Indmar 454 Carbureted Operator'S Manual Download Page 1

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Operator ’s Manual

Part No. OME0502-06

Printed in U.S.A.

J.D. Power and Associates Ranks Indmar

Inboards Highest In Customer Satisfaction

Inboard Gas Engines (Ski/Wake).

Ken Cook Co.

5400 Old Millington Road Millington, TN 38053

w w w. i n d m a r. c o m

Summary of Contents for 454 Carbureted

Page 1: ...Part No OME0502 06 Printed in U S A J D Power and Associates Ranks Indmar Inboards Highest In Customer Satisfaction Inboard Gas Engines Ski Wake Ken Cook Co 5400 Old Millington Road Millington TN 380...

Page 2: ...__________________________ Every 100 Hour Service Date ___________ Hours ____________ By _______________________________ Date ___________ Hours ____________ By _______________________________ Date ___...

Page 3: ...the presence of a hazard which WILL or CAN cause MINOR or MODERATE personal injury or property damage NOTICE Indicates installation operation or maintenance infor mation which is important but not haz...

Page 4: ...4 Carbureted Indmar 502 Carbureted Malibu LC2 PFI Malibu Monsoon 340 PFI Malibu 383 Hammerhead PFI Malibu LS1 PFI Malibu 8 1L PFI MasterCraft RTP 1 PFI MasterCraft MCX PFI MasterCraft LQ9 PFI MasterCr...

Page 5: ...performance Operational performance data will be retained to track product performance in the future It s our goal to continually improve our product and deliver all the benefits of the latest power...

Page 6: ...o produce the world s finest most advanced and most dependable gasoline inboard marine engines at the best possible price while respecting the needs of our employees customers vendors and the precious...

Page 7: ...rt Your Engine 3 1 If Engine Does Not Start 3 3 How to Clear the Engine 3 3 Engine Restart 3 4 Chapter 4 Normal Operation 4 1 Daily Routine 4 1 Operating the Controls 4 2 Unusual Vibration 4 3 Fuel Sy...

Page 8: ...ng 6 7 Internal Cooling System Care 6 10 Ignition Timing 6 13 Fuel System 6 13 Carburetor Adjustments 6 14 Transmission 6 14 Electrical System 6 17 Wiring 6 18 Chapter 7 Storage and Winter Lay up 7 1...

Page 9: ...e your Indmar engine and drive line To find your nearest Indmar dealer please call 901 353 9930 or visit our website at www indmar com To ensure that the proper information is available note the six d...

Page 10: ...en finished Warranty registration must be received within 10 days after date of purchase by the first owner If your engine is not registered all warranties may be void Warranty Registration Transfer T...

Page 11: ...ations for your boat can be obtained from your local US Coast Guard Auxiliary US Power Squadron state boating authorities or the American Red Cross Know the law and your responsibil ities as a boat ow...

Page 12: ...al environ mental label required by the California Air Resources Board CARB The label has 1 2 3 or 4 stars A hang tag provided with your inboard engine describes the meaning of the star system Operati...

Page 13: ...d as part of the emissions control system and are covered under the Emissions Control Warranty 1 Fuel Metering System A Fuel injectors B Fuel pressure regulator C Manifold Absolute Pressure Sensor D T...

Page 14: ...or that part Emission warranted parts that are scheduled for regular inspection but not regular replacement are warranted by Indmar for the entire warranty period of the inboard engine Any emission wa...

Page 15: ...Clean every 100 hours Replace as necessary Spark Plugs Replace every 300 hours or annually whichever occurs first PCV Valve Replace every 300 hours or annually whichever occurs first Spark Plug Wires...

Page 16: ...99 556188 556198 556199 556188 556198 556199 556188 556198 556090 PCV Valve 505001 506002 551364 N A 505001 551364 N A 505001 551364 N A 505001 Flame Arrestor 525006 521119 525022 525021 525011 521119...

Page 17: ...l injection system the ignition system and catalytic converter Also included may be hoses belts connectors and other emission related assemblies Where a warrantable condition exists Indmar Products wi...

Page 18: ...e if your inboard engine or part has failed due to abuse neglect improper maintenance or unapproved modifications If your engine is operated in salt or brackish water spe cial precautions such as flus...

Page 19: ...are installed and secure Check the boat owner s manual for additional pre operation checks 2 Make sure all engine drain plugs are installed Refer to Chapter 7 Storage and Winter Layup There are severa...

Page 20: ...heck transmission oil level for correct level Refer to Chapter 6 Maintenance 6 If your engine is equipped with fresh water cooling check the expansion tank for the correct level Refer to Chapter 6 Mai...

Page 21: ...required before starting your EFI engine for the first time This allows the electric fuel pump to fill the fuel injection lines with gasoline Each time you advance the ignition switch to the ON positi...

