Crusader 5.7L Carburetor 2008 Owners Manual
OWNER’S OPERATION
and
MAINTENANCE MANUAL
A Division of
Welcome to the growing family of Crusader Marine Engines owners. We are delighted you have chosen Crusader
power for your boat and wish you many years of enjoyment.
READ THIS MANUAL THOROUGHLY
Before starting your engine(s), READ THIS MANUAL CAREFULLY AND COMPLETELY. If you do not understand
any portion of the manual, contact your Dealer for clarifi cation or assistance. Ask your Dealer for a demonstration of
actual starting and operating procedures.
The descriptions and specifi cations contained in this manual were in effect at the time of printing. Crusader Marine
Engines’ policy of continued improvement reserves the right to change specifi cations or design without notice and
without obligation.
This manual will cover the following Crusader engines:
Year Model
2008 5.7L Carburetor
Part Number - L510019-08 Printed 01/08
TABLE OF CONTENTS
1 - SERVICE AND WARRANTY ............................................................................................... 4-17
Safety Information
Replacement Parts ......................................
Safety Warnings
Crusader Marine Engines’ Commitment to You
Owner Warranty Registration (Warranty Registration Card is located at the back of this manual)
Engine Operation and Care
Maintenance Records
Local Repair Service
Service Away From Home
Replacement Parts Inquiries
Replacement Service Parts
Applicable Limited Warranty
Crusader Marine Engines Two-Year Limited Warranty
(For Engines Sold and Used in the United States and Canada)
Items Not Covered Under the Limited Warranty
Things You Should Know About The Warranty
Marine Transmissions
Resolving a Service Problem
Crusader Master Distributors
Dealer’s Responsibilities
Transferable Warranty
Direct Sale By Owner
Notes
2 - BOATING RESPONSIBILITY
Carbon Monoxide Hazard
Safe Boating Suggestions
Water Wisdom
Operation and Maintenance
Rules of the Road
3 - ENGINE IDENTIFICATION
Engine Identifi cation
Owner Identifi cation and Registration Information
2007 Model Identifi cation / Advisory
4 - OPERATING INSTRUCTIONS
Instrumentation ..........
Engine Alarm System
Remote Controls
Starting Engine .....................................
Shifting Transmission
Stopping Engine
Freezing Temperature Operation
Operation in High Debris Areas
..................................................................................................................................... 17
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................ 5
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L510019-08
1
TABLE OF CONTENTS
5 - CONDITIONS AFFECTING OPERATION ................................................................................. 28
Trim and Weight Distribution
Boat Bottom
Propeller Selection
6 - ENGINE BREAK-IN PERIOD
7 - 25-HOUR ENGINE INSPECTION
8 - FUEL REQUIREMENTS
Gasoline Requirements
Gasoline Containing Alcohol
Piston Damage Due To Detonation and/or Pre-Ignition
9 - OIL REQUIREMENTS
Engine Oil Recommendations
Transmission and “V”-Drive Oil Requirements
10 - ENGINE MAINTENANCE
Engine Maintenance
Checking Fluid Levels
Lubrication
Electrical System Circuit Breaker
Electrical System Fuse
Ignition Fuse
Electrical System Wiring and Connectors
Battery
Fresh Water Cooling System Sacrifi cial Zinc Anode
Checking Coolant Level
Flushing Cooling System - Sea-Water Section
Testing Coolant For Alkalinity
Draining Fresh-Water Cooling System
Filling Fresh-Water Cooling System
Cleaning Sea-Water Section of Heat Exchanger (Fresh-Water Cooled Applications Only)
Fuel System Description
Electric Fuel Pump ......................................................................................................................................... 43
Priming the Fuel System ................................................................................................................................ 43
Flame Arrestor ............................................................................................................................................... 43
Serpentine Drive Belt
Changing Oils
Engine Alignment
Engine Maintenance Log
Maintenance Schedule
Visual Inspection
Engine Fluid Capacities
Transmission Fluid Capacities
Filter Requirements
............................................................................................................................. 28
.................................................................................................................... 28
.................................................................................................................. 34
........................................................................................................... 34-35
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................................................................................................................. 46-49
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................................................................................................................... 54
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................................................................................................... 31-32
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................................................................................................ 34-54
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2
L510019-08
TABLE OF CONTENTS
11 - ENGINE SPECIFICATIONS ............................................................................................. 55-56
12 - OUT-OF-SEASON STORAGE
Engine Storage
Draining Instructions
Battery Storage
Out-Of-Season Engine Warm-Up
Recommissioning After Storage
13 - TROUBLESHOOTING
14 - WATER FLOW DIAGRAM
15 - ENGINE HARNESS WIRING DIAGRAMS
16 - LITERATURE
17 - FORMS
18 - NOTES
CRUSADER WARRANTY / REGISTRATION FORM
........................................................................................................................ 57
.................................................................................................................. 58
........................................................................................................................ 58
.................................................................................................... 61-64
.................................................................................................................... 68
........................................................................................................................ 69-73
............................................................................................................................. 75
.......................................................................................... 57-61
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.............................................................................................. 59-60
................................................................................................... 65
.......................................................................... 66-67
L510019-08
3
SERVICE and WARRANTY - 1
SAFETY INFORMATION
“Safety Warnings” and additional information or
instructions are used to alert the installer/operator of
possible safety hazards in performing certain service
or maintenance procedures incorrectly or carelessly.
