STATEMENT OF LIMITED WARRANTY The Pleasurecraft Marine Engine Co warrants its new products to be free from defects in material and workmanship under normal use and service conditions, to the first registered owner or user. Covered under the Pleasurecraft warranty are all Pleasurecraft supplied components, except for those components warranted by Pleasurecraft Suppliers.
GENERAL INFORMATION IMPORTANT: read this manual carefully and thoroughly, particularly WARNING, CAUTION and IMPORTANT information in bold type, such as this paragraph. Engine and Transmission Identification WARNING: It is recommended that the battery cables be removed from the battery when the boat is placed in storage, on display or in transit. This will eliminate the possibility of the engine accidentally starting and causing damage to the engine due to lack-of water.
Front mounts are adjusted by loosening the upper lock nut on the mount stud and trunion locking stud nuts and tapping on the nuts to loosen the studs on the trunion The mount can then be raised or lowered by screwing the lower nut up or down in the desired direction and side to side by prying against the block. CAUTION: Side to side adjustment must be limited to a maximum 1-3/4: extension of the trunion from the mount bracket. Extension of more can cause bending of the trunion or possible mount failure.
Hoses, which are connected in a manner to bend in front of the exhaust outlet, will prevent discharge water from flowing around the entire inside diameter of the hose and will cause a hot spot that may burn through the hose. Water Pick-Up Installation Water pickup must be large enough to permit sufficient water flow to engine seawater pump in order to provide adequate engine cooling.
5. Repeat step #4 with the selector and control levers in reverse position. Battery and Battery Cable Installation 1. If the movement of the connector does not correspond with the movement of the selector lever it will be necessary to readjust the remote control head to provide the proper direction of control cable travel. 2. 3. CAUTION: Transmissions operated in reverse to propel the boat forward will fail early. Engine and propeller rotation must be matched according to the Serial Plate.
Operating Limits (See Specifications for Your Model) Directional References Directional references are given as they appear when viewing boat from stern, looking toward bow. Front of boat is bow; rear is stern. Starboard side is right side; port side is left side. Maximum RPM at wide open throttle under normal load conditions can be controlled only by propeller pitch, diameter, and design. It is essential that the propeller selected does not overload or underload the engine.
(With Engine Warmed-Up at Fast Idle to Normal Operating Temperature) 1. Oil pressure and cooling water flow 2. Ammeter or voltmeter function 3. Exhaust, oil and fuel system for leaks 4. Idling speed (adjust as necessary) 5. Operation of throttle and shift controls Service Information Request When contacting the factory, include the following information: 1. 2. 3. 4. 5. 6. Engine and transmission serial and model numbers. Date purchased. Name of selling dealer. Boat manufacturer, model and length.
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Cleaning Carburetor Inlet Filter Transmission Fluid Type Use only automatic transmission fluid type "A", suffix "A" in this transmission. This fluid is trade named Dexron. Change Frequency Change transmission fluid once each year. Maintaining Transmission Fluid Level Transmission fluid level should be checked frequently and fluid added if necessary. Level must be maintained between the two marks on dipstick. CAUTION: Be careful of spilled fuel. Gas vapor buildup is explosive. 1.
SPECIFICATIONS SECTION Model Bore Stroke Cubic Displacement Horsepower 351/4 4.00” 3.50” 351 cubic inches 240@4400 RPM 302/2, 302/4 4.00” 3.00” 302 cubic inches 175@4400 302 2/V 220@4400 302 4/V Intermittent Service 4400 4400 Continuous Cruise 3600 3600 NOTE: Do not cruise at high limits of above range unless propped to turn at or near maximum RPM's at full throttle. Idle Speed, in forward gear 600 RPM 600 RPM Timing 10 degrees BTC 10 degrees BTC @ 600 RPM @ 600 RPM or lower Breaker Point Gap .018” .
Models – INBOARD 351/4 302/4 302/2 Models – VEE DRIVE 351/4 302/4 302/2 10
Maintenance Chart Weekly After 1st 25 Hrs of Operation (1) • Every 50 Hours of Operation (1) • • • • • • • • Change Engine Oil Replace Oil Filter Clean Oil Filler Cap Check Transmission Fluid Level Change Transmission Fluid Check Sea Water Strainer Clean Flame Arrestor Clean Crankcase Ventilating System Check Water Pump and Alternator Belts for Tension Change Fuel Filter Check Fuel System Lines and Connections for Leaks Clean Carburetor Fuel Inlet Filter Clean Transmission Oil Strainer Screen Lubri
ENGINE TROUBLESHOOTING IMPORTANT: The following chart is a guide to aid you to find and correct minor engine malfunctions. If the problem has not been corrected after following the guide, DO NOT attempt further repairs. See your authorized P.C.M. Dealer WARNING: Before attempting any checks or repairs, battery cable MUST BE REMOVED from battery to prevent possible personal injury or damage to equipment. Trouble Cause What You Can Do About It 1. Starter won’t turn engine. A. B. Control lever.
