1994-2000 OMC Cobra SX & DP-S Duoprop Stern Drives Service & Repair Manual

Quick Reference Data MAINTENANCE TORQUE SPECIFICATIONS Fastener in.-lb. ft.-lb. N•m Drive unit dipstick 48-72 – 5.4-8.1 Drive unit lubricant vent plug 48-72 – 5.4-8.1 Drive unit drain/fill plug 60-84 – 6.8-9.5 Spark plugs GM 3.0L models – 20 27 GM 4.3L models Used cylinder head – 15 20 New cylinder head – 22 30 GM 5.0L and 5.7L models Used cylinder head – 15 20 New cylinder head – 22 30 Ford 5.0L and 5.8L models 120-180 – 14-20 GM 7.4L and 8.2L models – 22 30 Rear drive cover (plastic) screws 108-132 – 12.2-14.9 RECOMMENDED LUBRICANTS Lubricant Application SAE 30 NMMA-certified FC-W marine-use motor oil* Engine crankcase–all models SAE 30 motor oil: GM standard GM-6094-M* Crankcase–GM engines SAE 30 motor oil: Ford specification ESE-M2X153* Crankcase–Ford engines Mobil 1 SHC 75-90 fully synthetic gearcase lubricant Drive unit Volvo Penta Dura Plus synthetic gearcase lubricant Drive unit Ethylene glycol-based engine coolant Closed cooling system Dexron II automatic transmission fluid (ATF) Power steering and power trim pumps OMC power trim/tilt fluid Power steering and power trim pumps Volvo Penta power trim/tilt fluid (part No. 3851930) Power steering and power trim pumps Quicksilver power trim/tilt fluid (part No. 92-90199A21) Power steering and power trim pumps OMC EP/Wheel Bearing Grease Gimbal bearing OMC Moly Lube (part No. 175356) Engine coupling splines OMC Triple Guard Grease Steering cable ram Marine-grade water-resistant grease Steering cable ram Marine-grade fuel stabilizer Fuel tank OMC fuel conditioner and stabilizer (part No. 775614) Fuel tank Quicksilver fuel conditioner (part No. 92-858072KO1) Fuel tank IX (continued) MODEL: YEAR: VIN NUMBER: ENGINE SERIAL NUMBER: CARBURETOR SERIAL NUMBER OR IDENTIFICATION MARK:

RECOMMENDED LUBRICANTS (continued) Lubricant Application Marine fogging oil Storage fogging agent Quicksilver Storage Seal (part No. 92-858081KO1) Storage fogging agent *Recommended oil viscosity for operation in ambient air temperature exceeding 32° F (0° C). Refer to text for oil viscosity recommendation if operating engine at lower air temperatures. Refer to Chapter Three. ENGINE OIL AND DRIVE UNIT LUBRICANT CAPACITIES Model Capacity (approximate) Engine oil capacity GM 3.0L models With oil filter change 4.0 qt. (3.8 L) Without oil filter change 3.5 qt. (3.3 L) GM 4.3L models With oil filter change 4.5 qt. (4.3 L) Without oil filter change 4.0 qt. (3.8 L) GM 5.0L models With oil filter change 6.0 qt. (5.7 L) Without oil filter change 5.0 qt. (4.7 L) Ford 5.0L models With oil filter change 6.0 qt. (5.7 L) Without oil filter change 5.0 qt. (4.7 L) GM 5.7L models 57GL models With oil filter change 5.0 qt. (4.7 L) Without oil filter change 4.0 qt. (3.8 L) 57GI and 57GSI models With oil filter change 6.0 qt. (5.7 L) Without oil filter change 5.0 qt. (4.7 L) Ford 5.8L models 58FL (carburetor-equipped) models With oil filter change 6.0 qt. (5.7 L) Without oil filter change 5.0 qt. (4.7 L) 58FI and 58FSI (EFI) models With oil filter change 6.0 qt. (5.7 L) Without oil filter change 5.0 qt. (4.7 L) GM 7.4L models 74GL models With oil filter change 7.0 qt. (6.6 L) Without oil filter change 6.0 qt. (5.7 L) 74GI and 74GSI models With oil filter change 9.0 qt. (8.5 L) Without oil filter change 8.0 qt. (7.6 L) GM 8.2L models With oil filter change 7.0 qt. (6.6 L) Without oil filter change 6.0 qt. (5.7 L) Drive unit lubricant capacity Cobra SX (single propeller) 71 oz. (2.1 L) Cobra DP-S DuoProp (twin propeller) 81 oz. (2.4 L) ENGINE OPERATING SPEED SPECIFICATIONS Model Idle speed (rpm) Wide open throttle speed (rpm) GM 3.0L models 650-750 4200-4600 GM 4.3L models 43GL (carburetor-equipped) models 550-650 4200-4600 X (continued)