DANGERS and WARNINGS are accompanied by the
international HAZARD symbol:
These “Safety Warnings” alone cannot eliminate the
hazards that they signal. Strict compliance with
these warning instructions while performing service
and maintenance procedures, plus “common sense”
operation, are major accident prevention measures.
SAFETY WARNINGS
REPLACEMENT PARTS
DANGER
Electrical, ignition and fuel system components are
designed and manufactured to comply with U.S.
Coast Guard rules and regulations to minimize the
possibility of fi re or explosion hazard.
Use of replacement parts (i.e. automotive, after-market,
etc.) in the electrical, ignition and fuel systems, which are
not U.S. Coast Guard approved, could cause a fi re or
explosion hazard and should be avoided.
Always request that genuine Crusader Marine Engines
replacement parts be used in any repairs or maintenance
being performed on your engine(s).
DANGER
Signals serious damage, failure or breakdown of equipment; severe injury or high probability of death to the user if
proper precautions are not taken. This signal word is applied in extreme situations
WARNING
Indicates a potential hazard which could result in personal injury.
CAUTION
Indicates a hazard which could result in damage to equipment.
IMPORTANT: or IMPORTANT: Used to provide information to perform a procedure more easily.
WARRANTY NOTICE: Indicates a possible warranty exclusion.
4
L510019-08
SERVICE and WARRANTY - 1
OWNER’S SERVICE
AND
WARRANTY INFORMATION
CRUSADER MARINE ENGINES’ COMMITMENT TO YOU
Crusader Marine Engines is committed to assuring your satisfaction with your new Crusader engine. Your Dealer also
wants you to be completely satisfi ed, and invites you to return for all your servicing needs, both during and after the
warranty period.
OWNER WARRANTY REGISTRATION
It is important that your selling dealer fi ll out the “Warranty Registration Card” completely and mail it to the factory
immediately upon the purchase of the new product. It identifi es the name and address of the original purchaser, product
model(s) and serial number(s), and the selling dealer’s name and address. The dealer is also certifying that you are
the original purchaser of the product.
Upon receipt of the “Warranty Registration Card” at the factory, you will be issued an “Owner Warranty Registration
Card.” The “Owner Registration Card” is your only valid registration identifi cation, and must be presented to the
servicing dealer, should warranty service be required.
If your “Owner Registration Card” is not received within 30 days from the date of purchase, please contact your boat
dealer or engine seller. The product warranty is not effective until the Product is registered at the factory.
Mail registration information to:
Crusader Marine Engines
P.O. Drawer 369
Little Mountain, SC 29075
NOTE: OWNERS WARRANTY REGISTRATION CARD IS LOCATED AT THE BACK OF THIS MANUAL.
NOTICE: Registration lists must be maintained by the factory and dealer on marine products sold in
the United States and some foreign countries, should notifi cation under FEDERAL BOAT SAFETY
ACT be required. It is our desire to have all products registered at the factory, should it ever be
necessary to contact you. Make sure your Dealer/Distributor fi lls out the registration card immediately
and sends the card to the factory.
L510019-08
5
SERVICE and WARRANTY - 1
ENGINE OPERATION AND CARE
Considering the investment that you have made in your new Crusader engine(s), we know you will want to operate
and maintain it properly. We urge you to follow the maintenance instructions contained in your engine’s “Operation
and Maintenance Manual.”
If you have any questions on how to keep your engine in good working condition, see your selling dealer, the place
where many owners choose to have their maintenance work done. Your dealer can be relied on to use proper parts
and practices.
MAINTENANCE RECORDS
It is recommended that receipts covering the performance of regular maintenance be retained. Damage to your engine,
caused by lack of maintenance, is not covered under your warranty. Receipts can be very important if a question arises
as to whether a malfunction is caused by lack of maintenance or a defect in material or workmanship. An “Engine
Maintenance Log” is provided in the MAINTENANCE SCHEDULE section of the OPERATION AND MAINTENANCE
MANUAL for your convenience in recording the service performed.
LOCAL REPAIR SERVICE
To obtain service or make a claim under your warranty, contact your selling dealer. They have trained technicians,
knowledge and special tools and equipment to properly service your engine, if the need arises. They know you and
your boat best.
