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9-1

© 2020 Indmar Marine Engines

Section Nine

TROUBLESHOOTING

Before operating or maintaining the engine, review “Safety” on 
page 1-1.

Your Indmar engine is manufactured under strict quality control 
standards. It is tested along with a full spectrum gas analysis. It is 
operating at optimum levels before it is shipped.

Difficulties can occur. Use the following problem diagnosis 
charts to help pinpoint problems. In most cases, you will need 
the assistance of your Indmar dealer to correct the cause of the 
problem.

OTE: 

N

Modern boats are equipped with an onboard diagnostic system 
that displays a check engine indication and informs the operator 
of specific drive train faults.

Poor Gas Mileage

x

Fouled spark plugs

x

Plugged flame arrestor

x

Poor driving habits

x

Plugged positive crankcase ventilation system

x

Black smoke at exhaust outlet shows rich gas mixture

x

Excessive boat loads (weight)

x

Damaged or dirty hull

x

High altitude adjustment required

x

Adjustment for temperature extremes required

Hard Cold Start

x

Weak or discharged battery

x

Loose coil or ignition wires

x

Engine flooded

x

Fouled spark plugs

Содержание Premium 400

Страница 1: ...6 2L...

Страница 2: ...he four star label on the outside of the hull above the waterline Outboard and personal watercraft marine engines may also comply with these standards Operating servicing and maintaining a recreationa...

Страница 3: ...is another exciting year for Indmar and for the marine industry Indmar has joined forces with Ford Motor Company to produce a line of marine engines designed to exceed customer expectations The 6 2L...

Страница 4: ...mitable mix of unrivaled performance meticulous craftsmanship and groundbreaking innovations charting a course for others to follow yet leaving the competition behind INDMAR MARINE ENGINES COMPANY MIS...

Страница 5: ...Check Engine Indicator 2 9 Engine Cooling 2 10 Aquatic Invasive Species AIS Prevention 2 11 Exhaust Hoses 2 14 Selecting a Propeller 2 15 Section 3 Pre Start Checks 3 1 Pre Start Checks 3 1 Section 4...

Страница 6: ...System 7 27 Wiring 7 28 Accessory Drive 7 30 Section 8 Storage and Winter Lay Up 8 1 General Preparation 8 2 Reactivating Engine After Extended Storage 8 13 Extended Storage 8 15 Section 9 Troubleshoo...

Страница 7: ...cations parts and the special equipment needed to service your Indmar engine and drive train To nd your nearest Indmar dealer please visit our website at www indmar com or call 901 353 9930 To ensure...

Страница 8: ...ith federal regulations This registration enables us to contact you if it should become necessary to change or improve your product The engine serial number is stamped into the block For additional se...

Страница 9: ...sed on approval by Indmar The new boat owner will be noti ed within 10 days of Indmar s receipt of the transfer form whether the transfer has been accepted or not If the transfer has been accepted the...

Страница 10: ...ements set forth by the U S Environmental Protection Agency EPA and the California Air Resources Board CARB Indmar also uses propylene glycol anti freeze in the closed cooling system of your engine to...

Страница 11: ...synthetic 5W 30 oil meeting the API rating of SN for use in all its 360 400 and 440 engines and fully synthetic 15W 50 in its 450 460 and 575 engines Additives Over time oxidation of gasoline can for...

Страница 12: ...onsidered 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 Se...

Страница 13: ...or replacement of the part The emission warranty covers damage to other engine components that is caused by the failure of a warranted part This manual contains written instructions for the proper ma...

Страница 14: ...dmar and provides us with the required information listed below or b Indmar receives a proof that the former owner agreed to the transfer of ownership and we are provided with the information listed b...

Страница 15: ...ANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Indmar Products are pleased to explain the emission control system warranty on your 2021 inboard engine In Ca...

Страница 16: ...wner s Warranty Responsibilities As the inboard engine owner you are responsible for the performance of the required maintenance listed in your owner s manual Indmar Products recommends that you retai...

Страница 17: ...involved Please read and abide by the message that follows the safety alert symbol DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury WARNING Indicates...

