E N G I N E S

PRODUCT
INSTALLATION MANUAL

L510023-07 Retail Price $12.00 03/07

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Intentionally Left
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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.
When you chose Crusader, you selected the utmost in premium power for your boating application. Pleasurecraft
is the world’s largest manufacturer of gasoline marine inboards, and the clear-cut leader in cutting edge technology.
Over the years, we have introduced many breakthrough innovations that quickly became industry standards. No
matter which Crusader model you purchased, you can be sure it is equipped with the latest in modern technology for
added performance and durability.

READ THIS MANUAL THOROUGHLY

Before you begin the installation of your new Crusader engine, READ THIS MANUAL CAREFULLY AND
COMPLETELY. There are many new and exciting features available with your new Crusader that you may wish to
take advantage of and plan for as you begin the installation of your new Crusader engine.
Crusader Sync-N-Cruz - Every new fuel injected Crusader engine is capable of twin engine synchronization and
cruise control with the addition of the Crusader Sync-N-Cruz Kit RF152007. This kit includes a harness and control
panel which provides for a very simple installation for plug and play operation. For twin engine applications, the
Master/Slave engine harness is required.
Crusader Engines has worked closely with FW Murphy who makes available multifunction digital displays, such as
PowerView and HelmView, plus a complete line of CAN Bus Instrumentation that are completely compatible with your
new Crusader engine. The Crusader Engines’ ECM-07 engine management system outputs J1939 and NEMA 2000
protocol messages that may be compatible with other manufacturers’ multifunction display equipment. Check with
the manufacturer of the display and / or instrument you are considering, prior to purchase, for compatibility with the
Crusader ECM-07 system.
Crusader Engines has taken care to develop a complete line of adapters and boat harnesses to make your new
installation as seamless as possible. Items available include adapters for engine to existing boat harness, twin engine
Master/Slave harness, engine alarm kit, electric fuel solenoid valves, and water separating fuel filters.
Please read this manual carefully and plan ahead. There may be additional items that you may wish to replace or
upgrade as you install your new Crusader engine. If you do not understand any portion of the manual or require
additional supplies or accessories, contact your Distributor/Dealer for clarification or assistance.
The descriptions and specifications contained in this manual were in effect at the time of printing. Crusader Marine
Engines’ policy of continued improvement reserves the right to change specifications or design without notice and
without obligation.
This manual will cover the following Crusader engines:
Year Model
2007 5.0L MPI
2007 5.7L MPI
2007 6.0L MPI
2007 8.1L MPI
2007 8.1L MPI (HO)
2007 Classic 5.7L Carburetor
Part Number - L510023-07 Printed 03/07
 TABLE OF CONTENTS
SECTION ...................................................................................................................……................................................ Page
General Information ….....……...……...……..........................................……...……...……...………......... 3
Engine Models …..............…...…............…...……...……..............……...……...……...……...………...... 3
Crusader Accessories …..............…...……..................................……...……...……...……...………......... 3
Engine Installation Accessories …..................................................……...……...……...……...………......... 3
Installation Supplies …...................…...……...……................................……...……...……...………......... 3
Installation Drawings …...................…...…...……...…...................……...……...……...……...………........ 3
Engine and Transmission Combinations …..............….........……..……...……...……...……...………......... 4-6
Transmission Rotation …..............…...……...……...…................……...……...……...……...………....... 6-7
Gear Ratio Selection …..............….......……...……...……...............…...……...……...……...………......... 8
Propeller Shaft / Coupling …..............…...…....……...…..............……...……...……...……...………......... 8
Transmission and Propeller Rotation ….............…...……...........….……...……...……...….......………......... 8
Propeller Selection …..............…...…….........……...…...............…...……...……...……...………......... 8-11
Boat Construction …..............…...……..........……...…......................................…...……...………......... 12
Installation Requirements …...........…...……...……..........……...……...……...……...……...………......... 12
Instrumentation …..............…...…..........…...……...……............……...……...……...……...………........ 13
Twin Engine Synchronization and Speed Control (Optional) ...........................……...…….................……....... 13
Master/Slave Wiring Connection …................…...….....................……...……...……...……...………......... 14
Engine Warning Kit (Optional) …....................…..................................……...……...….......………....... 14-15
Electrical System Precautions …................…...…........................................……...……........................... 16
Engine Harness Electrical Connector Identification …........................….................…...…...……...……........ 17
Crusader Classic 5.7L Carburetor - Electrical System Precautions …....................….............……...……......... 18
Crusader Classic Installation Accessories …....................….......…...……...….............….....…...……......... 18
Crusader Classic Engine Wiring Diagram …....................….......…...……...…….........................……......... 19
Boat Adapter Harness Diagram …....................…................................…...……...……...……...……......... 20
Engine Boat Harnesses and Accessories Diagram …....................….......…...……...……...……...……......... 21
Crusader Boat Harness Wiring Diagram …....................….......…...........................……...……...……......... 22
Engine Speed Control/CAN-Bus Harness Diagram …....................….............……...……...……...……......... 23
Sync/Cruise Switch Panel Wiring Diagram …....................….................…...……...……...……...……......... 24
Crusader Boat Speed Control Harness Wiring Diagram ….............….......…...……...……...…..….……......... 25
Engine Compartment Ventilation …................…...…….........................……...……...…...……...……........ 26
Fuel Supply and Return Connections …............................................................................……...……........ 27
Fuel Inlet Restriction …..............…...…....…...……........................……...……...……...……...……......... 28
Fuel Lines …..............…...……...……...……...…….........................................….......……...……......... 28
Fuel System Pressure Check …................................................…...……...……...……...……...……......... 28
Gasoline Requirements …..............................................................................................……...……........ 29
Gasoline Containing Alcohol …..............…...…..............................……...……...……...……..................... 29
Fuel Stabilizer Recommendations for Ethanol Blended Fuel …...................................……...……...……......... 29
Fuel Filter Recommendations for Ethanol Blended Fuel …..............…...……...……...……...……...……......... 30
Exhaust System …...............................…...……....................…...……...……...……...……...……......... 31
Exhaust Risers …..............….....................……................…...……...……...……...……...……......... 31-34
Throttle/Shift Remote Control and Cables …..............................….……...……...……...……...………......... 35
Seawater Pickup Connection …..............…...……....................…...……...……...……...……...……......... 35
Seacock Size Recommendation …..............…...…...........…............……...……...……...……...……......... 35
Sea Strainer Recommendation …..............…...…...........…..........…...…...……...……...……...……......... 35
Crankcase Oil Dipstick Relocation …..............…................................……...……...……...……...……....... 35
Engine Installation …............................…...……....................…...……...……...……...……...……......... 36