SERVICE AWAY FROM HOME
If you are away from home and your local dealer, and the need for service arises, contact the nearest authorized
Crusader Marine Engines dealer. Refer to the yellow pages in the telephone directory. If, for any reason, you cannot
obtain service, contact the Crusader Master Distributor closest to you for referral to the nearest authorized servicing
dealer. (Refer to regional map and listing of Crusader Master Distributors on page 14.)
6
L510019-08
SERVICE and WARRANTY - 1
REPLACEMENT PART INQUIRIES
All inquiries concerning replacement parts should be directed to your local authorized dealer. The dealer has the
necessary information to order parts for you if they are not in stock. Only authorized distributors can purchase parts
from the factory. Crusader Marine Engines does not sell to unauthorized dealers or retail customers. When checking on
parts, the dealer will require the engine model and serial number to order the correct parts.
REPLACEMENT SERVICE PARTS
WARNING
Electrical, ignition and fuel system components on Crusader Marine Engines are designed and manufactured to
comply with U.S. Coast Guard rules and regulations to minimize the risks of fi re or explosion. Use of replacement
electrical, ignition or fuel system components, which do not comply with these rules and regulations, could result in a
fi re or explosion hazard and should be avoided.
When servicing the electrical, ignition and fuel systems, it is extremely important that all the components are properly
installed and tightened. If not, any electrical or ignition component opening, if a fuel system leak were to exist, would
permit sparks to ignite fuel vapors from the fuel system leaks.
APPLICABLE LIMITED WARRANTY
Following is the limited warranty applicable to Crusader Marine Engines sold and used in the United States and
Canada.
Distributors and Dealers are not agents of Crusader Marine Engines. Crusader Marine Engines does not authorize any
person to create any other obligation or liability in connection with this product.
L510019-08
7
SERVICE and WARRANTY - 1
CRUSADER, INC. INBOARD MARINE ENGINES
TWO YEAR LIMITED WARRANTY
(For Engines Sold and Used in the United States and Canada Only)
1. Crusader, Inc. (hereinafter referred to as “Crusader”) warrants each of its new inboard marine engines an
accessories attached thereto (“Products”), to be free from defects in material and workmanship for a period of
two (2) years, except to the extent limited herein. This Limited Warranty commences on the day of the fi rst retail
sale and/or the fi rst date used, and extends to the original and subsequent retail sales; however, in no event
shall the duration of the Limited Warranty exceed two (2) years, as measured from the original retail sale date.
2. Under this Limited Warranty, Crusader’s obligation is limited to repairing or replacing those parts of Products that
have become defective within the applicable warranty period, because of defective materials or workmanship.
Crusader will arrange for the correction of all defects under this Limited Warranty to be made free of charge
at the selling dealership or an authorized Crusader service center. Crusader, in its discretion, may provide for
the repair or replacement of any defective part at Crusader’s facility. Crusader will make payment for labor to
replace such parts as provided in the, then, current fl at rate labor manual or Warranty Procedures Manual.
3. This Limited Warranty does not apply to Product defects caused by normal wear and tear to Products, and/or
damage to Products arising out of negligence or lack of proper care, improper installation or service, operation
with fuels, oils or lubricants which are not suitable for use with Products, alterations or removal of parts,
water entering an engine through the exhaust system or carburetor, installation of accessories or parts not
manufactured or sold by Crusader, or Products rendered defective by accident.
4. If a part should become defective within the applicable warranty period, advance authorization by Crusader is
necessary before the part is replaced or a defect is corrected by a service representative; otherwise Crusader
will not be liable for the expense of the replacement or correction.
5. Replacement parts and accessories supplied by Crusader, and installed on a Product during the period when
the Product is covered under the provisions of this Limited Warranty, are warranted for the unexpired portion of
the existing warranty period, or ninety (90) days from the date of installation of such new parts or accessories,
whichever is longer.
6. Reasonable access to the Product must be provided for warranty service. This Limited Warranty does not cover:
(1) telephone or telegram charges, towing charges, storage, launch and haul out charges, loss or damage to
personal property, loss of revenue, loss of time, travel, lodging, inconveniences or other CONSEQUENTIAL
DAMAGES, or (2) removal and/or replacement of boat partitions or material, because of boat design, for
necessary access to the Product.
8
L510019-08
SERVICE and WARRANTY - 1
7. NO OTHER WARRANTY GIVEN
THE OBLIGATIONS SET FORTH IN THE PRECEDING PARAGRAPHS ARE CRUSADER’S SOLE
OBLIGATIONS AND OWNER/USER’S EXCLUSIVE REMEDY. CRUSADER MAKES NO OTHER
WARRANTY, EXPRESS OR IMPLIED (except to the extent provided in the immediately following
paragraph), AND MAKES NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE.
However, to the extent that any warranty may be implied by law, the term of such implied warranty shall
be limited to a period of time corresponding to the period of express warranty applicable to the particular
Product, and its use by the owner/user, as set forth herein, commencing on the date of the fi rst retail sale
of the Product to the fi rst registered owner or registered user. Some states do not allow limitations on
how long an implied warranty lasts, so the above limitation may not apply to you.