Страница 18: ...e heaters and water heaters Do not confuse carbon monoxide poisoning with seasickness intoxication or heat stress If someone complains of irritated eyes headache nausea weakness dizziness or drowsines...

Страница 19: ...still DO be aware that the station wagon effect or backdrafting can cause carbon monoxide to accumulate inside the cabin cockpit and bilge when the boat is underway moving at slow speed or idling DO...

Страница 20: ...ing time out to carefully inspect your boat at least once a day for gasoline fumes oil leaks and areas where wiring may be worn or damaged WARNING Always operate the bilge blower at least 4 minutes pr...

Страница 21: ...x Do not check for a dead battery by placing a metal object between the battery posts Sparks could cause an explosion x Do not place your head directly above a battery when making or breaking electric...

Страница 22: ...WARNING Rotating or moving parts can entangle or sever body parts x Do not wear jewelry unbuttoned cuffs ties or loose tting clothing x Tie long hair back when working near moving or rotating parts x...

Страница 23: ...alcohol mixture in the bottom of the fuel tank and a layer of gasoline on the top Because the gasoline layer has had some or all of the alcohol removed from it the remaining fuel will be of lower oct...

Страница 24: ...com and click on LICENSED BRANDS Over time oxidation of gasoline can form a buildup of harmful solids called gums Water and impurities in the fuel system can cause corrosion To stabilize the fuel and...

Страница 25: ...e used in Indmar engines Fuels that contain more than 10 ethanol will damage your engine Damages caused by the use of fuels that contain more than 10 ethanol are not covered by your warranty NOTICE Fu...

Страница 26: ...e or reliability Bu16 can be mixed with any E10 or other approved fuel already in the boat s fuel tank s Biobutanol is chemically different from ethanol and does not have ethanol s negative characteri...

Страница 27: ...anty FUEL SYSTEM WARNING Never remove or modify any components of the engine s fuel system Tampering with fuel components may cause a hazardous condition that could result in severe personal injury or...

Страница 28: ...eplacement is needed use only a marine battery with minimum 800 cold cranking amps at 0 F 18 C Battery Switches Most of today s boats have signi cant electrical requirements and are equipped with two...

Страница 29: ...on 1 and 2 would be used in an emergency situation where both batteries are low and power is needed from both batteries to start the engine Once the engine has started carefully select battery 1 or ba...

Страница 30: ...2 8 SECTION TWO Be sure to connect cables properly 1 Red cable to the positive or post 2 Black or yellow cable to the negative or post INDM A010 Figure 2 2 Typical Marine Battery...

Страница 31: ...ble fault code displayed to have the issue veri ed with a Diagnostic Scan Tool If any of the following conditions is noted x Low Oil Pressure x High Coolant Temperature x High Transmission Oil Tempera...

Страница 32: ...water pumps One circulates coolant throughout the engine The other pump uses water from the sea lake or river to feed raw water to the engine This raw water pump is designed to use the water it pumps...

Страница 33: ...e temperature rises past 210 F 99 C or your oil pressure drops below 10 psi 69 kPa severe engine damage may result Damage due to running the engine with excessive temperature or low oil pressure is no...

Страница 34: ...rce for the area you are in The following procedures will help you through the process Drain the engine as described in Storage and Winter Lay Up on page 8 1 of this manual Reinstall the drain plugs i...

Страница 35: ...ll of the water through the engine drive train 7 Turn on the hot water supply to between 1 4 and 1 2 pressure Start engine and let it run at idle with the transmission in neutral 8 Turn water supply t...

Страница 36: ...n neutral 5 Turn water supply to full pressure 6 Let the engine run until the temperature indicator in the boat or the temperature of the water exiting the exhaust outlet reaches the designated temper...

Страница 37: ...T range for each application Propping the boat should be done after engine break in and the initial 10 hour dealer check The boat should be loaded the way it would normally be for each application For...

Страница 38: ...arent 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 performance can be regained by dropping to a low...

Страница 39: ...ealer for assistance INDM 0027 13 12 11 10 9 8 7 6 5 4 3 2 15 14 16 1 1 Figure 3 1 Pre Start Check Points 1 Check the boat hull and or garboard drain plug Make sure they are installed and secure 2 Car...

