Malibu Boats 2002 Response Series Owner'S Manual Download Page 60 | Manualshive

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4-4

Transmission

Check fluid only with engine OFF and boat floating level, or level on trailer. The
transmission dipstick is located on the top of the transmission. Dipsticks may be marked
“ADD” and “FULL” or “H” and “L” (high and low); maintain fluid level between the two
marks.

Check level immediately after turning engine off.

Transmission fluid may be hot. Be careful not to burn yourself.

TRANSMISSION

MODEL

CAPACITY

FLUID TYPE

ZF Hurth In-Line

450D

1.7 qt (1.6L)

Pennzoil Dexron II, III or MERCON

ZF Hurth In-Line

450A

2.12 qt (2L)

Pennzoil Dexron II, III or MERCON

ZF Hurth In-Line

630A

4.2 qt (4L)

Pennzoil Dexron II, III or MERCON

ZF Hurth V-Drive

630V

4.2 qt (4L)

Pennzoil Dexron II, III or MERCON

Walters V-Drive

RV-26D-71V

0.5 qt (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.

Operate boat approximately five minutes to warm the transmission fluid. Turn engine off
and disconnect the engine safety switch. Ensure throttle is neutral.

Note: Check immediately after shutdown to prevent incorrect reading.
•

Open engine compartment and locate transmission fluid level dipstick.

•

Remove dipstick and wipe with a clean rag. Quickly re-insert the dipstick fully
and immediately remove. Check the fluid level is at the full warm mark on the
stick.

Figure 4-1. Typical Transmission Dipstick

HIGH

LOW

KC-2175

Caution

Caution

®

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Summary of Contents for 2002 Response Series

Page 1: ...essee Plant Malibu Boats 5075 Kimberly Way Loudon TN 37774 Phone 423 458 5478 Fax 423 458 9052 Internet www malibuboats com info malibuboats com Australian Headquarters Malibu Boats 813 Hope Court Albury N S W 2640 Phone 026 040 1174 Fax 026 040 4656 Printed in U S A Malibu Cover 2002 O M 1 4 05 3 21 PM Page 2 ...

Page 2: ...___ Date Purchased __________________________________________________________ Dealer Phone ____________________________________________________________ Fax E mail ______________________________________________________________ Engine Model _____________________________________________________________ Serial ______________________________________________________________ Transmission Model __________...

Page 3: ...ut incurring any obligation Trademarks Malibu the Malibu Logo Flightcraft and Computron ATD are registered trademarks of Malibu Boats West Inc Mercury Mercury Marine Merc and Mercruiser are registered trademarks of Brunswick Corporation All other product names are copyright and registered trademarks trade names of their respective owners 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 Malibu Boa...

Page 4: ...ii ...

Page 5: ... Draining Ice Chest 2 13 Sundeck 2 13 V Drive Engine Access Hatch 2 13 Ski Pylon 2 14 Swim Platform 2 14 Navigational Lights 2 15 Storage Areas 2 15 Drain Plugs 2 16 Speedometer Pickups 2 16 Tilt Steering Wheel 2 17 Exhaust 2 17 Ventilation 2 18 Optional Equipment 2 19 Wedge 2 21 Warning Labels 2 22 OPERATION 3 1 Trailering 3 1 Fueling 3 4 Starting 3 4 Shifting Running 3 5 Steering 3 5 Stopping 3 ...

Page 6: ... 2 13 Figure 2 17 Engine Access Hatch 2 13 Figure 2 18 Pivoting Head Ski Pylon 2 14 Figure 2 19 Swim Platform 2 14 Figure 2 20 Swim Step Pins 2 14 Figure 2 21 Bow Light 2 15 Figure 2 22 Lockable Transom Storage 2 15 Figure 2 23 Transom Drain Plug 2 16 Figure 2 24 Bilge Drain Plug 2 16 Figure 2 25 Venturi Speedometer Pickup 2 16 Figure 2 26 Tilt Steering 2 17 Figure 2 27 Heater 2 19 Figure 2 28 Bim...