Page 22: ...care now to break in your new Indmar engine is VERY important When broken in properly your engine will last longer run better and require fewer repairs over its lifetime Your new Indmar engine does n...

Page 23: ...at to the dealer for its first engine and trans mission oil and filter change and engine checkup Your Indmar dealer is best equipped to check the engine immediately after break in After the break in p...

Page 24: ...1 6 Indmar Marine Engines OM0502 05 Body qxd 6 7 05 1 31 AM Page 1 6...

Page 25: ...r boat at least once a day for gasoline fumes oil leaks and areas where wiring may be worn or damaged Explosive gasoline and battery fumes may accumulate in your engine compartment Failure to properly...

Page 26: ...a safe boating experience every time DON T swim or sit near the swim platform when any engine is running DON T hold on to the swim platform while the boat is underway no Teak Surfing DON T moor next t...

Page 27: ...engine or through the heat exchanger on closed cooled engines Freezing tempera tures will severely damage the engine block cooling system components and exhaust system components Contact your dealer...

Page 28: ...t Figure 2 3 Engine Oil Filter 7 Check transmission fluid level Check V Drive fluid level if equipped 8 If your engine is equipped with a fresh water cooling system check coolant level in the expansio...

Page 29: ...signs of wear and abrasion 14 Verify throttle shift control is functional and properly adjusted 15 Verify steering controls are functional and properly adjusted 16 Verify battery connections are clean...

Page 30: ...2 6 Indmar Marine Engines OM0502 05 Body qxd 6 7 05 1 31 AM Page 2 6...

Page 31: ...serious injury to you and your passengers When refueling make sure to open the motor box and run the blower during and after the re fueling operation Failure to do so may result in fire or explosion...

Page 32: ...rms up NOTICE Because of the electronic engine controls there is no need to advance the throttle to set an automatic choke The throttle should be in the neutral position with the neutral detent button...

Page 33: ...ng the starter motor is not covered by the warranty Hold key in START position for 3 5 seconds If engine still does not start advance throttle lever about 1 4 of its total travel Turn key and hold it...

Page 34: ...ure that your throttle lever is in NEUTRAL 3 Turn key OFF Try to start engine again If it does not start disengage the shift interlock and advance throttle to about 1 4 while holding key in the START...

Page 35: ...amage due to water is not covered by the warranty 2 Follow the starting procedures outlined in Chapter 3 Engine Starting Procedures Don t forget to run your engine blower for at least 4 minutes before...

Page 36: ...l should take precedence The shift throttle control is important to daily operation Have your dealer check it regularly for proper adjustment and lubrication NOTICE Avoid using the throttle lever duri...

Page 37: ...f water collects in the engine cylinder for any reason it can cause hydrostatic lock not allowing the pistons in the engine to move properly Hydrostatic lock can severely damage your engine which is n...

Page 38: ...uire special service tools You could damage the fuel system by not using specified tools This could cause a fire or explosion and subsequent death or seri ous personal injury to you or your passengers...

Page 39: ...ns are noted Low Oil Pressure High Coolant Temperature High Transmission Oil Temperature Any of these conditions may also put the engine into Power Reduction mode If the Check Engine light should go o...

Page 40: ...ays lit above 2000 RPM take the boat to your Indmar dealer for service ENGINE COOLING Raw water cooled engines have two water pumps One circulates water throughout the engine The other pump uses water...

Page 41: ...ere damage to your engine Monitor the temperature and oil gauges continuously If the temperature rises past 200 F 93 C or your oil pressure drops below 4 psi 41 kPa STOP THE ENGINE IMMEDIATELY Damage...

Page 42: ...ne operation If you use your boat for several differ ent applications such as wakeboarding barefooting and cruising it may be necessary to have 2 or more pro pellers which will allow the engine to ope...

Page 43: ...menon can become particularly apparent when an engine is propped out on a cool dry day in spring and later on a hot humid day in summer does not have the same performance Although some per formance ca...

Page 44: ...4 10 Indmar Marine Engines OM0502 05 Body qxd 6 7 05 1 31 AM Page 4 10...

Page 45: ...highly flammable and explosive Never smoke while refueling Keep sparks and flames away from fuel Only refuel in well ventilated area Never overfill fuel tank Stop engine before fueling Swallowing or...

Page 46: ...nal boater If your boat has not been used for more than 30 days with fuel in the tank even stabilized fuel the engine may run poorly until the old fuel is used up Indmar will not pay for repairs to ca...

Page 47: ...can corrode metal parts in your fuel system and engine Fuels that contain methanol will damage your engine Damage caused by the use of fuels that contain methanol is not covered by your warranty FUEL...