This is sole warranty provided respecting Crusader’s Products, and no other party may make a warranty
to owner/user.
CRUSADER SHALL NOT BE LIABLE FOR ANY LOSS OF TIME, INCONVENIENCE, COMMERCIAL LOSS
OR DIRECT OR INDIRECT, INCIDENTAL (except as specifi cally provided herein) OR CONSEQUENTIAL
DAMAGES. Some state do not allow the exclusion or limitation of incidental or consequential damages,
so this limitation or exclusion may not apply to you. This Warranty gives you specifi c legal rights, and
you may also have other rights which vary from state to state.
Any owner/user hereby waives for himself/herself/itself and his/her/its successors and assigns (a) any and all
claims for punitive damages, and (b) all claims of negligence or strict liability or both. In no event will Crusader’s
liability exceed the purchase price of the Products which is actually paid to Crusader.
8. To make a claim under this Limited Warranty, contact the selling dealer from which your Crusader powered
boat was originally purchased or the nearest authorized Crusader servicing dealer. It is recommended that your
warranty service be performed by the dealer which sold the Product to you because of that dealer’s personal
interest in you as a customer. Your Crusader powered Product must be delivered to the servicing dealer within
the applicable warranty period. Proof of purchase may be required by the Crusader dealer to substantiate any
warranty claim. Use your Crusader Owner Warranty Registration Card to establish proof of purchase.
L510019-08
9
SERVICE and WARRANTY - 1
9. ITEMS NOT COVERED UNDER LIMITED WARRANTY
This Limited Warranty is limited to defects in material and workmanship. To avoid misunderstandings regarding
warranty coverage, the following describes some, but not all, of the more common types of service that are not covered
by this Limited Warranty.
• Normal service requirements arising during the warranty period, such as fuel system or ignition adjustments,
tune-ups, fi lter, adjusting controls or lubrications.
• Damage caused by neglect, lack of maintenance, abnormal operation accident or improper installation or
service.
• Normal wear of the piston rings, cylinders, water pump and other engine parts.
• Haul out, launching, towing charges, dockage or storage fees, removal and/or replacement of boat partitions or
material, because of boat design, for necessary access to the product.
• All related transportation charges and/or travel time.
• The cost of shipping replacement parts by air freight or other premium freight methods.
• Additional service work requested by the customer or performed by the dealer other than that necessary to
satisfy the warranty obligation.
• Labor performed by other than an authorized dealer may be covered only under the following circumstances:
when performed on an emergency basis (providing there are no authorized dealers in the area who can perform
the work required, and prior factory approval has been given to have the work performed at this facility).
• Damage from participating in, or preparing for, racing or other competitive activity.
• Water entering the engine cylinders or oiling system through the intake manifold system, exhaust system,
submersion, or in any manner if not caused by a Crusader manufacturing defect.
• Water in starters.
• Improper winterizing resulting in freezing and breaking of the engine block, cylinder heads, exhaust manifolds,
heat exchanger or other damage.
• Repairs made necessary by normal wear, rust, electrolysis or corrosion, or by the use of the parts or accessories
which are either incompatible with the Crusader product or adversely affect its operation, performance or durability
• Valve or valve seat grinding required because of wear.
• Failure or damage due to lack of cooling water caused by starting the Product out of the water or by foreign
material blocking the water inlets.
• Cleaning of the engine fuel system due to water or dirt contamination of the boat fuel system.
• Use of fuel and lubricants which are not suitable for use with or on the Product. Refer to the Operation and
Maintenance Manual.
• Damage to the engine and/or transmission caused by striking a submerged object. (This is considered a
marine hazard).
.
10. This Limited Warranty shall be governed by, and construed and interpreted in accordance with, the laws of
the State of Ohio, without application of its confl icts of laws principles, except only to the extent replaced or
precluded by other law of mandatory application.
11. SPECIAL STATE LEGAL REQUIREMENTS
This Warranty gives you specifi c legal rights, and you may also have other rights which vary from State to State.
The Crusader California Model Years 2003-2008 Emissions Warranty and California Emission Control Warranty
Statement is a separate document included in this Manual. Any questions concerning the Emissions Warranty
can be obtained by calling 1-803-345-0050.
10
L510019-08
SERVICE and WARRANTY - 1
THINGS YOU SHOULD KNOW ABOUT THE WARRANTY
Warranty Repair Component Exchanges
In the interest of customer satisfaction, Crusader Marine Engines may offer an exchange service on some engine
components. This service is intended to reduce the amount of time that your boat is not available for use, due to repairs.
Components used for the exchange service may be new, remanufactured, reconditioned or repaired, depending upon
the component involved. All exchange components used meet Crusader standards and are warranted the same as
new components.
Production Changes
Crusader Marine Engines and its Distributors reserve the right to make changes in the engines built and/or sold by it at
any time without incurring any obligation to make the same or similar changes on engines previously built and/or sold.
