Volvo Penta Sterndrive SX-M / DP-S Service & Repair Manual

Workshop Manual AC 2(2) Sterndrive SX-M, SX-MTD DP-SM, DP-SMTD, DP-SMTD1 Transom Shield SX-M, SX-MLT, SX-MACLT, SX-MHP, SX-MDA, SX-MDB Sterndrive Transom Shield

VPA 7743008 07-2003 1 General Information . . . . . . . . . . . . . . . . . . . 3 Transom Shield Assembly - SX-M . . . . . . . 17 Transom Shield Assembly SX-MHP . . . . . . 53 Upper Gear Housing . . . . . . . . . . . . . . . . . . 89 SX Lower Gearcase . . . . . . . . . . . . . . . . . . 145 DP-S Lower Gearcase . . . . . . . . . . . . . . . . 179 Sterndrive Removal and Installation . . . . 227 Trim/Tilt Hydraulic System . . . . . . . . . . . . 241 Propellers . . . . . . . . . . . . . . . . . . . . . . . . . . 259

2 VPA 7743008 07-2003 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Information VPA 7743008 07-2003 3 General Information Sterndrive Lubrication - SX Models . . . . . . . . . . . . . . 6 Adding Lubricant to Sterndrive . . . . . . . . . . . . . . . . . . . . . . . . 6 Sterndrive Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Draining and Filling Sterndrive . . . . . . . . . . . . . . . . . . . . . . . . 6 Sterndrive Lubrication - DP-S Models . . . . . . . . . . . . 8 Adding Lubricant to Sterndrive . . . . . . . . . . . . . . . . . . . . . . . . 8 Sterndrive Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Draining and Filling Sterndrive . . . . . . . . . . . . . . . . . . . . . . . . 8 Power Trim/Tilt-Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Off -Season Storage Preparations - All Models . . . . . 9 Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Preparation for Boating After Storage . . . . . . . . . . . . . . . . . 10 Gimbal Bearing and Universal Joints Lubrication . . . . . . . 10 Recommendations For Antifouling Paints . . . . . . . . . . . . . . 11 Painting The Stern Drive With Antifouling Paint . . . . . . . . . 12 Paints For Stern drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Painting The Hull With Antifouling Paint . . . . . . . . . . . . . . . 12 Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Periodic Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . 16 Safety Warnings Before working on any part of a Volvo Penta sterndrive, read the section called Safety at the end of this manual. 1 Introduction This service manual is divided into sections concerning various systems and assemblies. Refer to the Contents to locate the section covering the system or assembly requiring service. Each section title page has an additional listing that will describe the section’s contents in more detail. Be sure to read the Safety Section at the end of this manual, and pay special attention to all safety warnings as they appear throughout the text. Since models are subject to change at any time, some photos may not depict actual product.

General Information 4 VPA 7743008 07-2003 Good Service Practice Service required for this product is generally one of three kinds: • Normal care and maintenance - which includes putting a new stern drive into operation, storing engines, lubrication, and care under special operating conditions such as salt water and cold weather. • Operating malfunctions - due to improper engine or drive mounting, propeller condition or size, boat condition, or the malfunction of some part of the engine. This includes engine servic- ing procedures to keep the engine in prime operating condition. • Complete disassembly and overhaul - such as major service or rebuilding a unit. It is important to determine before disassembly just what the trouble is and how to correct it quickly, with minimum expense to the owner. When repairing an assembly, the most reliable way to ensure a good job is to do a complete overhaul on that assembly, rather than just to replace the bad part. Wear not readily apparent on other parts could cause a malfunction soon after the repair job. Repair kits and seal kits contain all the parts needed to ensure a complete repair, to eliminate guesswork, and to save time. Repair time can also be minimized by the use of special tools. Volvo Penta Special Tools are designed to perform service procedures unique to the product that cannot be completed using tools from other sources. They also speed repair work to help achieve service flat rate times. In some cases, the use of substitute tools can damage the part. Note! Do not operate engine out of water even momentarily. If operated in test tank, use proper test wheel. Failure to do so can damage water pump, overheat engine, or allow excessive engine RPM. Preparation for Service Proper preparation is extremely helpful for efficient service work. A clean work area at the start of each job will minimize tools and parts becoming misplaced. Clean an engine that is excessively dirty before work starts. Cleaning will occasionally uncover trouble sources. Obtain tools, instruments and parts needed for the job before work is started. Interrupting a job to locate special tools or repair kits is a needless delay. Use proper lifting and handling equipment. Working on stern drives without proper equipment can cause damage and personal injury. Always use clean fresh fuel when testing engines. Troubles can often be traced to the use of old or dirty fuel.