Page 48: ...5 4 Indmar Marine Engines OM0502 05 Body qxd 6 7 05 1 31 AM Page 5 4...

Page 49: ...on your use of marine parts When servicing the electrical ignition and fuel systems it is extremely important that all components are properly installed and tightened If not any electrical or ignitio...

Page 50: ...Water Operation por tion of this chapter for details Never operate engine without adequate water supply to the raw water pump Failure to properly cool engine will cause severe engine damage and void y...

Page 51: ...nge X Spark Plugs Replace X Engine Timing Check X X Engine Tune Up X Flame Arrestor Clean Change X Belts Inspect X X X Shaft Alignment Check X X Spark Plug Wires Inspect X Raw Water Pump Impeller Insp...

Page 52: ...n giving you a more accurate reading Figure 6 2 Dipstick 1 Pull dipstick from engine 2 Wipe oil off stick with clean towel cloth 3 Insert dipstick completely into the dipstick tube 4 Remove dipstick a...

Page 53: ...covered by your warranty Synthetic Oil Synthetic oil that meets our viscosity requirements and API SL SJ CI 4 CH 4 CG 4 is acceptable to use after 100 hours of operation with the recommended oil The u...

Page 54: ...itial start up always carefully inspect oil drain plug and oil filter gasket area for leaks 8 Stop the engine and re check oil level Add if neces sary Oil Additives Do not use oil additives Indmar eng...

Page 55: ...thoroughly and blow dry The metal flame arrestor must dry completely before it is returned to the engine Paper Type This type of flame arrestor should be blown clean from the inside monthly and replac...

Page 56: ...the cooling system must be flushed with clean water immediately to prevent corrosion and blockage in the cooling system Open Cooling Systems usually consist of a raw water intake on the bottom of the...

Page 57: ...engine from use of any other type of coolant is not covered by warranty The coolant system should be flushed and coolant replaced every two years This should be performed by a qualified Indmar service...

Page 58: ...engine will be used in salt water more that 25 of the time that the engine be equipped with a closed cooling system External Care Your engine has been carefully primed and painted to protect it again...

Page 59: ...ace these risers every two or three years on boats used exclusively in salt water Some half system installations use the one piece alu minum Tri Y or ETX manifolds and do not have separate risers or r...

Page 60: ...lar materials which are just lodged in the tubes Zinc Anodes The sacrificial zinc anodes frequently spall and there will probably be zinc bits in the exchang er which should be cleaned out Inspect the...

Page 61: ...he idle to 750 850 RPM 5 Set timing to 10 degrees BTDC Figure 6 10 6 Disconnect timing shunt from 12 volts and remove plug from distributor 7 Reset idle to 750 RPM for inboard engines and 1000 RPM for...

Page 62: ...reater than 2500 feet above sea level it may be necessary to have your carburetor re jetted to operate properly It may also be necessary to reduce your propeller size to allow the engine to operate at...

Page 63: ...rication while the ZF Hurth transmission uses Automatic Transmission Fluid The Walters V Drive also has a low oil pressure sensor and a dashboard mounted light If low oil pres sure is sensed this lamp...

Page 64: ...Remove the dipstick and read fluid level 3 Return dipstick after level check Make sure it is secured in place 4 If level is below ADD mark add the proper fluid until it reaches the full mark Add fluid...

Page 65: ...0 5L Pennzoil SAE 30 Motor Oil Do not overfill the transmission Overfilling can damage the transmission Damage to your transmission due to too much or too little fluid is not covered by your warranty...

Page 66: ...hat all harnesses are routed correctly If a wiring clip or retainer breaks replace it immediately Wiring is specifically routed to eliminate problems related to engine heat and spray or immersion in l...

Page 67: ...storage is not covered under terms of Indmar s limited warranty Because of the complexity of preparing your engine for winter storage and the danger of catastrophic engine damage from freezing water...

Page 68: ...torage with fuel in the tank s that does not contain alcohol fill the fuel tank s with fresh fuel and a sufficient amount of Sta Bil gasoline stabilizer to treat the entire tank Follow instructions on...

Page 69: ...d 7 Drain seawater section of the cooling system All Engines 1 Drain water from exhaust manifolds except on salt water series engines Uncouple the hose quick disconnect and drain the manifolds Indmar...

Page 70: ...Inspect the cooler for any debris such as weeds plastic etc Figure 7 3 Transmission Cooler 5 On Walters V Drive equipped units remove the two small square headed drain plugs from the front and rear o...

Page 71: ...ust be removed and inspected Replace if they are 50 eroded Figure 7 4 Ski Vee Figure 7 5 Walter V Drive Drain Plugs NOTICE Placing the drain plugs impeller etc in a plastic bag and attaching the bag t...