Proof of Date of Purchase
Crusader will accept the return of a properly fi lled out “Warranty Registration Card”, supplied with each engine, as proof
of purchase. Failure of purchaser to return such card will require the owner to provide a copy of the original “Bill of Sale”
(sales contract) for the Product to be serviced. Warranty claims will not be accepted until adequate “Proof of Purchase”
is presented by the purchaser, and the date of purchase is substantiated.
Access to Product
Reasonable access must be provided to the Product for warranty service. The warranty does not cover the removal
and/or replacement of boat partitions and/or other components which must be removed for necessary access to the
Product.
L510019-08
11
SERVICE and WARRANTY - 1
MARINE TRANSMISSIONS
Crusader Marine Engines are equipped with transmissions designed, built and warranted by other manufacturers.
Although much of the transmission warranty is handled through Crusader Marine Engines, there may be issues for
which, you, the owner, may want to contact the transmission manufacturer directly. The transmission suppliers are
listed below for your reference. A tag is attached to each transmission showing the manufacturer, transmission model
and serial number. Have this tag information available whenever contacting the manufacturer.
Velvet Drive Transmissions
1208 Old Norris Road
P.O. Box 238
Liberty, SC 29657
Phone: (864) 843-9234
www.velvetdrive.com
ZF Marine - Hurth Marine Transmissions
3131 SW 42nd Street
Ft. Lauderdale, FL 33312
Phone: (954) 581-4040
12
L510019-08
SERVICE and WARRANTY - 1
RESOLVING A SERVICE PROBLEM
Your satisfaction and faith in the product are of major importance to your dealer and to Crusader Marine Engines. Any
problems with service, warranty or operation of your Crusader powered boat will be resolved by your dealer. He should
be your primary source of information on your boat. Should there be a misunderstanding, or if your problem has not
been resolved to your satisfaction, please follow these steps:
Step One - Discuss Your Problem With One Of The Dealership Management Personnel
Misunderstanding or complaints can be resolved quickly by the dealer. Discuss your problem with the dealership’s
service manager. If you are still unable to obtain satisfaction, contact the dealership’s owner.
Step Two - If Your Complaint Has Not Been Resolved To Your Satisfaction, Contact The Distributor Closest To
You (Refer to page 14 for a listing of Crusader Master Distributors.)
When contacting the nearest distributor, please provide the following information:
• Your name and address
• Daytime telephone number
• Engine model and serial number(s)
• Transmission model and serial number(s)
• Your dealer’s name and location
• Date of purchase
• Present hours of operation
• Details of problem or complaint
Please remember that the distributor will fi rst try to resolve the problems through your selling or servicing dealership,
using the dealer’s facilities, equipment and personnel. It is for this reason we request that you use the preceding steps
when you have a problem. Experience has shown that this is the fastest method to obtain satisfaction.
ALL SERVICE WORK IS DONE BY AUTHORIZED DEALERS & SERVICING DISTRIBUTORS USING THE DEALER’S
FACILITIES. NOT ALL CRUSADER DISTRIBUTORS MAY HAVE FACILITIES TO SERVICE OR REPAIR YOUR
PRODUCT.
L510019-08
13
A
A
one: 800
00
SERVICE and WARRANTY - 1
CRUSADER MARINE ENGINES
DISTRIBUTORS
Marysville
Marine
Engine
Distributors
Engine
Distributors
Engine
Distributors II
Engine Distributors Inc.
400 University Court
Blackwood, NJ 08012
Jaime Cummins
Phone: 800-220-2700
Fax: 856-228-5657 - Parts
Fax: 856-228-5531 - Sales
jcummins@edi-dist.com
Trans Pacific
Marysville Marine Distributors
Trans Pacific Distributors
AER Supply
Engine Distributors Inc.
Trans Pacific Distributors
1941 Walters Court
Fairfield, CA 94533
Henry Bramhall - Owner
rley Harty
Phone: 800-688-6208
Fax: 707-426-0206
sales@marinegate.com
AER Supply
Marysville Marine
Distributors
282 Progress Way
Sun Prairie, WI 53590
Brian Hunter
Phone: 608-825-3878
Fax: 608-825-2790
marysvillemarine.com
Marysville Marine
Distributors
1551 Michigan Avenue
Marysville, MI 48060
Steve Riehl
Phone: 810-364-7653
Fax: 810-364-4112
marysvillemarine.com
Engine Distributors -
Jacksonville
Engine Distributors -
Ft. Lauderdale
Engine Distributors Inc.