Page 7: ...you that your satisfaction and boating enjoyment will continue to be our 1 priority CERTIFICATIONS STANDARDS NMMA Certification Your Malibu boat has been built to meet or exceed the standards set by the National Marine Manufacturers Association NMMA NMMA verifies annually or whenever a new boat model is introduced to determine that they meet not only Coast Guard regulations but also the more compr...

Page 8: ... 18 18 24 24 26 Weight 2100 lbs 2450 lbs 2800 lbs 2900 lbs 2900 lbs 3400 lbs 3300 lbs 4500 lbs Fuel Cap 38 Gal 35 Gal 38 Gal 35 Gal 35 Gal 55 Gal 43 Gal 80 Gal Seating Cap 6 8 6 8 10 10 11 12 12 14 Std Engine 310 310 310 Vortec 310 Vortec 325 Monsoon 325 Monsoon 325 Monsoon 8 1 Liter Vortec Vortec 425 HP Std Gelcoat 3 4 3 4 4 3 4 3 4 3 3 Std Prop 3 Blade 3 Blade 3 Blade 3 Blade 4 Blade Brass 4 Bla...

Page 9: ...afety It is highly recommended that if you are unfamiliar with the use and operation of a boat you seek advice and training from a qualified individual or organization Check with your local boating agency or Malibu dealer for more information about boating safety classes in your area Safety Statements Throughout this manual specific precautions and symbols identify safety related information Follo...

Page 10: ...ation numbers In nearly all states this means registration with the designated state agency In a few jurisdictions the Coast Guard retains registration authority Your Malibu dealer will either supply registration forms or tell you where they may be obtained The agency will supply you with a certificate which must be carried with you when the boat is in operation Education If you have never owned a...

Page 11: ...f a skier has fallen Notice If a type V PFD is to be counted toward the minimum carriage requirements it must be worn 2 Emergency Stop Switch Factory installed lanyard emergency stop switch It is highly recommended that you use this switch since it can prevent your boat from becoming a runaway See page 2 13 for specific use 3 Fire Extinguishers A fire extinguisher is required if your boat has an i...

Page 12: ...u don t panic Learn your boating lessons and safety procedures well and you will have the confidence and ability to handle an emergency should one arise Fires Many boat fires involve flammable liquids such as gas or oil Many inboard fires start in the bilge area which at times can be filled with gas vapors Since gas vapors cannot be seen boat fires tend to travel very fast If you encounter a fire ...

Page 13: ...gine to overheat and can clog speedometer pickup tubes affecting correct speedometer readings Shallow Water Operation Shallow water brings on obvious hazards such as sand bars stumps rocks etc Know the area you will be operating the boat in Hitting objects at high speeds can cause severe damage to people and the boat If you know you will be navigating the boat in shallow water post a lookout and p...

Page 14: ...noxide gas CO is colorless odorless and extremely dangerous All engines and fuel burning appliances produce CO as exhaust Direct and prolonged exposure to CO will cause BRAIN DAMAGE or DEATH Signs of exposure to CO include nausea dizziness and drowsiness Sources of CO include Figure 1 5 Carbon Monoxide Hazards Blockage of boat exhausts by obstruction Exhausts traveling along obstruction Operating ...

Page 15: ...e actively enforced Impaired operation may result in severe personal injury or death Basic Rules Of The Road The nautical rules of the road must be followed to prevent collisions between vessels Like traffic laws for automobiles the operator is legally required to follow the rules The following information outlines only the most basic of the nautical rules of the road For more information contact ...

Page 16: ...e cardinal system Pass north or east of BLACK TOPPED WHITE buoy Pass south or west of RED TOPPED WHITE buoy RED and WHITE VERTICALLY STRIPED buoy indicates boat should pass outside of the buoy away from shore Uniform State Regulatory Markers USWMS regulatory markers are white with international orange geometric shapes you must obey regulatory markers Figure 1 6 Regulatory Markers KC 0320 BOATS STA...

Page 17: ...marked with RED and WHITE vertically striped buoys pass close to these buoys Obstructions channel junctions etc are marked with RED and GREEN horizontally striped buoys A RED band at the top means the preferred channel is to the left of the buoy a GREEN top band means the preferred channel is to the right of the buoy Figure 1 8 Spherical Marker Day markers are colored and numbered the same as buoy...