General Information VPA 7743008 07-2003 5 Service Policy It is a policy to provide dealers with service knowledge so they can give professional service demanded by today’s consumer. The Volvo Penta Training Centers, frequent mailing of Service Bulletins, Letters and Promotions, Special Tools and this Service Manual represent our continuing efforts to assist dealers in giving consumers the best and most prompt service possible. If a service question does not appear to be answered in this manual, you are invited to write to the Volvo Penta Service Department for additional help. Always be sure to give complete information, including engine model number and serial number. Be sure that you are familiar with the warranty statement supplied with the product. If you have any questions, write the Volvo Penta Service Department. If other than genuine Volvo Penta replacement components or parts are used, subsequent warranty claims involving that engine may be refused. When a brand-name product or specific tool is called for, another item may be used. However, the substitute must have equivalent characteristics, including type, strength, and material. You must determine if incorrect substitution could result in product malfunction and personal injury to anyone. To avoid hazards, equivalent products which are used must meet all current U.S. Coast Guard Safety Regulations and ABYC standards. Replacement Parts When replacement parts are required, always use genuine Volvo Penta parts, or parts with equivalent characteristics, including type, strength, and material. Failure to do so may result in product malfunction and possible injury to the operator and/or passengers. Parts Catalogs Parts Catalogs contain exploded views showing the correct assembly of all parts, as well as a complete listing of the parts for replacement. These catalogs are helpful as a reference during disassembly and reassembly, and are available from Volvo Penta Parts. Special Service Tools Special service tools have been specially designed to simplify some of the disassembly and assembly operations. These tools are illustrated in this Service Manual, in many cases in actual use. All Volvo Penta special tools can be ordered from Volvo Penta Parts. Individual purchasers of Service Manuals must order Special Tools through an authorized dealer.

General Information 6 VPA 7743008 07-2003 Product References, Illustrations & Specifications Volvo Penta reserves the right to make changes at anytime, without notice, in specifications and models and also to discontinue models. The right is also reserved to change any specifications or parts at any time without incurring any obligation to equip same on models manufactured prior to date of such change. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of printing. The right is reserved to make changes at anytime without notice. All photographs and illustrations used in this manual may not depict actual models or equipment, but are intended as representative views for reference only. The continuing accuracy of this manual cannot be guaranteed. Sterndrive Lubrication - SX Models Adding Lubricant to Sterndrive Occasionally check oil level in sterndrive. Screw dipstick fully into hole. Remove and read oil level in reference to mark on dipstick. If oil level is low, add oil through dipstick opening. Add only enough lubricant to bring the oil level to the proper level somewhere in the range on the dipstick. Sterndrive Oil Capacity Draining and Filling Sterndrive When a complete change of lubricant is required in the sterndrive, proceed as follows: 1. Place sterndrive in the run (full down) position. Place a 4 quart drain pan under lower gear case skeg to catch oil. 2. Remove oil drain plug (port side of lower gear case) and oil level dipstick (top of sterndrive). Removing dipstick vents drive to improve oil draining. Allow oil to drain completely. 34086 33836 Change Lubricant Every 100 Hours or Once Each season Use Volvo Penta Synthetic Gearcase Lubricant or Mobilube 1 SHC Fully Synthetic SAE 75W-90 gear lubricant All SX Models 71oz. (2100 cc)

General Information VPA 7743008 07-2003 7 3. Remove three screws securing the shift link access cover to access the oil level plug. Fill sterndrive with Volvo Penta Synthetic Gearcase Lubricant SAE 75W-90 through oil drain plug hole. Fill slowly to purge air. 4. Sterndrive is properly filled when the oil level appears at the oil level plug hole. When filled to the proper level, install oil level dipstick and the oil level plug first to prevent excessive oil loss, then the oil drain plug. Tighten oil level gauge, plug, and drain plug fin- ger tight. Note! Filling sterndrive too quickly may form air pockets that will cause an inaccurate oil level reading. Running the sterndrive with improper oil level will result in immediate internal damage. 5. Check oil level with dipstick. Oil level must appear on the blade of the dipstick. Add oil if required, through the dipstick hole See “Adding Lubricant to Sterndrive” on page 8. 6. Tighten drain plug to 60-84 in. lb. (6,8-9,5 N•m). Tighten oil level dipstick to 48-72 in. lb. (5,4-8,1 N•m) 7. Install shift link access cover and tighten screws to 108-132 in. lb. (12,2-14,9 N•m). If lubricant has been completely changed, oil level must be rechecked after unit has been run and trapped air purged. Improper oil level will result in serious internal sterndrive damage. Add make-up oil through dipstick opening to bring oil up to proper level. VOLVO PENTA 42722 47117

General Information 8 VPA 7743008 07-2003 Sterndrive Lubrication - DP-S Models Adding Lubricant to Sterndrive Occasionally check oil level in sterndrive. Screw dipstick fully into hole. Remove and read oil level in reference to mark on dipstick. If oil level is low, add oil through dipstick opening. Add only enough lubricant to bring the oil level to the proper level somewhere in the range on the dipstick. Sterndrive Oil Capacity Draining and Filling Sterndrive When a complete change of lubricant is required in the sterndrive, proceed as follows: 1. Remove both propellers See “Propeller Removal and Installa- tion - DP-S Models” on page 263. 2. Place sterndrive in the run (full down) position. Place a 4 quart drain pan under lower gear case skeg to catch oil. 3. Remove the oil drain plug (inside lower gear case) and the oil level dipstick (top of sterndrive). Removing dipstick vents drive to improve oil draining. Allow oil to drain completely. 34086 33836 Change Lubricant Every 100 Hours or Once Each Season Use Volvo Penta Synthetic Gearcase Lubricant or Mobilube 1 SHC Fully Synthetic SAE 75W-90 gear lubricant All DP-S Models 81 oz. (2400ml) 37260

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Volvo Penta Sterndrive SX-M / DP-S Service & Repair Manual

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