ENGINE OPERATING SPEED SPECIFICATIONS (continued) Model Idle speed (rpm) Wide open throttle speed (rpm) GM 4.3L models (continued) 43GS (carburetor-equipped) models 550-650 4200-4800 43GI (EFI) models 600* 4400-4800 GM 5.0L models 50GL (carburetor-equipped) models 550-650 4400-4800 50GI (EFI) models 600* 4600-5000 Ford 5.0L models 50FL (carburetor-equipped) models 550 4200-4600 50FI (EFI) models 600* 4200-4600 5.7L models 57GL (EFI) models 600-650 4200-4600 57GS (EFI) models 550-650 4400-4800 57GI (EFI) models 600* 4200-4600 57GSI (EFI) models 600* 4600-5000 Ford 5.8L models 58FL (carburetor equipped) models 550-650 4000-4400 58FI (EFI) models 600* 4200-4600 58FSI (EFI) models 600* 4600-5000 GM 7.4L models 74GL (carburetor-equipped) models 550-650 4200-4600 74GI (EFI) models 600* 4200-4600 74GSI (EFI) models 600* 4800-5200 GM 8.2L models 82GL (carburetor-equipped) models 550-650 4400-4800 82GSI (EFI) models 600* 4600-5000 *The idle speed is nonadjustable on this model. SPARK PLUG SPECIFICATIONS Model Spark plug No. Gap specification GM 3.0L models AC plug MR43LTS Champion plug RS12YC NGK plug TR5 Plug gap – 0.045 in. (1.14 mm) GM 4.3L models 1994-1996 (with 12-bolt intake) 43GL and 43GS models AC plug MR43T NGK plug BR6FS Plug gap – 0.045 in. (1.14 mm) 43GI models AC plug R43TS NGK plug BPR6FS Plug gap – 0.045 in. (1.14 mm) 1997-2000 (with 8-bolt intake) AC plug MR43LTS Champion plug RS12YC NGK plug BPR6EFS Plug gap – 0.045 in. (1.14 mm) GM 5.0L models 1994-1997 (with 12-bolt intake) AC plug MR43T NGK plug BR6FS Plug gap – 0.045 in. (1.14 mm) 1998-2000 (with 8-bolt intake) 50GL and 50GS (carburetor-equipped) AC plug MR43LTS (continued) XI

SPARK PLUG SPECIFICATIONS (continued) Model Spark plug No. Gap specification GM 5.0L models 1998-2000 (with 8-bolt intake) (continued) 50GL and 50GS (carburetor-equipped) Champion plug RS12YC NGK plug BPR6EFS Plug gap – 0.035 in. (0.89 mm) 50GI (EFI) Champion plug RS12YC NGK plug BPR6EFS Plug gap – 0.045 in. (1.14 mm) Ford 5.0L models 50FL (carburetor-equipped) AC plug MR43T Motorcraft plug ASF32C NGK plug UR4 Plug gap – 0.035 in. (0.89 mm) 50FI (EFI) AC plug MR43T Motorcraft plug AWSF32C NGK plug TR5 Plug gap – 0.045 in. (1.14 mm) GM 5.7L models 1994-1997 (with 12-bolt intake) 57GL (carburetor-equipped) AC plug MR43T NGK plug BR6FS Plug gap – 0.045 in. (1.14 mm) 57GI (EFI) AC plug R43TS NGK plug BPR6FS Plug gap – 0.045 in. (1.14 mm) 1998-2000 (with 8-bolt intake) 57GS (carburetor-equipped) models AC plug MR43LTS Champion plug RS12YC NGK plug BPR6EFS Plug gap – 0.035 in. (0.89 mm) 57GSI (EFI) models AC plug MR43LTS Champion plug RS12YC NGK plug BPR6EFS Plug gap – 0.045 in. (1.14 mm) Ford 5.8L models 58FL (carburetor-equipped) models AC plug MR43T Motorcraft plug ASF32C NGK plug UR4 Plug gap – 0.035 in. (0.89 mm) 58FI (EFI) models AC plug MR43T Motorcraft plug AWSF32C NGK plug BPR6EFS Plug gap – 0.045 in. (1.14 mm) GM 7.4L models 1994-1997 74GL (carburetor-equipped) models AC plug MR43T NGK plug BR6FS Plug gap – 0.045 in. (1.14 mm) 74GI (EFI) models AC plug R43TS NGK plug BPR6FS Plug gap – 0.045 in. (1.14 mm) XII (continued)