Страница 40: ...has drain plugs Refer to Section 7 Maintenance for speci c instructions Fresh Water Cooling System The heat exchanger has a single drainage point that can be accessed by removing the anode or drain pl...

Страница 41: ...on tank 9 Check serpentine belt for wear and proper tension 10 Verify that exhaust hoses are in good condition and clamped tight 11 Ensure that the propeller shaft coupler bolts are tight 12 Verify en...

Страница 42: ...EE 16 Verify battery connections are clean and securely fastened Make sure the battery is fully charged INDM A010 Figure 3 4 Battery Connections 17 Check the boat s owner s manual for additional pre o...

Страница 43: ...e oil before it is broken in Check your oil level hourly during the break in period Once the engine is broken in check the oil level before each day s use and more often during sustained periods of hi...

Страница 44: ...the fuel pump cycles for 2 seconds 3 This procedure is only necessary for the rst time the engine is started or in the event the fuel tank is run dry Prime the fuel system by cycling the fuel pump th...

Страница 45: ...erature keep a close eye on the gauges If any of the gauges indicate an engine problem stop the engine immediately and bring the boat to your Indmar dealer for assistance NOTICE Do not operate the sta...

Страница 46: ...ng break in Do not run at the same speed very long x Observe gauge readings and check for loose mountings ttings nuts bolts and clamps x Report abnormal operation noises or vibrations to your dealer B...

Страница 47: ...til the engine starts whichever happens rst This same feature will prevent accidental engagement of the starter when the engine is running NOTICE Some boats are equipped with a pushbutton start instea...

Страница 48: ...pulled out NOTICE Refer to the boat owner s manual for ignition system information 4 When the engine starts to crank you can release the key and let Smart Start take over When the engine starts it wil...

Страница 49: ...operation IF ENGINE DOES NOT START NOTICE Do not operate starter motor for more than 15 seconds without a 2 two minute cool down period Excessively long cranking times will permanently damage the star...

Страница 50: ...1 Figure 5 4 Typical Shift Throttle Lever 3 Disengage the shift interlock Advance the throttle lever to full throttle and hold Turn the key to the START position to clear extra gasoline from the engin...

Страница 51: ...shift interlock and advance throttle to about 1 4 while holding key in the START position When engine starts release the key and immediately return throttle to IDLE position NOTICE Your engine is des...

Страница 52: ...5 6 SECTION FIVE NOTES...

Страница 53: ...an the boat was designed to handle Damage to the engine that can be attributed to excessive RPM and or loading may not be covered by the engine s limited warranty DAILY ROUTINE 1 Open the engine cover...

Страница 54: ...he starting procedures outlined in Section 5 Engine Starting Procedures 3 Once the engine is started allow it to reach operating temperatures of at least 120 140 F 49 60 C before accelerating to speed...

Страница 55: ...ur engine has a safety feature that allows the engine to crank only in the neutral position If during the starting process your engine will not turn over make sure that the shift throttle control is i...

Страница 56: ...covered by your warranty unless caused by defects in material or workmanship UNUSUAL VIBRATION If your engine is used in a direct coupled application inboard you need to know that damage to the drive...

Страница 57: ...engine failure which may result in death or serious personal injury GENERAL SERVICE NOTES Your Indmar dealer is your best source for engine repair and maintenance Indmar certi ed technicians attend o...

Страница 58: ...als while other moving parts are heavy duty for extended high RPM duty If you perform minor service procedures make sure to use genuine Indmar parts for marine use NOTICE If the temperature falls belo...

Страница 59: ...er RPM range above 4000 RPM Many of these engines are also exposed to extended periods of idling RPM below 1000 Boats used in these conditions often have engines that may suffer from fuel dilution of...

Страница 60: ...Change Check Change Spark Plugs Change Every 500 Hrs Fuel Injectors Inspect Clean X Fuel Filter Replace X Flame Arrestor Clean Change X Belts Inspect X X X Shaft Alignment Check X X Spark Plug Wires...

Страница 61: ...boat on the other hand is utilizing a signi cantly larger amount of the engine s output to keep the boat moving Then add the extra load of ballast bags and a wakeboarder surfer or skier and we are ut...