Maintaining Engine Oil Level ENGINE LUBRICATION It must be emphasized that every internal combustion engine should use a certain amount of oil to act as a lubricating and cooling agent, particularly during the break-in period, and the initial rate of consumption gradually will decrease until it becomes stabilized after approximately 100 hours operation.
Starting Motor Starting and Operating Starting motor end frames are equipped with oil-less bearings which do not require lubricant. A routine pre-starting procedure should always be carried out before the first startup of the day. 1. 2. 3. 4. 5. Check oil in engine. Inspect sight tube of fuel pump. Check for gasoline fumes in bilges or engine compartment. Operate engine room blower for sufficient time to remove any fumes. Operate bilge pump until bilges are dry.
During the warmup period, scan the instrument panel for correct operation of all systems. Oil pressure should read 35 to 65 lbs. Water temperature should gradually increase to the normal controlled level of 140-160 degrees on direct water cooled models, 180-200 degrees on fresh water cooled models. Alternator charge output should be indicated on the ammeter by the needle indicating toward the (+) side of zero. IF EQUIPPED WITH A VOLTMETER, THE VOLTAGE SHOULD GRADUALLY RISE TO APPROXIMATELY 13.
HOLLEY CARBURETOR The following description covers a sample Holley Carburetor. The carburetor on your engine may look different from the illustrations but the carburetor functions exactly the same way. Carburetor service demands particular care in cleanliness and precise adjustments. If you are not equipped with the proper knowledge, tools and equipment it is recommended that you have a knowledgeable dealer repair any and all carburetor malfunctions.
CARBURETOR PROBLEM DIAGNOSIS Flooding or Leaking Carburetor Hard Starting Stalling Rough Idle Poor Acceleration Cracked carburetor body, or fuel bowl. Defective main body and/or bowl gasket(s). High fuel level or float setting. Fuel inlet needle not seating properly or worn needle and/or seat. Ruptured accelerating pump diaphragm. Excessive fuel pump pressure. Defective power valve gasket. Ruptured power valve diaphragm. Loose fuel inlet needle valve seat or seat gasket damaged or missing.
CARBURETOR PROBLEM DIAGNOSIS Poor Acceleration (cont.) Inconsistent Engine Idle Speed Automatic Choke Slow Warm-Up, on Too Often or Long Surging (Cruising Speeds to Top Speeds) Reduced Top Speed Air leak between the carburetor and manifold caused by loose mounting bolts or defective gasket. Air leak at the throttle shaft caused by a worn throttle shaft. Accelerating pump fuel inlet valve not seating on acceleration. Restriction in the accelerating pump discharge passage.
Cleaning Flame Arrestor DUAL DIAPHRAGM FUEL PUMP 1. 2. Description Remove nut and washer from center stud. Remove flame arrestor from carburetor and wash it in solvent. Dry with compressed air and reinstall on carburetor. Cleaning Oil Filler Cap These pumps have 2 diaphragms (separated by a metal spacer) and a sight tube attached. 1. 2. Remove cap from valve cover. Wash cap in solvent and dry with compressed air. Cleaning Crankcase Ventilating System 1. 2. 3.
Batteries tend to discharge when not in use, the rate of discharge varying with the condition of the battery itself and/or the entire electrical system. ELECTRICAL SYSTEM At the connector plug of the engine wiring harness, at the rear of the engine, a short orange wire is provided which connects to the battery cable terminal of the starter solenoid. This wire is provided to shunt the alternator output directly to the battery, if a voltmeter is used in the instrument panel.
To ensure good contact, the battery cables should be tight on the battery posts. If the battery posts or cable terminals are corroded, the cables should be cleaned separately with a soda solution and wire brush. After cleaning and before installing clamps, apply a thin coating of petroleum to the posts and cable clamps to help retard corrosion.
1. 2. 3. 4. 5. 1. When installing battery, always be certain that ground polarity of battery and ground polarity of alternator are same. When connecting a booster battery, make certain to connect negative (-) battery terminals together and positive (+) battery terminals together. When connecting a charger to battery, connect charger positive lead to battery positive terminal and charger negative lead to battery negative terminal. Do not short across or ground any terminals on alternator or regulator.
