Crusader Owner’s Operation and Maintenance Manual (2010 MPI)

This manual will cover the following year of manufacture Crusader engines …This manual will cover the following year of manufacture Crusader engines: 2010 5.0L MPI, 2010 5.7L MPI, 2010 6.0L MPI, 2010 8.1L MPI, 2010 8.1L MPI (HO)

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Crusader Owner’s Operation and Maintenance Manual (2010 MPI)
SERVICE AND WARRANTY … 4-19
Safety Information … 4
Replacement Parts … 4
Safety Warnings … 4
Crusader Marine Engines’ Commitment to You … 5
Owner Warranty Registration (Warranty Registration Card is located at the back of this manual) … 5
Engine Operation and Care … 6
Maintenance Records … 6
Local Repair Service … 6
Service Away From Home … 6
Replacement Parts Inquiries … 7
Replacement Service Parts … 7
Applicable Limited Warranty … 7
Crusader Marine Engines Two-Year Limited Warranty
(For Engines Sold and Used in the United States and Canada) … 8
Items Not Covered Under the Limited Warranty … 10
Things You Should Know About The Warranty … 11
California Emission Control Warranty Statement … 12
General Emissions Warranty Coverage … 13
Marine Transmissions … 15
Resolving a Service Problem … 16
Dealer’s Responsibilities … 17
Transferable Warranty … 18
Direct Sale By Owner … 18
Notes … 19
BOATING RESPONSIBILITY … 20-22
Carbon Monoxide Hazard … 20
Safe Boating Suggestions … 21
Water Wisdom … 21
Operation and Maintenance … 21
Rules of the Road … 22
ENGINE IDENTIFICATION … 23-24
Engine Identification … 23
Owner Identification and Registration Information … 23
Engine Model Identification / Advisory … 24
ELECTRONIC FUEL INJECTION INFORMATION … 25
Electronic Fuel Injection System … 25
OPERATING INSTRUCTIONS … 26-34
Instrumentation … 26
Engine Alarm System … 26
Remote Controls … 27
Starting Engine (Fuel Injected Engines) … 28
Shifting Transmission … 29
Stopping Engine … 30
Freezing Temperature Operation … 30
Operation in High Debris Areas … 30
Electronic Twin-Engine Synchronization and Cruise … 30-34
Determining the Master/Slave Engine Positions … 30-31
Crusader Sync/Cruise Panel Functions … 31
Normal Operation … 32
Entering Sync Mode … 32
Entering Cruise Mode … 32
Adjusting Cruise Speed … 32
Cancelling the Cruise Set Point … 33
Resume Mode … 33
Exiting Sync/Cruise Mode … 33
Crusader Sync/Cruise Functions vs. Throttle Positions … 33
Crusader Sync/Cruise – Possible Operator Concerns … 34
CONDITIONS AFFECTING OPERATION … 35-36
Trim and Weight Distribution … 35
Boat Bottom … 35
Propeller Selection … 36
ENGINE BREAK-IN PERIOD … 37
25-HOUR ENGINE INSPECTION … 38
FUEL REQUIREMENTS … 39
Gasoline Requirements … 39
Gasoline Containing Alcohol … 39
OIL REQUIREMENTS … 40
Engine Oil Recommendations … 40
Transmission and “V”-Drive Oil Requirements … 40
ENGINE MAINTENANCE … 41-69
Engine Maintenance … 41
Checking Fluid Levels … 41-42
Lubrication … 43
Electrical System Relay and Fuse Block … 44
Electrical System Fuses … 44
Boat’s Ignition Fuse … 44
Electrical System Wiring and Connectors … 44
Battery … 45
Fresh Water Cooling System Sacrificial Zinc Anode … 46
Checking Coolant Level … 47
Flushing Cooling System – Sea-Water Section … 48
Testing Coolant For Alkalinity … 49
Draining Fresh-Water Cooling System … 49
Filling Fresh-Water Cooling System … 50
Cleaning Sea-Water Section of Heat Exchanger (Fresh-Water Cooled Applications Only) … 51
Fuel System Description … 52
Fuel Control Cell (FCC) Fuel System … 52
Servicing the FCC … 53
FCC Service Instructions (Clamp-On Canister) … 54
Primary Fuel Filter … 55
Priming Fuel System … 56
Flame Arrestor … 57
Accessory Drive Belt … 58-60
Changing Oils … 61
Engine Alignment … 62-64
Engine Maintenance Log … 65
Maintenance Schedule … 66-67
Visual Inspection … 68
Engine Fluid Capacities … 68
Transmission Fluid Capacities … 68
Filter Requirements … 69
On-Board Parts Kits … 69-71
ENGINE SPECIFICATIONS … 72-74
OUT-OF-SEASON STORAGE … 75-78
Engine Storage … 75
Draining Instructions … 76
Battery Storage … 76
Out-Of-Season Engine Warm-Up … 77
Recommissioning After Storage … 77-78
TROUBLESHOOTING … 79-81
WATER FLOW DIAGRAMS … 82-85
INSTRUMENTATION WIRING DIAGRAM … 86
LITERATURE … 87
FORMS … 88-93
CRUSADER OWNERSHIP CHANGE NOTICE … 88
CRUSADER WARRANTY TRANSFER APPLICATION (PORT OR SINGLE ENGINE) … 89
CRUSADER WARRANTY TRANSFER APPLICATION (STARBOARD ENGINE) … 91
NOTES … 93
CRUSADER WARRANTY / REGISTRATION FORM

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