SPARK PLUG SPECIFICATIONS (continued) Model Spark plug No. Gap specification GM 7.4L models (continued) 1998-2000 74GI (EFI) models AC plug MR43LTS Champion plug RS12YC NGK plug BPR6EFS Plug gap – 0.045 in. (1.14 mm) 74GSI (EFI) HP models AC plug MR43T NGK plug BR6FS Plug gap – 0.045 in. (1.14 mm) GM 8.2L models AC plug MR43T NGK plug BR6FS Plug gap – 0.045 in. (1.14 mm) XIII

Chapter One General Information This detailed and comprehensive manual covers OMC stern drive engines from 1994-2000. This manual can be used by anyone from first-time do-it-yourselfers to professional mechanics. The text provides step-by-step information on maintenance, tune-up, repair and overhaul. Hundreds of photos and drawings guide the reader through every job. this in mind. All chapters are thumb-tabbed, and important items are indexed at the end of the manual. All procedures, tables, photos and instructions in this manual are designed for the reader working on the machine or using the manual for the first time. Keep the manual in a handy place such as a toolbox or in the boat. It will increase understanding of how the boat runs, lower repair and maintenance cost and generally increase enjoyment of the boat. Frequently used specifications and capacities from indi- vidual chapters are summarized in the Quick Reference Data at the front of the manual. Specifications concerning a specific system are included in the tables at the end of each chapter. Tables 1-6 at the end of this chapter list technical abbreviations, conversion formulas, U.S. standard tap and drill sizes, metric tap and drill sizes, general torque recommendations and engine identification codes. MANUAL ORGANIZATION All dimensions and capacities are expressed in U.S. standard and metric units of measure. This chapter provides general information on shop safety, tool use, service fundamentals and shop supplies. Chapter Two provides methods and suggestions for quick and accurate diagnosis of engine trouble. The troubleshooting procedures describe typical symptoms and pro- vide logical troubleshooting methods. Chapter Three explains all periodic lubrication and rou- tine maintenance necessary to keep the stern drive engine operating at peak efficiency. Chapter Three also includes all recommended tune-up procedures, which eliminate the need to refer to other chapters on the various systems. Chapter Four describes the procedures for preparing the stern drive engine for storage. Preparation for operation after the lay-up period is also described in this chapter. Chapter Five describes adjustments for the fuel, shifting and power trim systems. 1

Subsequent chapters describe specific systems and pro- vide disassembly, repair and assembly procedures in simple step-by-step form. Some of the procedures in this manual specify special tools. When possible, the tool is illustrated in use. Well-equipped mechanics may substitute similar tools or fabricate a suitable replacement. However, in some cases, the specialized equipment or expertise might make it im- practical for the home mechanic to attempt the procedure. When necessary, such operations are identified in the text with the recommendation to have a dealership or specialist perform the task. It may be less expensive to have a professional perform these jobs, especially when considering the cost of the equipment. This is true regarding machine work for engine rebuilds because machinists spend years perfect- ing their trade, and even professional mechanics often rely upon their services. WARNINGS, CAUTIONS AND NOTES The terms WARNING, CAUTION, and NOTE have specific meanings in this manual. A WARNING emphasizes areas where personal injury or even death could result from negligence. Mechanical damage may also occur. WARNINGS are to be taken seriously . A CAUTION emphasizes areas where equipment damage could occur. Disregarding a CAUTION could cause perma- nent mechanical damage; however, personal injury is un- likely. A NOTE provides additional information to make a step or procedure easier or clearer. Disregarding a NOTE could cause inconvenience or misdiagnosis but would not cause damage or injury. SAFETY Professional mechanics can work for years and never sustain a serious injury. Follow these guidelines and prac- tice common sense to safely service the stern drive engine. 1. Do not operate the stern drive engine in an enclosed area. The exhaust gasses contain carbon monoxide, an odorless, colorless, tasteless and poisonous gas. Carbon monoxide levels build quickly in small enclosed areas and can cause unconsciousness and death in a short time. Make sure to properly ventilate the work area or operate the stern drive engine outside. 2. Never use gasoline or any extremely flammable liquid to clean parts. Refer to Handling Gasoline Safely and Clean- ing Parts in this chapter. 3. Never smoke or use a torch in the vicinity of flammable liquids such as gasoline or cleaning solvent. 4. After removing the engine cover, allow the engine com- partment to air out before performing any service work. 5. Use the correct type and size of tools to avoid damaging fasteners. 6. Keep tools clean and in good condition. Replace or repair worn or damaged equipment. 7. When loosening a tight or stuck fastener, always con- sider what would happen if the wrench should slip. In most cases, it is safer to pull on a wrench or ratchet than it would be to push on it. Be careful and protect yourself accord- ingly. 8. When replacing a fastener, make sure to use one with the same measurements, material and strength as the old one. Refer to Fasteners in this chapter for additional information. 9. Keep the work area clean and uncluttered. Keep all hand and power tools in good condition. Clean grease or oil from tools after using them. Unkept tools are difficult to hold and can cause injury. Replace or repair worn or damaged tools. Do not leave tools, shop rags or anything that does not be- long in the hull. 10. Wear safety goggles during all operations involving drilling, grinding or the use of a cold chisel or anytime the eye safety is in question (when debris may spray or scatter). Always wear safety goggles when using solvent or compressed air. 11. Do not carry sharp tools in clothing pockets. 12. Always have an approved fire extinguisher available. Make sure it is rated for gasoline (Class B) and electric (Class C) fires. Read and fully understand the operating instructions for the fire extinguisher before beginning the work. 13. Do not use compressed air to clean clothes, the boat/engine or the work area. Debris might blow into eyes or skin. Never direct compressed air at anyone. Do not allow children to use or play with any compressed air equipment. 14. When using compressed air to dry rotating parts, hold the park so that it cannot rotate. The air jet is capable or rotating the parts at extremely high speed. The part may be- come damaged or disintegrate and cause serious injury. Handling Gasoline Safely Gasoline is a volatile flammable liquid and is one of the most dangerous items in the shop. 2 CHAPTER ONE 1