Page 18: ... speed necessary to keep out of the way of the privileged boat Crossing Situation In crossing situations the boat to the right from the 12 o clock to the 4 o clock position has the right of way It must hold course and speed The burdened boat keeps clear and passes behind the privileged boat Boats going up and down a river have the privilege over boats crossing the river Figure 1 10 Crossing Situat...

Page 19: ...les of the Road both boats must act to avoid collision Night Running Boats operating between sunset and sunrise hours vary by state must use navigational lights Nighttime operation especially during bad weather or fog can be dangerous All Rules of Road apply at night but it is best to slow down and stay clear of all boats regardless of who has right of way Protect your night vision by avoiding bri...

Page 20: ...1 12 ...

Page 21: ...ill Fuel Shutoff Valve Emergency Engine Shutoff Interior Lights Optional Speakers Transom Grab Tow Handle 12 Volt Adapter Circuit Breaker Locking Ski Locker Optional Speakers MAL109 2 Engine Cover Fuel Vent Interior Lights Engine Cover Engine Compartment Air Intake Interior Lights Sundeck Ski Pylon Gunwale Step Pads Battery Under Cover Engine Ventilation Fuel Fill Fuel Shutoff Valve Bilge Drain Em...

Page 22: ... warranty Engine Hourmeter Located on the bottom center of the tachometer gauge is the engine hourmeter This meter will help identify how much your boat is being used and at what time the engine will require servicing The hourmeter will run whenever the ignition is on The engine hour gauge acts as an odometer for the engine Engine hours should always be noted so maintenance and lubricant changes m...

Page 23: ... proper operating range for your engine is between 140 160 degrees Fahrenheit Engines equipped with the optional Monsoon engine have a control in the engine control module that will cause the engine to run at reduced speeds if the module senses that the engine is running to hot If you notice that your speed has reduced during normal operation without reducing the throttle monitor your temperature ...

Page 24: ...mperatures oil viscosity and other environmental factors but readings above the low pressure zone indicate the normal operating range If the oil pressure reading is below the normal range you should stop the engine immediately and check your oil as soon as possible Average pressure ranges are between 6 PSI at 1000 RPM and 40 PSI at cruising speeds If you are experiencing low oil pressure stop your...

Page 25: ...ps until the word OFF is on the display screen Analog Clock The Analog Clock is located on the right side of the dash and provides a display of the current time To set the clock depress the button above the clock until the correct time is displayed The hands should rotate in a clockwise motion Malibu Message Center The optional Malibu Message Center enables the operator to observe and control many...

Page 26: ...E T E E T e e T e T T T T H T H H H H H H H d t MAL109 12 Contrast Engine Tach Spd Cruise T H H H Alarms Time Date Setup H H GPS Depth Temp Timers H H H H H T T Optional T H e E MAL109 14 Figure 2 9 Malibu Message Center Schematics ...

Page 27: ...3 Operation Records an interval each time it is pressed up to a maximum of 7 The 8th interval is the total of all interval times recorded MAL109 15 Main Menu 2 Alarms Time Date Setup T Main Menu 3 standard time date E T Main Menu 1 H H T T E battery low high H T temp high H T oil low high H T fuel low H T military time date Edit time and date E E T E E For each of the 7 time and date fields AM PM ...

Page 28: ...reakers Figure 2 10 Circuit Breaker Panel All major boat circuits are protected from shorting and overload by resettable circuit breakers If a problem develops with one of the following circuits switch off the circuit and wait about one minute Then push the appropriate breaker button fully and switch on the circuit If the circuit continues to trip there is a problem somewhere in the system See you...

Page 29: ...lly whenever two inches or more of water is detected Blower This switch activates the blower for the engine compartment The primary function of the blower is to eliminate any fumes in the motor compartment when starting the engine or during idling Gasoline Vapors Can Explode Before starting engine operate blower for 4 minutes and check engine compartment for gasoline leaks or vapors Run Blower bel...

