Malibu Boats Sportster Series Owner'S Manual Download

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Corporate Headquarters

Malibu Boats

One Malibu Court

Merced, CA 95340

Phone: (209) 383-7469

Fax: (209) 383-0499

Tennessee Plant

Malibu Boats

5075 Kimberly Way
Loudon, TN 37774

Phone: (423) 458-5478

Fax: (423) 458-9052

Internet:

www.malibuboats.com

[email protected]

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

Summary of Contents for Sportster Series

Page 1: ...ssee 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 Albu...

Page 2: ...__ Date Purchased __________________________________________________________ Dealer Phone ____________________________________________________________ Fax E mail ______________________________________...

Page 3: ...t 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...

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 Steer...

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 Transo...

Page 7: ...ou 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 th...

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...

Page 9: ...fety 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 age...

Page 10: ...tion 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 r...

Page 11: ...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 highl...

Page 12: ...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...

Page 13: ...ine 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...

Page 14: ...oxide 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 e...

Page 15: ...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 t...

Page 16: ...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 fro...

Page 17: ...arked 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...

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...

Page 19: ...es 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 ba...

Page 20: ...1 12...

Page 21: ...ll 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...

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 r...

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...

Page 24: ...peratures 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 st...

Page 25: ...s 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 abov...

Page 26: ...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 Ma...

Page 27: ...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 stan...

Page 28: ...eakers 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...

Page 29: ...ly 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 compart...

Page 30: ...s 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...

Page 31: ...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 Emergen...

Page 32: ...partment 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 se...

Page 33: ...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 Acce...

Page 34: ...kiing 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 i...

Page 35: ...ck 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...

Page 36: ...t 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...

Page 37: ...hat 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 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 s...

Page 39: ...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...

Page 40: ...t 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 access...

Page 41: ...ibu 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 t...

Page 42: ...e 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 COR...

Page 43: ...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 d...

Page 44: ...p 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 th...

Page 45: ...ater 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...

Page 46: ...ur 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 t...

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...

Page 48: ...ect 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...

Page 49: ...ering 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...

Page 50: ...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 cur...

Page 51: ...ines 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 pu...

Page 52: ...thy 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 mod...

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 t...

Page 54: ...sly 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...

Page 55: ...s 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 wat...

Page 56: ...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 dea...

Page 57: ...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...

Page 58: ...ore 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...

Page 59: ...PM 18PSI 124kPa Minimum Hot FuelPumpPressure 8PSIMax 30PSIMinat 40PSIMinat 50PSIMinat 55 2kPa Keyup 206 8kPa Keyup 275 8kPa Keyup 344 7kPa ElectricalSystem 12VoltDCNegative Ground MinimumBatteryRequir...

Page 60: ...rth 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 Da...

Page 61: ...g 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 b...

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 w...

Page 63: ...at 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 y...

Page 64: ...e 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 tha...

Page 65: ...ith 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...

Page 66: ...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 def...

Page 67: ...ealer 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...

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 engine...

Page 69: ...ntial 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...

Page 70: ...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 Mali...

Page 71: ...milar 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...

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 O...

Page 73: ...e 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 lo...

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 c...

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

Page 76: ...ssee 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 Albu...

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Malibu Boats Sportster Series, Owner'S Manual

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