Because gasoline is used so often, many people forget that it is hazardous. Only use gasoline as fuel for gasoline internal combustion engines. Do not use it as a cleaner or degreaser. When working, keep in mind gasoline is always present in the fuel tank, fuel lines and carburetor or fuel rail. To avoid a disastrous accident when working around the fuel system, carefully observe the following precautions. 1. Never use gasoline to clean parts. Refer to Cleaning Parts in this chapter. 2. When working on the fuel system, work outside or in a well-ventilated area. 3. Do not add fuel to the tank or service the fuel system while near open flames, sparks or where someone is smok- ing. Gasoline vapor is heavier than air. It collects in low areas and is more easily ignitable than liquid gasoline. 4. Allow the engine to cool completely before working on any fuel system component. 5. When draining the carburetor, fuel rail or fuel lines, catch the fuel in a suitable plastic container. Then pour it into an approved gasoline storage device. 6. Do not store gasoline in a glass container. If the glass breaks, a serious explosion or fire can occur. 7. Immediately wipe up spilled gasoline with suitable shop towels. Store the towels in a metal container with a lid until they can be properly disposed of, or place them outside in a safe place so the fuel can evaporate. 8. Do not pour water onto a gasoline fire. Water spreads the fire and makes it more difficult to extinguish. Use a class B, BC or ABC fire extinguisher to extinguish the fire. 9. Always turn off the engine before refueling. Do not spill fuel onto the engine components. Do not overfill the fuel tank. Leave an air space at the top of the tank to allow the fuel to expand. Cleaning Parts Cleaning parts is one the more tedious and difficult service jobs performed in the home garage. There are many types of chemical cleaners and solvents available for shop use. Most are poisonous and extremely flammable. To pre- vent chemical exposure, vapor buildup, fire and serious injury, observe each product warning label and note the following: 1. Read the entire product label before using any chemical. Always know what type of chemical is being used and whether it is poisonous and/or flammable. 2. Do not use more than one type of cleaning solvent at a time. If mixing chemicals is necessary, measure the proper amounts according to the manufacturer. 3. Work in a well-ventilated area. 4. Wear chemical-resistant gloves. 5. Wear safety glasses. 6. Wear a vapor respirator if the instructions call for it. 7. Wash hands and arms thoroughly after cleaning parts. 8. Keep chemical products away from children and pets. 9. Thoroughly clean all oil, grease and cleaner residue from any parts that must be heated. 10. Use a nylon brush when cleaning parts. Metal brushes can cause a spark. 11. When using a parts washer, use only the solvent recommended by the equipment manufacturer. Make sure the parts washer is equipped with a metal lid that lowers if a fire occurs. MODEL IDENTIFICATION The Cobra SX drive system consists of three major assemblies: the engine, transom bracket and drive unit. Be- fore servicing, troubleshooting or ordering parts for the engine, always identify the model number and serial number of these assemblies. Engine Identification Engine model name decal A decal on the flame arrestor cover (Figure 1) or the plastic throttle body/intake cover on 5.0L and 5.8L Ford EFI models identifies the engine model name. The numbers on the decal (A, Figure 1) indicate the engine displacement in liters and tenths of a liter. The first letter following the numbers (B, Figure 1) indicates the source of the base engine. The letter G is used for General Motors (GM) base engines, and the letter F is used for Ford base engines. The letter following the G or F (C, Figure 1) identifies the version of the model. An I indicates the engine uses an electronic fuel in- jection (EFI) system. An L indicates the engine is the lower output version of the indicated displacement. An S indicates the standard or higher output version of the indicated displacement. Engine identification tag The engine identification tag (Figure 2, typical) is lo- cated on the rocker arm cover, fuse and circuit breaker housing, or ignition system mounting bracket (Ford EFI GENERAL INFORMATION 3 1 2