3. 4. Adjust spark plug gaps with a round feeler gauge. (See "Specifications".) Replace defective plugs. Always keep spark plug seats in cylinder head clean. 5. 6. NOTE: Improper installation is one of the greatest single causes of unsatisfactory spark plug performance. Install spark plugs to engine and torque to 15 ft. lbs. (2.07 mkg). Replace or repair any loose or damaged spark plug wires. Install all wires to proper spark plug.
COOLING SYSTEMS See lay-up instructions for inspection and/or replacement of the supply pump impeller. The cooling system of each PCM Marine Engine incorporates a full circulation bypass system, permitting a ful flow of water through the engine, even during warmup. Two heavy-duty marine-type pumps are used to accomplish this.
Flushing Instructions NOTE: When engine is operated in salt water, flush it with fresh water periodically and before storage. If engine is flushed while boat is in water, water intake must have a sea water cock installed between water pickup and pump inlet. 2. 3. CAUTION: DO NOT operate engine without cooling water flowing through water pump, or water pump will be damaged, and subsequent engine damage may result. 1. 2. 3. 4. 5. 6. 7. 8. Close sea water cock (if flushed while boat is in water).
3. 4. 5. Cylinder Block - Two plugs - one in each side of cylinder block. "Y" Fitting - One plug. Seal plugs and replace in heat exchanger. Tighten securely. Fill system, according to procedure if heat exchanger is removed, and operate engine. Check for leaks. Adjusting Water Pump Drive Belt Tension 1. 2. 3. Check belt tension by depressing upper strand of belt at point midway between the two pulleys. Belt should depress 1/4" (6.35mm).
5. Precautions Fill crankcase as outlined under "Filling Engine Crankcase", following, and check for oil leaks while engine is running. 1. Filling Engine Crankcase 2. 3. 4. 5. 6. 7. The engine crankcase capacity is approximately 5 qts. with a new, dry oil filter. Because of the effect the installed angle of the engine has on the oil level, the following procedure must be followed and the boat must be at rest in the water. 1.
NOTE: Be sure that cooler is properly installed and that transmission contains oil before cranking or starting. Procedure for Checking Oil Level Oil level should be checked immediately after stopping engine, and sufficient oil added to again bring transmission oil level to full mark on dipstick assembly. Dipstick assembly need not be threaded into case to determine oil level. Merely insert into case until cap or plug rests on surface surrounding oil filler hole. 1. 2. 3. 4. 5. 6. 7.
5. Oil Capacity Transmission Model Transmission Oil Capacity Level 15° Inclined AS 1-7C Reduction Gears Vee Drives 1.8 Qts. 2.5 Qts 1 Gal. 6. 1.3 Qts. 2.7 Qts. 7. V-Drive Transmission 1. Filling Transmission IMPORTANT: Use only automatic transmission fluid Type "A", Suffix "A" in this transmission. 1. 2. 3. 4. Start engine and operate at idle speed for a short time to fill all circuits. Stop engine and immediately check fluid level as outlined in Step 3.
WARNER GEAR TROUBLE SHOOTING CHART REMEDY COMPLAINTS & SYMPTOMS Transmission in Boat KEY TO TROUBLESHOOTING CHART Transmission Removed INTERNAL & EXTERNAL LEAKS 1. Oil leaks at pump 2. Oil on exterior of trans. 3. Oil leaks at rear bearing retainer 4. Water in transmission oil or oil in cooling water 5. Leaks at coupling 6. Oil leaks out breather 1 4 6 7 1 2 3 8 2 5 8 1 2 3 8 9 31 44 15 19 22 40 45 12. 13. 17 23 TRANSMISSION MALFUNCTIONS IN ALL RANGES 1. No oil pressure 2. Low oil pressure 3.
LAY-UP INSTRUCTIONS Long periods of storage can adversely affect the internal parts of the engine unless proper methods of preservation are used. Most marines or boat yards with storage facilities offer proper lay-up services. If such service is not available, or not to be utilized, the following procedures should be followed: (Prior to Haul-Out, a through e) a. Warm engine up to normal operating temperature. Stop engine. b. Change crankcase oil and oil filter. Remove flame arrestor.
Winter Storage of Batteries 1. 2. 3. l. When the system has been filled with antifreeze, reconnect and tighten the water hose. m. Disconnect the hose from the lower fitting of the raw water supply pump, and lower the end to eliminate any water which may be trapped. n. Remove the raw water supply pump, and remove the impeller. If inspection proves the impeller to be in good condition, store it in an accessible spot for reinstalla tion at the end of the storage period.
OPERATION AND MAINTENANCE LOG Engine Model Port Drive Port and Serial Serial Stbd Stbd. Inspection Date Fire Extinguisher Checked Runs Made Date Gals. Qts.