Page 30: ...ts and is a warning device used to safeguard against low V Drive fluids which could result in overheating the unit and eventual failure If the light is on above 1200 RPM the oil pressure is low Check V Drive oil Check while cool If the problem persists see your local Malibu dealer Throttle Control The throttle lever is located to the right of the driver When the throttle is vertical it is in the N...

Page 31: ...e Flightcraft Outboard boats Push and hold the switch until the engine is at the desired angle Use this switch to maximize boat performance in the water The tilt raises the drive for trailering Emergency Engine Stop Switch The emergency engine stop switch attaches to the driver of the boat and shuts down the engine if the driver of the boat is accidentally forced away from the helm The switch cons...

Page 32: ...mpartment when opened Running the engine with the motor box open exposes rotating machinery which can cause injury to occupants of the boat Driver s Seat The driver s seat can be adjusted moving the seat forward and backward by pulling lever located on front left side of the drivers seat Pull lever outward and adjust seat as needed The seat is also equipped with Air Lumbar Support To adjust the lu...

Page 33: ...2 16 Sundeck The Sundeck is not to be used while the boat is in operation Serious injuries or death could occur to persons not seated properly should the boat come to an abrupt halt V Drive Engine Access Hatch An engine access hatch is located behind the rear observers seat on the V Drive Access allows the ability to service engine for required maintenance and for additional storage on both sides ...

Page 34: ...skiing activities slalom jumping kneeboarding tricks and barefooting Any other uses such as parasailing kite flying towing pyramids of skiers etc may over stress the pylon and possibly cause personal injury and or equipment damage Swim Platform A removable swim step is located at the stern of the boat to provide easy access into and out of the water for both skiers and swimmers To remove the swim ...

Page 35: ...ack The size of the storage differs between open and closed bow versions On all open bow boats The seat cushions can be removed to provide additional storage Gunnel Ski Storage Conveniently located on both sides of the boat these storage areas are ideal for the storage of water skis and other items Floor Ski Storage Located on the floor between the driver s and observers seats on open bow models w...

Page 36: ...at is equipped with two venturi type speedometer pitot pickups located on each side of the boat at the bottom of the transom The water pressure applied to these pickups determines the measured speed of the boat The venturi design reduces the potential of clogging due to shallow water operation and uses two separate tube channels One channel is open at the front and rear so that water passes throug...

Page 37: ...that you will be checking engine while turned on and that you will need to take safeguards against getting yourself or others caught in the moving parts Use extreme caution while performing this task Turn engine off and disconnect the engine safety switch Be sure the throttle shift control is neutral The engine must be cool Open the engine and visually check the exhaust system from the engine to t...

Page 38: ... boat is the blowers located in the bottom of the bilge and at the transom venting points See Section 2 page 2 1 Your boat is also equipped with a natural air intake that forces air through a venting system on the deck of your boat and channels air from the bilge to the transom vent Cooling Most boats will be cooled with a continuous intake of lake water circulating it around engine components Clo...

Page 39: ...d in the front and rear of the windshield and adjust strap for tightness of the canvas The bimini top can be stored by releasing the adjustable strap placing the canvas protective covering over the top and then folding down the top to the front of the windshield For additional installation and assembly instructions refer to the information that came with the bimini top Notice If the canvas top is ...

Page 40: ...at simply press the cleat downward until it locks into place Docking Lights The docking lights should only be used during slow speed docking maneuvers The lights are activated by a switch on the accessory switch panel and have a 10 amp circuit breaker Bulb access is through the lens cover outside the boat Port a Potty SaniPottie Sunscape 25 model boats only The portable port a potty provides simpl...

Page 41: ...libu Launch System MLS is a water ballast tank found in the bow ski locker of walk through open bow models The system can be found by opening the ski locker door Depressing the rocker switch found on the accessory panel activates the system Press the switch up to fill and down to drain Wakeboard wakes can be adjusted by adding or decreasing water to the tank and will require a minimal amount of fi...

Page 42: ...re to add the weight of the water to the weight of the persons and gear Caution Caution WARNING LEAKING FUEL IS A FIRE AND EXPLOSION HAZARD INSPECT SYTEM REGULARLY EXAMINE FUEL SYSTMEM FOR LEAKS OR CORROSION AT LEAST ANNUALLY NMMA 1990 NO 200 WARNING WARNING WARNING MALIBU BOATS PATENTED SWIVEL HEAD SKI PYLON IS DESIGNATED FOR NORMAL WATERSKIING ACTIVITIES SLALOM JUMP KNEEBOARDING TRICKS AND BAREF...