Страница 62: ...o drain into the oil pan giving you a more accurate reading 1 CAUTION Engine and engine oil may be hot Pull dipstick from engine 2 Wipe oil off stick with clean towel cloth 3 Insert dipstick completel...

Страница 63: ...TICE The use of engine oil other than the recommended viscosity with an API SN designation can cause engine damage Damage to your engine caused by the use of improper oils is not covered by your warra...

Страница 64: ...QuickDrain to storage position 3 Replace the hull or garboard drain plug 4 For Engines with Cartridge Style Filter Remove the oil lter cap from the canister assembly and wipe clean Carefully remove an...

Страница 65: ...sing Used engine oil contains dangerous chemicals and is considered a hazardous waste Do not allow used oil to remain on your skin for any length of time Make certain to drain all free owing oil from...

Страница 66: ...gure 7 5 Flame Arrestor Periodically inspect ame arrestor to prevent clogging by dirt or corrosion High Performance Element Type Flame Arrestor Your engine is equipped with a high performance USCG app...

Страница 67: ...ning your engine with your boat out of water will damage or ruin your engine Damage to your engine caused by overheating is not covered by your warranty Marine engines are cooled by the raw water outs...

Страница 68: ...the ushing feature of the Strainer Pro the transmission must be in neutral Do not exceed 1200 RPM Monitor the engine temperature to ensure the engine does not run excessively hot The temperature must...

Страница 69: ...ea strainer 4 Remove the wire mesh screen from the sea strainer and remove the debris from the screen 5 Reinstall the wire mesh screen in the sea strainer 6 Reinstall the inlet cap making sure to not...

Страница 70: ...the ON position Fresh Water Closed Cooling Systems WARNING Avoid possible skin burns turn the engine OFF and allow it to cool enough so no heat is registered on the temperature gauge Only after the e...

Страница 71: ...types can cause engine damage Damage to your engine from use of any other type of coolant is not covered by warranty The coolant system should be ushed and coolant replaced every two years This should...

Страница 72: ...mmends applying an anti corrosion compound Regular application every 3 months of this protectant particularly on exposed metal surfaces motor mounts and electrical connections will displace water and...

Страница 73: ...er Note that if you use a clean out rod it should be softer than the copper tubes and should not be used to dislodge materials which are rmly stuck to the tube surface as this could damage the tubes T...

Страница 74: ...year as a routine Be sure there are no impeller parts lodged in the hoses or elsewhere in the system as they will eventually move to a different place and restrict water ow The raw water pump impelle...

Страница 75: ...s Your Indmar engine may be equipped with a spin on type water separating fuel lter that needs to be replaced every 100 hours or annually whichever occurs rst WARNING The fuel lter is under pressure T...

Страница 76: ...d turn it by hand till the seal contacts the lter head 3 Tighten the lter an additional 3 4 turn by hand 4 Reconnect the negative battery cable s or turn the battery switch ON 5 Engine may be dif cult...

Страница 77: ...If the water level in the bilge is too high the coupler can splash water inside the engine compartment and cause corrosion and water intrusion problems High water levels can also allow water intrusio...

Страница 78: ...7 22 SECTION SEVEN 1 1 Dipstick Figure 7 11 Midships Mount Indmar In Line...

Страница 79: ...7 23 MAINTENANCE 2020 Indmar Marine Engines 1 1 1 Dipstick Figure 7 12 Stern Mount Indmar Vee Throughshaft Models...

Страница 80: ...e changed and the lter cleaned after the rst 10 20 hours of operation and once each year thereafter Refer to the transmission owner s manual for information The transmission is water cooled by a heat...

Страница 81: ...N Transmission uid may be hot OTE N Refer to page 7 26 for correct transmission and uid capacities for your model of transmission Checking Fluid Shifting Portion Red Dipstick 1 Start the engine and le...

Страница 82: ...ive Portion Yellow Dipstick 1 Remove the dipstick and wipe it clean 2 Reinstall the dipstick but do not thread it in 3 Remove the dipstick and check the oil level It should be between the two marks on...

Страница 83: ...ns in the electrical box Always keep spare fuses in these locations If you use the 40A fuse obtain another from your dealer or from an automobile parts store and replace the spare fuse in the electric...