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SECTION ...................................................................................................................……................................................ Page
Torque Specifications …........................…...……....................…...……...……...……...……...……......... 36
Preliminary Engine Alignment ….............…...…….....................…...……...……...……...……...……......... 36
Final Engine Alignment …......................…...…….....................…...................…...……...................... 37-39
Throttle/Shift Cables …..............…..............……...............…...……...……...……...……...………....... 39-43
Audio Alarm System …..............…..............…….....................…...……...……...……...……...……......... 43
Exhaust System Connection …....…..............…….........................……...……...……...……...………....... 44
Engine Harness Connection ….....................……..................…...……...……...……...……...………........ 44
Battery Connection …..............…..............……..........…............……...……...……...……...………......... 44
Master Engine Specifications ….......................……..............…...……...……...……...……...……........ 45-48
Delivery Preparation …..............…..............……......................…...……...……...……...……...……........ 49
Pre-Delivery Checklist …............…................……..................….......…...……...……...……...……......... 49
Pre-Delivery Procedure …............…........................................…...……...……...…..……...……......... 50-59
INSTALLATION DRAWINGS:
EXHAUST SYSTEM INSTALLATION GUIDELINES ...................................................................................... 60
CAPTAIN’S CHOICE INSTALLATION DRAWINGS:
5.7L BOSCH / VELVET DRIVE 72 REDUCTION .......................................................................................... 61
5.7L BOSCH / HURTH 630 8° DOWN ANGLE ............................................................................................. 62
5.7L BOSCH / HURTH 630V .................................................................................................................... 63
5.7L BOSCH / VELVET DRIVE 72 DIRECT DRIVE ...................................................................................... 64
6.0L W/4 IN. RISERS / HURTH 630 8° DOWN ANGLE ................................................................................. 65
8.1L / HURTH 630A 8° DOWN ANGLE ...................................................................................................... 66
8.1L / VELVET DRIVE 72 DIRECT DRIVE ...................................................................................................67
8.1L / VELVET DRIVE 72 REDUCTION ...................................................................................................... 68
CRUSADER XL SERIES INSTALLATION DRAWINGS:
350XL-HT WITH HURTH V-DRIVE GEAR .................................................................................................. 69
350XL-HT WITH VELVET DRIVE 5000V GEAR .........................................................................................70
350XL-HT WITH HURTH SERIES - 8° DOWN ANGLE .............................................................................. 71
350XL-HT WITH VELVET DRIVE 72 SERIES V-DRIVE ............................................................................... 72
350XL-HT WITH VELVET DRIVE 72 SERIES REDUCTION .......................................................................... 73
350XL-HT WITH VELVET DRIVE 5000 SERIES - 8° DOWN ANGLE ............................................................. 74
Crusader Engines Distributors ….......…........................................…...……...……................................... 75
Appendix A Captain’s Choice and Xli Installation Drawings …........……...……...……...……...……......... A1-A40
Appendix B XL Series Installation Drawings …......................…...……...……...……...……...…............. B1-B30