Page 43: ...l weight of your boat gear and trailer does not exceed the GVWR Notice Consult your trailer dealer for other state regulations concerning brakes lighting and other equipment options Hitch Hitches are divided into classes that specify the gross trailer weight GTW and maximum tongue weight for each class Always use a hitch with the same class number as the trailer or greater Most boat trailers conne...

Page 44: ...op to hold the front of your boat in place is located on the winch stand It should be positioned so that the winch line pulls straight and is parallel to the trailer frame A separate tie down should then be attached to hold the boat downward and forward This may be accomplished by a line from the bow eye to an attachment point on the trailer frame or winch stand Rear Tie Downs It is very important...

Page 45: ...water and stop Be sure to properly secure your vehicle Prepare for placing the boat in the water by removing any tie down straps disconnecting tail light connections and attaching a line to the bow eye fitting If you are using an outboard be sure that the outboard unit is trimmed up Be sure to re install the bilge drain plug if it has been removed To launch back the trailer into the water to a poi...

Page 46: ...our Malibu Consult the engine owner s manual for more specific information regarding starting operation and troubleshooting for your particular engine Pay close attention to the information regarding the break in period listed in your engine owner s manual Top engine performance is dependent upon following the guidelines listed Pre Start Checklist A routine pre starting procedure should always be ...

Page 47: ... engaging the transmission from neutral to either forward or reverse you must pull up on the safety collar located directly below the throttle lever knob Notice For more information regarding the safe operation and maintenance of the throttle control refer to the separate instructions located in the information packet shipped with your boat Steering It is important that you get the feel of your bo...

Page 48: ...fect is to steer the boat back and forth in an attempt to compensate for wandering Invariably the compensation will result in oversteer and only worsen the effect Keep the steering wheel in the center position the boat will wander back and forth somewhat but the overall course will be a straight one Warning KC 1071R BACKING TO LEFT Turn wheel to left Stern will pull to left RIGHT TURN Turn wheel t...

Page 49: ...eering in the straight ahead position to drift to starboard when going forward and to port when going backward At high speed this effect is usually unnoticed but at slow speed especially during backing it can be powerful For this reason many veteran boaters approach the dock with the port side of the boat toward the dock if possible Stopping When stopping the boat it is important to remember there...

Page 50: ...g Approach docks with the starboard side of the boat if possible Come to a stop a short distance from the dock then proceed slowly Have fenders mooring lines and crew ready Observe how the wind and current are moving your boat Approach the dock with the boat pointed into the wind if possible If the wind or current is pushing you away from the dock use a sharper angle of approach If you must approa...

Page 51: ...lines when departing Very slowly shift into forward at idle speed When the stern moves away from the dock turn the engine away from the dock Cast off bow line and back away If the wind or current is pushing away from the dock cast off all lines and allow to drift until you are clear High Speed Operation A great deal of caution must be exercised when operating any boat at high speeds This is partic...

Page 52: ...lthy respect for Common Sense Rules of waterskiing safety on the part of the skier driver and observer will ensure the risk of skiing accidents is kept to a minimum at all levels of participation A moderate ability to swim is advisable for waterskiers but swimming ability is no substitute for a well fitting life jacket The wearing of a life jacket or personal flotation device PFD is essential even...

Page 53: ... can be found for review at your local Malibu dealership or by contacting the American Waterski Association at 813 324 4341 Figure 3 11 Hand Signals Once a skier has fallen or is ready to quit skiing the driver must be prepared for immediate removal of the skier from the water The driver of the boat should keep the skier in line of sight as much as possible until the skier is reached Once the boat...

Page 54: ...usly Fasten the towline as far forward as possible on the upwind or up current side of the boat being towed Fastening it to the stern will restrict maneuverability Attach the line to the stern lifting eyes of the towing boat Keep lines free of propellers on both boats Keep hands and feet clear of other boat and never hold towline after it is pulled taut Move slowly to prevent sudden strain on slac...

