader authorized technician. She can personally expedite parts orders so that in most cases, shipment is made within 24 hours, delivered on time to the location you specify.

7 L510001-09 SERVICE and WARRANTY - 1 REPLACEMENT PART INQUIRIES All inquiries concerning replacement parts should be directed to your local authorized Crusader Premier dealer. The dealer has the necessary information to order parts for you if they are not in stock. Only authorized distributors can purchase parts from the factory. Crusader Marine Engines does not sell to unauthorized dealers or retail customers. When checking on parts, the dealer will require the engine model and serial number to order the correct parts. REPLACEMENT SERVICE PARTS WARNING Electrical, ignition and fuel system components on Crusader engines are designed and manufactured to comply with U.S. Coast Guard rules and regulations to minimize the risks of ﬁre or explosion. Use of replacement electrical, ignition or fuel system components, which do not comply with these rules and regulations, could result in a ﬁre or explosion hazard and should be avoided. When servicing the electrical, ignition and fuel systems, it is extremely important that all the components are properly installed and tightened. If not, any electrical or ignition component opening would permit sparks to ignite fuel vapors from fuel system leaks, if they existed. APPLICABLE LIMITED WARRANTY Following is the limited warranty applicable to Crusader Marine Engines sold and used in the United States and Canada. Distributors and Dealers are not agents of Crusader. Crusader does not authorize any person to create any other obligation or liability in connection with this product.

Crusader 5.0L MPI / 5.7L MPI / 6.0L MPI / 8.1L MPI / 8.1L MPI (HO) engines Owner's Operation and Maintenance Manual

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