41 Pope Road
Holliston, MA 01746
Jaime Cummins
Phone: 800-220-2700
Fax: 856-228-5657 - Parts
Fax: 856-228-5531 - Sales
jcummins@edi-dist.com
Engine Distributors Inc. II
303 Interstate Dr.
Archdale, NC 27263-3148
Jaime Cummins
Phone: 800-220-2700
Fax: 856-228-5657 - Parts
Fax: 856-228-5531 - Sales
jcummins@edi-dist.com
Engine Distributors Jacksonville
259 Ellis Road South
Jacksonville, FL 32254
Jaime Cummins
Phone: 800-220-2700
Fax: 856-228-5657 - Parts
Fax: 856-228-5531 - Sales
jcummins@edi-dist.com
ER Supply
2301 NASA Road One
PO Box 349
Seabrook, TX 77586
Richard Miller
Phone: 800-767-7606
Fax: 281-474-2714
aersupply.com
14
Marysville Marine
Distributors
127 Industrial Dr.
White House, TN 37188
Randy Hall
Phone: 615-672-1142
Fax: 615-672-8084
marysvillemarine.com
L510019-08
Engine Distributors - Ft.
Lauderdale
2917 SW 2nd Avenue
Ft. Lauderdale, FL 33315
Jaime Cummins
Ph
Phone: 800-220-2700
Fax: 856-228-5657 - Parts
Fax: 856-228-5531 - Sales
jcummins@edi-dist.com
-220-27
SERVICE and WARRANTY - 1
DEALERS RESPONSIBILITIES
In general, the dealer’s responsibilities to you, the customer, include pre-delivery inspection and preparation such as:
• Make sure that the boat is properly equipped
• Prior to delivery, make certain that the Crusader Engine is in proper operating condition
• Make all necessary adjustments for maximum effi ciency
• Familiarize you, the owner, with the on-board equipment
• Explain and demonstrate the operation of the engine, and also the boat
• Explain warranty policies and deliver all operating manuals for the engine and the boat
• Complete the owner’s warranty registration card and return it to the factory
L510019-08
15
SERVICE and WARRANTY - 1
TRANSFERABLE WARRANTY
The product limited warranty is transferable to a subsequent purchaser, but only for the remainder of the unused portion
of the limited warranty. This will not apply to the products used for commercial applications.
DIRECT SALE BY OWNER
The second owner can be registered as the new owner, and may retain the unused portion of the limited warranty.
The forms and instructions necessary to transfer the unused portion of the Crusader Two year Limited Warranty are
provided in Forms, section 17 of this manual.
Upon receipt of the transfer application a new “Owner Warranty Registration Card” will be issued with the new owner’s
name and address. Registration records will be changed on the factory computer registration fi le.
16
L510019-08
SERVICE and WARRANTY - 1
L510019-08
17
BOATING RESPONSIBILITIES - 2
CARBON MONOXIDE HAZARD
DANGER
Carbon Monoxide (CO) is a colorless, odorless
and tasteless gas. You cannot see it, smell it or
taste it. Prolonged exposure to carbon monoxide
can lead to unconsciousness, brain damage or
death!
Carbon monoxide is produced when anything that
contains carbon, such as gasoline, natural gas, oil,
propane, coal or wood is burned. Carbon monoxide is
commonly found in the exhaust of internal combustion
engines (boat power plants, generators, etc.). In
addition, open fl ame devices like cooking ranges,
heaters and charcoal grills also produce carbon
monoxide.
Carbon monoxide accumulation, in and around boats
is affected by vessel geometry; overall vessel design;
closeness to other structures; wind direction; boat speed;
and many other variables. In no way can this section
cover all of the possible variables. Do not rely on this
section as the exclusive listing of measures to prevent
the accumulation of carbon monoxide.
To fi nd out more about making boating safer, including
how you can prevent carbon monoxide poisoning on
recreational boats, contact:
National Marine Manufacturers Association
200 East Randolph Drive
Suite 5100
Chicago, IL 60601-6528
www.nmma.org
312-946-6200
United States Coast Guard
Offi ce of Boating Safety
CG Headquarters G-OPB-3
2100 Second Street SW
Washington, DC 20593
www.uscgboating.org
202-267-0984
American Boat & Yacht Council, Inc.
3069 Solomon’s Island Road
Edgewater, MD 21037-1416
www.abyc.com
410-956-1050
Consult your boat operators manual for detailed
information on the inspection and/or maintenance of
the exhaust system for your particular application. If
an inspection reveals possible leaks, DO NOT operate
your engine(s) until it can be serviced by a qualifi ed
technician.
Proper and adequate air circulation, around and
throughout the boat, is absolutely necessary to aid in
the prevention of carbon monoxide build-up. If you
have any questions or concerns regarding the operation
of your boat and carbon monoxide hazards, DO NOT
operate your engines until you have contacted your boat
manufacturer.