Page 55: ...as brass or stainless steel The first number is the diameter of the prop and the second is the pitch The pitch is the angle of the blades and is measured in how far the boat will travel through the water in one revolution In this case for every one revolution the boat will travel 14 inches Do not operate engine above the manufacturer s recommended RPM rating severe damage could result voiding the ...

Page 56: ...e water The zinc anode being the softer metal will deteriorate and erode much faster than the other metals in the boat Inspect the anode periodically and replace as needed Consult your local Malibu dealer for this part Salt Water Corrosion The entire boat should be rinsed with fresh water immediately after use in salt water If the boat is used primarily in salt water wash the hull monthly and appl...

Page 57: ...o prevent mildew which will rot the upholstery threads and backing We also recommend that you tip up all seat base cushions on edge after each use to allow any accumulated water to drain Exterior Your Malibu boat is highly resistant to weathering water pollution and minor scrapes which occur during normal use However regular care and maintenance of your boat is a general responsibility for all Mal...

Page 58: ...tore the gelcoat to like new condition Underwater Corrosion Corrosion occurs in saltwater conditions from the interaction of the saltwater and the direct current of the battery To prevent corrosion it is important to keep the bilge area as dry and clean as possible Care For Boats That Are Moored Due to gelcoat discoloration osmosis blistering and algae growth it is not recommended that you leave y...

Page 59: ...RPM 18PSI 124kPa Minimum Hot FuelPumpPressure 8PSIMax 30PSIMinat 40PSIMinat 50PSIMinat 55 2kPa Keyup 206 8kPa Keyup 275 8kPa Keyup 344 7kPa ElectricalSystem 12VoltDCNegative Ground MinimumBatteryRequirements 550cca 700mca 120Ah FiringOrder 1 8 4 3 6 5 7 2 1 8 7 2 6 5 4 3 SparkPlugType MR43LTS AC41 931 SparkPlugGap 030in 76mm 045in 1 1mm 050in 1 3mm BaseTimingat1000RPM Note3 10DegreesBeforeTopDeadC...

Page 60: ...urth V Drive 630V 4 2 qt 4L Pennzoil Dexron II III or MERCON Walters V Drive RV 26D 71V 0 5 qt 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 Operate boat approximately five minutes to warm the transmission fluid Turn engine off and disconnect the...

Page 61: ...ng periods of inactivity or storage Please note where the location of your Fuel Shutoff Valve is on your particular boat Since Fuel Shutoff Valves are located in the storage compartment the valve can be inadvertently closed by stowed equipment If your boat should suddenly loose power check the valve to ensure that the valve is in the ON position in line with the fuel hose Fuel Filter A fuel filter...

Page 62: ... or POSITION 2 rather than in the ALL position This will keep one battery charged should one of the batteries fail Circuit Breakers and Fuses Most electrical standard equipment devices are controlled with circuit breakers These breakers will activate if overloaded and cut power to the switch To restore power simply push the breaker button in and release Breakers do not require fuse replacement The...

Page 63: ...oat life Here is our list of suggestions to keep your boat in top condition Prepare the engine according to the instructions found in your engine owner s manual It our recommendation that you contact your local Malibu dealer for full winterization procedures Clean and dry the boat interior and exterior thoroughly Inspect boat hull for residue and remove any if present Clean the bilge area thorough...

Page 64: ...ne owner s manual for complete engine winterization procedures as well as scheduled maintenance Note Damage done due to improper engine winter storage will void your warranty It is highly suggested that you allow a trained Malibu technician to perform this service After performing engine winterization remove engine safety switch and spin engine over a few seconds to remove excess water found in pu...

Page 65: ...with optional fresh water cooling and was drained at winterization fill at this time Turn fuel shut off valve to the ON position Handle is in line or parallel with the fuel line Turn key on and off 2 3 times to allow fuel to return to engine then start engine When engine starts watch gauges closely and watch for abnormal readings Troubleshooting The following charts will assist you in finding and ...