Page 72: ...om the brass fillings on both sides of the engine to drain water from the block NOTICE Placing the drain plugs in a plastic bag and attaching it to the steering wheel of the boat will act as a reminde...

Page 73: ...acrificial anode The active material on a new anode is approximately 1 1 2 inches long If more than 1 2 of the active material is missing from the anode it must be replaced with a new P N S865055 anod...

Page 74: ...the block drains with pipe sealant and install in the engine block EFI engines may have knock sensors located in the drain holes If your engine has knock sensors they must be reinstalled using thread...

Page 75: ...7 9 Prop Shaft Flange Alignment NOTICE With the boat in the water or a hose and adapter installed cycle the key switch ON then OFF for five second intervals 8 10 times before cranking the engine to al...

Page 76: ...7 10 Indmar Marine Engines OM0502 05 Body qxd 6 7 05 1 31 AM Page 7 10...

Page 77: ...st outlet shows rich gas mixture 7 Excessive boat loads weight 8 Damaged or dirty hull 9 High altitude adjustment required 10 Adjustment for temperature extremes required Hard Cold Start 1 Weak or dis...

Page 78: ...in need of tune up 5 Engine needs to be adjusted for high altitude operations 6 Engine needs to be adjusted for temperature extremes 7 Carburetor out of adjustment Carbureted Engines Only Hard Start H...

Page 79: ...d propylene glycol ZF Hurth Transmission 1 1 Transmission Ski Vee Transmission Pennzoil Type A Dexron II III or Dexron Mercon ZF V Drive and Reduction Gears 15W 40 Pennzoil Marine API Service SL SJ CI...

Page 80: ...All Raw water cooled Indmar 985009 All Closed cooled except LS1 LQ9 6 0 Indmar 986034 LS1 LQ9 Indmar 986110 Spark Plugs All 5 7 Liter except LS1 AC Delco 41 932 Platinum LS1 LQ9 6 0 AC Delco 41 985 8...

Page 81: ...00 5400 RPM Oil Pressure at Idle 4 PSI 41 kPa Minimum Hot 5 PSI 34kPa Min Oil Pressure at 2000 RPM 18 PSI 124 kPa Minimum Hot 10 PSI 69kPa Min Oil Filter Pennzoil PZ3 AC PF25 AC PF454 on engine Pennzo...

Page 82: ...ote 4 4 2 Quarts 4 L Pennzoil 15W40 Walter V Drive 0 5 Quart 0 5 L Pennzoil SAE 30 Motor Oil Notes 1 Minimum recorded compression in any one cylinder should not be less than 70 of the highest recorded...

Page 83: ...ange at WOT 4400 4800 RPM Oil Pressure at Idle 5 PSI 34 kPa Minimum Oil Pressure at 2000 RPM 10 PSI 69 kPa Minimum Oil Filter AC PF454 Fuel Pump Pressure 8 PSI Max 55 2 kPa Electrical System 12 Volt D...

Page 84: ...any one cylinder should not be less than 70 of the highest recorded cylinder 2 Measured using an accurate shop tachometer at normal operating temperature Idle RPM on EFI models is not adjustable 3 Ti...

Page 85: ...limited only to the foregoing obligations as stated here in 3 Customer This Limited Product Warranty is extended only to the original retail purchaser of a boat or the original lessor in the case of a...

Page 86: ...ssary access to the Product h Transportation charges and travel time incurred by Indmar to fulfill any of its obligations pursuant to this Limited Product Warranty i Service or work to the Product as...

Page 87: ...g any warranty coverage on the Product under this Limited Product Warranty 6 Warranty Period Warranty coverage shall be provided only for the periods of time hereinafter set forth a For Product instal...

Page 88: ...roduct or defective part thereof together with a written notice of itemized defects must be returned to the retailer from whom the Product was purchased or to any other convenient Indmar authorized de...

Page 89: ...OR OBLIGATIONS OF INDMAR FOR DAMAGES ARISING OUT OF OR IN CONNECTION WITH THE DEVELOPMENT DELIVERY USE OR PERFOR MANCE OF THE PRODUCT IN ANY EVENT THE LIABILITY OF INDMAR FOR ANY REASON AND UPON ANY C...

Page 90: ...C 6 Indmar Marine Engines OM0502 05 Body qxd 6 7 05 1 31 AM Page C 6...

Page 91: ...__________________________ Every 100 Hour Service Date ___________ Hours ____________ By _______________________________ Date ___________ Hours ____________ By _______________________________ Date ___...

Page 92: ...Part No OME0502 06 Printed in U S A J D Power and Associates Ranks Indmar Inboards Highest In Customer Satisfaction Inboard Gas Engines Ski Wake Ken Cook Co 5400 Old Millington Road Millington TN 380...

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