models). This tag includes the model identification number and engine serial number. The model identification number (A, Figure 2) consists of nine characters. The first two numbers indicate the engine displacement in liters and tenths of a liter. For exam- ple, the number 57 would indicate the engine displaces 5.7 liters. The character following the displacement identification numbers indicates the type of fuel system used on the engine. The fourth character indicates the engine version and is used to identify models produced with lower or higher power output for the given displacement. The fifth character is a letter that indicates whether the engine is produced as an OMC Cobra SX engine or Volvo Penta SX engine. The sixth character indicates the type of steering system on the engine. The seventh and eighth characters are letters that indicate the model year of the engine. The final character is a letter that indicates the production version for the given model year. The production version always starts with an A for each model year. The letter changes to B, C and so on as changes occur during the production year. The model year version letter is very important when ordering parts and servicing the engine. Before servicing the engine or ordering replacement parts, compare the model identification number with the information in Table 6 to correctly identify the engine. The serial number on the identification tag (B, Figure 2) is unique to the engine and identifies the engine from other engines of the same model. Some states require this number for registration and title of the vessel. The serial number might also be required when ordering parts and servicing the engine. Transom bracket identification tag The transom bracket identification tag (Figure 3, typical) is affixed to the inner transom plate and above the steering cable connection point. The tag lists the seven-digit transom bracket model number (A, Figure 3) and the serial number (B) unique to the transom bracket. Some states require the number for registration and title of the vessel. The serial number might also be required when ordering parts and servicing the transom bracket. A decal listing the information on the transom bracket identification tag may be lo- cated next to the engine identification tag. The decal is supplied with the transom plate and is applied next to the engine tag during the original engine installation. This tag is useful when boat structure limits access to the inner transom plate. Drive unit identification tag The drive unit identification tag is riveted to the upper port side of the drive unit (Figure 4). The tag lists the drive unit model number (A, Figure 4), overall gear ratio (B) and serial number (C) unique to the drive unit. Some states require this number for registration and title of the vessel. All of the information on the tag must be supplied when ordering replacement parts for the drive unit. NOTE The manufacturer might make changes during a model year. When ordering parts, always order by model and serial number. For reference, record the model and serial number in the Quick Reference Data (QRD) sec- tion at the front of the manual. Compare new parts with old before purchasing them. If the parts are not alike, have the parts manager explain the difference and verify compatibil- ity before installing the part. ENGINE OPERATION All marine engines, whether two- or four-stroke, gasoline or diesel, operate on the Otto cycle of intake, compres- sion, power and exhaust phases. The models covered in this manual are a four-stroke design. Figure 5 shows typical four-stroke gasoline engine operation. FASTENERS Proper fastener selection and installation is important to make sure that the stern drive engine operates as designed 4 CHAPTER ONE 3 4

GENERAL INFORMATION 5 1 5 TYPICAL FOUR-STROKE ENGINE OPERATION As the piston travels downward on the intake stroke, the exhaust valve is closed, and the intake valve opens and allows the fresh air/fuel mixture to be drawn into the cylinder. When the piston reaches the bottom of its travel (BDC), the intake valve closes and remains closed for the next one and one-half revolutions of the crankshaft. While the crankshaft continues to rotate, the piston moves upward in the cylinder. Because both valves are closed, the piston compresses the fresh air/fuel mixture. When the piston nears the top of its travel, the spark plug fires and ignites the compressed air/fuel mixture to start the power phase. Due to crankshaft rotation, the piston continues movement to top dead center (TDC) and is then pushed downward by expanding gasses formed by the burning fuel. When the piston nears the bottom of its travel on the power stroke (BDC), the exhaust valve opens and remains open until the piston moves upward and nears the top of its exhaust stroke. The upward travel of the piston forces the exhaust gasses out of the cylinder. The exhaust valve closes to end the exhaust phase, and the cycle starts all over again.

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1994-2000 OMC Cobra SX & DP-S Duoprop Stern Drives Service & Repair Manual

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