18
L510019-08
BOATING RESPONSIBILITIES - 2
SAFE BOATING SUGGESTIONS
The nation’s waterways are becoming increasingly
crowded and, in order to enjoy them safely, the
operator should acquaint himself/herself with safe
boating practices. Boating safely and seamanship
courses are offered by the following national and state
organizations:
• Power Squadrons
• Coast Guard Auxiliary
• Red Cross
• State, provincial or local agencies in charge of
water safety enforcement
Crusader Marine Engines highly recommends that all
power boat operators attend one of these courses. To
help locate a course being offered near you, contact
Boat U.S. Foundation’s toll-free national boating safety
hotline, 1-800-336-BOAT, and in Virginia, 1-800-245BOAT.
WATER WISDOM
The following are suggestions for safe operation of
your boat to ensure the safety of yourself and your
passengers:
• Know your boat’s loading and operating
limitations. DO NOT OVERLOAD!
• Make periodic checks of safety equipment
onboard.
• Do not consume alcoholic beverages or take
illegal drugs when operating a boat. Some state
laws apply to boats as well as motor vehicles.
• File a “fl oat plan.” Let someone know your
destination and your expected time of return.
• Monitor the weather. Know the signs of weather
change and avoid severe weather and rough
seas whenever possible.
• Follow the “Rules of the Road” when boating.
Always be on the alert and watch out for “the
other guy.”
• Plan and chart your course. Be aware of, and
avoid, hazardous areas.
• Be sure your boat is equipped with the required
safety equipment. Check with the Coast Guard
and local government agencies as to the
regulations and restrictions in your area. Contact
your local Coast Guard Auxiliary and take
advantage of their seasonal boat inspections.
The following is a list of suggested safety equipment
and spare parts which may be useful in case of an
emergency:
• Approved personal fl otation devices (life jackets);
one for each person on board.
• Approved throwable personal fl otation device for
man-overboard protection.
• Approved fi re extinguishers
• Signal devices: fl ares, spotlight, signal fl ag and
horn or whistle
• Crusader Marine Engines’ “Onboard Kit,” plus
spare fuses, bulbs, batteries, etc. Tools
necessary for minor repairs
• Spare propeller
• Anchor and anchor line
• First aid kit and fi rst aid book
• Ship-to-shore radio, compass and chart of the
area in which you are traveling
• Manual bilge pump and spare drain plugs
• Waterproof storage containers
OPERATION AND MAINTENANCE
It is the owner’s/operator’s responsibility to perform
all safety checks before operating his/her boat. All
lubrication and maintenance schedules must be adhered
to assure optimum performance and dependability from
your Crusader engine. When service and maintenance
are required, return to your authorized Crusader Marine
Engines Dealer.
L510019-08
19
BOATING RESPONSIBILITIES - 2
RULES OF THE ROAD
Channel Buoy Guide
The color of the paint is the only characteristic which
has the same meaning on all buoys. Red buoys always
indicate the starboard side of the channel from seaward.
(Red Right Returning)
2
2. Can Buoy: This buoy indicates the port
5
3. Lighted Buoy (RED): This buoy has a
4. Lighted Buoy (GREEN): This buoy has
1. Nun Buoy: This buoy indicates the
starboard side of the channel when
returning from sea. It is conical shape,
the color red and indicates even numbers.
A nun buoy with red and green horizontal
bands (top band red), and not numbered,
indicates an obstruction. The principal
channel is to the left of the buoy when
returning from sea.
side of the channel when returning from
sea. It is cylindrical shape, the color green
and indicates odd numbers. A can buoy
with green and red horizontal bands (top
band green), and not numbered, indicates
an obstruction. The principal channel is to
the right of the buoy when returning from
sea.
fl ashing red light. It indicates the starboard
side of the channel when returning from
sea.
a quick fl ashing green light. It indicates
the port side of the channel when returning
from sea. The quick fl ashing light indicates
special caution required.
Boat Capacity
• Load only to manufacturer’s specifi cations
• Distribute load evenly; keep it low
• Passengers should only ride on the parts of the
boat that are designed for that purpose
• If water is rough, carry fewer passengers
Observe the Rules of the Road
PORT (Left) - Leaving the harbor with green buoys to
your right.
STARBOARD (Right) - Entering the harbor with red
buoys to your right.
Keep to Right
in narrow
channels.
Boat being overtaken
has right of way.
Overtaking boat must
stay clear.
Yield to boats
approaching in
this area.
Know Your Horn Signals
1 Short Blast = Passing you on my port side
2 Short Blasts = Passing you on my starboard side
3 Short Blasts = I am going astern
5 Short Blasts = Danger
Always refer to the latest U.S. Coast Guard Navigation
Rules CG-169.
Keep An Alert Lookout For:
Bad weather, Swimmers, Other boats, Water skiers,
Fisherman, Divers and/or any other obstructions
Small Craft
Winds up to
38 MPH
Gale Winds
38 - 54 MPH
Storm Winds
over 55 MPH
Storm Warning Signals - Pennants (by day)
Lights (by night)
20
Hurricane
Winds over
63 MPH
Keep Your Wake Under Control, particularly upon
entering or leaving harbor areas. You are responsible
for wake damage to other vessels and/or property.