Страница 84: ...RITY When reconnecting the battery after winter storage it is easy to accidentally reverse the battery leads and connect positive to negative and negative to positive This generally results in a large...

Страница 85: ...draw can overheat the diodes and cause them to fail These types of failures are not covered by Indmar s Limited Warranty 4 NEGATIVE GROUND CIRCUIT FAULTS The primary mount of the alternator serves as...

Страница 86: ...sion protectant and lubricant Check boat owner s manual for recommendations Work the cable back and forth and then spray to completely lubricate In highly corrosive locations a complete cable lubricat...

Страница 87: ...7 31 MAINTENANCE 2020 Indmar Marine Engines ALT IDLER IDLER CIRC PUMP CRANKSHAFT TENS IDLER IDLER S C BELT ROUTING 575 INDM 0087 Figure 7 15 Serpentine Belt Routing Supercharged Models...

Страница 88: ...7 32 SECTION SEVEN ALT IDLER IDLER CIRC PUMP CRANKSHAFT TENS 360 400 440 450 460 BELT ROUTING INDM 0085 Figure 7 16 Serpentine Belt Routing Naturally Aspirated Engines...

Страница 89: ...CE Because of the complexity of preparing your engine for winter storage and the danger of catastrophic engine damage from freezing water in the engine it is recommended that you have your dealer perf...

Страница 90: ...s of Appropriate Engine Oil x Indmar Oil Filter P N 872025 or 501022S x 4 6 ounces of Fogging Oil x 1 can Corrosion Protectant and Lubricant x Transmission Oil As Required x Indmar Marine Waterproof G...

Страница 91: ...the label 2 Start the engine and operate at Idle RPM until the engine reaches normal operating temperature If using a hose and adapter adjust the faucet to avoid over cooling the engine at low RPM Ru...

Страница 92: ...be found on many websites that sell automotive related tools and equipment Follow the instructions that come with the tester and make sure the antifreeze in the engine will protect to lower than the...

Страница 93: ...8 5 6725 1 17 5 83 2020 Indmar Marine Engines INDM 0089 1 2 1 Remove Blue Plug or Separate Fitting on Exhaust Manifold Crossover Hose 2 Remove Blue Plug from Transmission Drain Anode Figure 8 1...

Страница 94: ...e Plug from Transmission Drain Anode Figure 8 2 5 4 3 INDM 0088 3 Remove Blue Drain Plug from Bottom of Heat Exchanger 4 Remove the Blue Drain Plug from the Raw Water Inlet Tube 5 Raw Water Pump Impel...

Страница 95: ...ng system is protected from freezing by draining the raw water from the system The raw water drain points are indicated on the winterization drain point drawings on the following pages There are also...

Страница 96: ...Blue Plug from Transmission Drain Anode 3 Remove Blue Plug from Transmission Cooler Drain Hose Figure 8 5 4 5 INDM 0091 4 Remove Blue Drain Plug from Bottom of Heat Exchanger 5 Raw Water Pump Impelle...

Страница 97: ...zing by draining the raw water from the system The raw water drain points are indicated on the winterization drain point drawings on the following pages There are also blue stickers attached to the en...

Страница 98: ...move Blue Plug from Transmission Cooler Drain Hose Figure 8 8 INDM 0094 5 3 4 4 3 Remove Blue Plug from Transmission Cooler Drain Hose 4 Remove Blue Drain Plugs from Bottom of Heat Exchanger and from...

Страница 99: ...ission uid following the instructions in the transmission owner s manual 2 Drain the water from the cooling section of the V drive transmission a Indmar Vee On these models you must remove the plug fr...

Страница 100: ...r INDM 0022 Figure 8 11 Indmar Vee Through Shaft Drain Plug General Power Package Preparation 1 Clean dirt grime and grease from painted surfaces of the engine and drive train 2 Touch up painted areas...

Страница 101: ...the hose that goes between the two exhaust manifolds 3 Reinstall the water pump impeller Be sure to use a new gasket for the housing cover 4 Reinstall the anode drain plug in the raw water side of the...