Page 66: ...r Clean and tighten battery corroded cables Weak battery Charge or replace the battery Ignition problems See your dealer Engine misses or Fouled spark plugs Replace spark plugs idles rough Loose of defective high Tight or replace the high tension leads tension leads Plugged PVC valve Replace PVC valve Weak ignition coil Replace ignition coil Vacuum leak See your dealer Poor boat performance Fouled...

Page 67: ...dealer for proper realignment Bent propeller shaft See your dealer Electrical problems Open circuit breaker or Reset the circuit breaker blown fuse or replace the fuse Loose wing connections Clean and tighten wiring or corrosion connections Defective sending unit Replace the sending unit Shorted wiring harness Repair the wiring harness Defective switch or gauge See your dealer No speedometer Disco...

Page 68: ... that these parts are warranted Malibu Boats will if possible furnish the manufacturer s warranty documents to the original owner 2 Damage or effects of such damage caused by the installation of engines accessories or other equipment installed by anyone other than Malibu Boats 3 Boats that have been sold or transferred by the original owner outside of the five 5 year transferable option period boa...

Page 69: ...ential damages therefore these limitations may not apply to you This warranty gives you specific legal rights and you may also have other rights that vary from state to state Malibu Boats West Inc One Malibu Court Merced CA 95340 Phone 209 383 7469 Fax 209 383 0499 Effective 2000 Boat Models Other Manufacturer Warranties Along with Malibu s warranty policy many of the components used to build your...

Page 70: ...e the knowledge technical staff and equipment needed to properly service your boat Service Away From Home If you are away from home and require service to your boat contact your nearest authorized Malibu dealer Check the yellow pages of the telephone directory in the area If you are unable to locate an authorized dealer in the area contact Malibu directly We will be happy to give you the name and ...

Page 71: ...imilar to wool or cotton but made from fibrous glass Glass fiber forms include cloth yarn mat milled fibers chopped strands roving and woven roving GELCOAT A surface either colored or clear providing a cosmetic enhancement and exposure improvements to a fiberglass laminate GUNNEL The upper edge of a boat s side HELM Device attached to rudder for steering a vessel HULL The bottom section of the boa...

Page 72: ... 21 Malibu Message Center 2 5 Miscellaneous 4 7 Motorbox Cover 2 12 N Navigational Lights 2 15 O Operation by Minors 1 7 Optional Equipment 2 19 Optional Gauges 2 5 Other Manufacturer Warranties 4 13 Owner Service Assistance 4 13 P Passenger Safety 1 7 Power Trim 2 11 Propellers 3 13 R Regulations 1 2 Responsibilities 1 2 S Safety Statements 1 1 Shifting Running 3 5 Ski Pylon 2 14 Speedometer Cali...

Page 73: ...ke fluid level if applicable LAKE TEST ____ 1 Perform TECH I data list scan ____ 2 Check PROM ID and record in customer file ____ 3 Check engine timing in service mode ____ 4 Check fuel pressure and log reading ____ 5 Verify oil levels engine Trans V Drive ____ 6 Verify blower operation check hose attachment ____ 7 Verify bilge pump operation and float control ____ 8 Check for engine boat water le...

Page 74: ... 7 Engine tune up Cap Rotor Plugs 8 Clean for change flame arrestor 9 Inspect belts hoses and clamps Tight 10 Shaft alignment Within 003 11 Inspect spark plug wires 12 Inspect Raw water pump impeller change annually 13 Inspect rudder lube key way bolt tight 14 Inspect Prop Shaft Packing 15 Inspect Steering Kit Assembly Lube bolts tight 16 Check Engine Coolant closed cooling only 50 50 mix water w ...

Page 75: ...SERVICE MAINTENANCE LOG HOUR DATE READING SERVICE REPAIRS PERFORMED ...

Page 76: ...essee Plant Malibu Boats 5075 Kimberly Way Loudon TN 37774 Phone 423 458 5478 Fax 423 458 9052 Internet www malibuboats com info malibuboats com Australian Headquarters Malibu Boats 813 Hope Court Albury N S W 2640 Phone 026 040 1174 Fax 026 040 4656 Printed in U S A Malibu Cover 2002 O M 1 4 05 3 21 PM Page 2 ...

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