Do Not Fool With Fuel
1/2 pint of gasoline = 15 sticks of dynamite
1. During fueling, moor boat properly; remove all
passengers.
2. Keep all doors, hatches and ports closed.
3. Shut down all electronic gear; extinguish galley
fi res, pilot lights and smoking materials.
4. Do not overload tanks.
5. Keep fi lling nozzles in contact with the fi ll pipe to
prevent sparks.
6. Secure the fi ll cap tightly; wipe away any spillage.
7. Ventilate all components for a minimum of fi ve
minutes before starting engines.
8. Keep fuel lines and bilges clean.
L510019-08
ENGINE IDENTIFICATION - 3
ENGINE IDENTIFICATION
When ordering service parts or obtaining information,
always give the engine model and the serial number.
This information can be found on the following decal.
MAKE
MODEL SERIAL
FIRING ORDER
THIS ENGINE CONFORMS TO ALL APPLICABLE U.S.
GOVERNMENT STANDARDS FOR MARINE ENGINES
IN EFFECT AT DATE OF MANUFACTURE.
LITTLE MOUNTAIN, SC 29075
Figure 3-1 Engine Identifi cation Decal
OWNER IDENTIFICATION AND REGISTRATION
INFORMATION
We suggest that you record the following information
for quick reference when ordering parts or requesting
service or warranty.
5.7L
f
Important!See your Owners Manualto insure that specifications
foryour engine have notchanged or been omittedfrom the
specificationslisted.
FUELRECOMMENDATIONS
Unleaded89 (R+M)/2 OctaneMinimum)
FUELPRESSURE
AllTBI 30 psi+/- 2 psi
AllMPI 40-45psi
ENGINEOILRECOMME NDATIONS 15W-40 Above50 F
AllEngines 5W-40Below 50 F
MARINEGEAR OILRECOMMENDATIONS
AllPCM, Warnerand Hurth Transmissions De xron III
ELECTRICALSPECIFICATIONS
12Volts Negative Ground
IGNITIONTIMING Carbureted- 6 BTDC
AllEngines @ 1000 RPM FuelInjection - 10 BTDC
SPARKPLUG
AllEngines GAP.045"
ENGINEIDLE RPM
Carburetor 700 +/- 50
EFI (NotAdjustable)
MAXIMUMCONTINUOUS CRUISE RPM3800
MAXIMUMENGINE SPEED(WOT) RPM 5000
1. ENGINE SPECIFICATION DECAL
MAKE
MODEL SERIAL
FIRING ORDER
THIS ENGINE CONFORMS TO ALL APPLICABLE U.S.
GOVERNMENT STANDARDS FOR MARINE ENGINES
IN EFFECT ATDATE OF MANUFACTURE.
LITTLE MOUNTAIN,SC 29075
2. ENGINE IDENTIFICATION DECAL
3
InTiming Mode
R143120A
1
ZF HURTH MARINE
ARCO ITALY
MARINE
MODEL
RATIOI
RATIOII
S/N-P/N
3. TRANSMISSION
IDENTIFICATION PLATE
2
2
Figure 3-2 Engine Identifi cation Tag Locations (5.7L)
(Typical)
PORT STARBOARD
Engine Model Number:
Serial Number(s):
Gear Model Number:
Serial Number(s):
Boat Make:
Boat Model:
Hull Serial Number:
Propeller Size:
Ignition Key Number:
L510019-08
21
ENGINE IDENTIFICATION - 3
CRUSADER
MODEL IDENTIFICATION / ADVISORY
MODEL 50 - 572 V - 0 1 SERIAL 680000
1st - 2nd Space: MANUFACTURING CODE
rd - 5th
Space: ENGINE CODE
3
810 = 8.1L (496 CID MPI) (GM)
811 = 8.1L (496 CID H.O. MPI) (GM)
600 = 6.0L (364 CID MPI) (LQ4 Base) (GM)
570 = 5.7L (350 CID LH MPI) (GM)
571 = 5.7L (350 CID RH MPI) (GM)
572 = 5.7L (350 CID LH Carburetor) (GM)
573 = 5.7L (350 CID RH Carburetor) (GM)
500 = 5.0L (305 CID LH MPI) (GM)
501 = 5.0L (305 CID RH MPI) (GM)
502 = 5.0L (305 CID LH Carburetor) (GM)
503 = 5.0L (305 CID RH Carburetor) (GM)
*SERIAL NUMBER I.D.*
1st DIGIT INDICATES DECADE ENGINE WAS
MANUFACTURED ( 5 = 1990, 6 = 2000, 7 = 2010 )
2nd DIGIT INDICATES CALENDAR YEAR ENGINE WAS
MANUFACTURED.
th - 8th
Space: DRIVE CONFIGURATION
6
blank - Direct Drive
V - V-Drive
th - 10th
9
Space: SPECIFICATION CODE
22
L510019-08
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