Страница 102: ...adapter installed cycle the key switch ON then OFF for ve second intervals 3 4 times before cranking the engine to allow the fuel pump to prime the fuel lines 10 Review boat manufacturer s starting pr...

Страница 103: ...lignment Adjust as necessary Connect the propshaft and transmission coupler 3 Remove and clean the fuel injectors and ush the entire fuel system 4 Install a new fuel lter 5 Change all of the engine ui...

Страница 104: ...12 Put the boat in the water and operate it at various RPM Monitor the engine temperature oil pressure charging voltage and fuel pressure to make sure all stay within speci cation Check the various e...

Страница 105: ...our Indmar dealer to correct the cause of the problem OTE N Modern boats are equipped with an onboard diagnostic system that displays a check engine indication and informs the operator of speci c driv...

Страница 106: ...Restricted exhaust system x Plugged ame arrestor x Insuf cient air supply to engine x Engine needs tune up x Damaged or incorrect propeller Engine Cranks Won t Start x Weak or shorted coil no spark a...

Страница 107: ...x Battery cables loose or corroded x Weak or discharged battery Engine Won t Crank x Weak or discharged battery loose or corroded battery cables x Defective neutral safety switch or adjustment needed...

Страница 108: ...9 4 SECTION NINE NOTES...

Страница 109: ...ater P N 872027 Flame Arrestor P N 525900 Indmar V Drive Main Gearbox Indmar ATF P N 872020 V drive Indmar Synthetic 50 Transmission Oil P N 872022 In Line 1 1 Transmission Indmar ATF P N 872020 Fuel...

Страница 110: ...SC 575 Models 230 Amp Alternator P N 725905 Thermostat P N 985901 Spark Plugs 360 400 440 450 and 460 P N 597037 16 575 597128 16 Surface Corrosion Protection Corrosion protectant and lubricant Engine...

Страница 111: ...A 3 MAINTENANCE COMPONENTS AND FLUIDS 2020 Indmar Marine Engines SERVICE LOG Date Maintenance Performed...

Страница 112: ...A 4 33 1 NOTES...

Страница 113: ...um Oil Pressure at Idle 8 psi 55 kPa Oil Filter P N 501022S cartridge Fuel Pump Pressure 60 psi 414 kPa Electrical System 12V DC Negative Ground Minimum Battery Requirements 800 CCA 1000 MCA 150 AH Fi...

Страница 114: ...apacities Engine Oil 8 qt 7 6 L Closed Cooling System 12 14 qt 11 4 13 3 L Indmar V Drive 2 3 qt 2 18 L Main Gearbox Indmar ATF 1 25 qt 1 18 L V Drive unit Indmar Synthetic 50 Transmission Oil Indmar...

Страница 115: ...dmar to be defective Indmar shall repair or at its sole option provide either a new or rebuilt replacement of equivalent quality Indmar shall have the sole discretion to determine whether the replacem...

Страница 116: ...on d Water pump impellers water hoses cooling system anodes or any component determined solely by Indmar to be damaged due to normal wear lack of maintenance or abuse such as operating without cooling...

Страница 117: ...fects to the Product as determined solely by Indmar to be caused by servicing errors made by the Customer or by any servicing dealer mechanic not approved or authorized by Indmar r Product warranty cl...

Страница 118: ...curs in the case of commercial use In the event that more than one warranty time period may be applicable to a particular Product pursuant to this Section 6 the shortest period of time shall apply and...

Страница 119: ...f the Product or its new or rebuilt replacement to the retail purchaser or lessor shall be paid by such purchaser or lessor The Customer shall be solely responsible for any and all labor expenses rela...

Страница 120: ...ING OUT OF OR IN CONNECTION WITH THE DEVELOPMENT DELIVERY USE OR PERFORMANCE OF THE PRODUCT IN ANY EVENT THE LIABILITY OF INDMAR FOR ANY REASON AND UPON ANY CAUSE OF ACTION WHATSOEVER SHALL BE LIMITED...

Страница 121: ...and maintained as stated in the Indmar Operator s Manual e Customs charges import duties taxes and VAT on warranty replacement parts INTERNATIONAL WARRANTY PROCEDURES Indmar is excited to expand inte...

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Страница 124: ...P N OME0902 21...

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