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GENERAL INFORMATION We could not possibly know of and advise the marine
trade of all conceivable procedures by which an
Notice to Installer installation might be performed and of the possible
Throughout this manual, “Warnings” and “Cautions” hazards and/or results of each method. We have not
(accompanied by the International Hazard Symbol) undertaken any such wide evaluation. Therefore,
are used to alert the installer to special instructions anyone who uses an installation procedure and/or tool,
concerning a particular service or operation that may which is not recommended by the manufacturer, first
be hazardous if performed incorrectly or carelessly. must completely satisfy himself that neither his nor the
Observe them carefully! product’s safety will be endangered by the installation
These “Safety Alerts” alone cannot eliminate the hazards procedure selected.
that they signal. Strict compliance to these special All information, illustrations and specifications contained
instructions when performing the service, plus “common- in this manual are based on the latest product
sense” operation, are major accident prevention information available at the time of publication.
measures.
ENGINE MODELS
This manual gives installation guidelines for the following
WARNING engine models.

Hazards or unsafe practices which could result in MP 5.0L / MP 5.7L

severe personal injury or death. MP 6.0L
MP 8.1L STD
MP 8.1L HO
CAUTION
Carb. 5.7L
Hazards or unsafe practices which could result in CRUSADER ACCESSORIES
minor personal injury or product or property damage.
Instrument panels, wiring harnesses, propeller shaft
couplers, etc. are available for this product. Contact
IMPORTANT: Indicates information or instructions your Crusader Engines Distributor or Crusader Engines
that are necessary for proper installation and/or Sales Department for a listing of these options. A list of
operation. Distributors is provided at the end of this manual.

Experience gained over the past several years has ENGINE INSTALLATION ACCESSORIES
shown that marine engines fitted with electronic fuel Electric Fuel Solenoid Valve P/N 23532
injection (EFI) require carefully integrated fuel delivery
systems. More specifically, the fuel tank, fuel supply Solenoid Valve Power Harness P/N 98452
and return lines, fuel filters and all their associated Water Separating Fuel Filter Kit P/N RK080033
valves and fittings must be considered an integral part
Check Engine Lamp / Alarm Kit P/N RK179008
of any fuel injection engine package. This may require
changes in both fuel system components and/or layout Crusader Sync-N-Cruz Kit P/N RF152007
to assure compatibility and 100% customer satisfaction Master / Slave Wire Harness: P/N RA121072C
with the latest EFI engines.
Adapter - Engine to Boat Harness see page 20
Any new or re-power application involving the
replacement of a non-EFI engine with an EFI engine Boat to Engine Harness see page 21
may require a new or modified fuel delivery system, INSTALLATION SUPPLIES
from the tank to the engine, for proper operation. This
installation manual has been published by Crusader Marine Lubricant
Engines to aid installers when installing the products Liquid Neoprene
described herein. Perfect Seal or equivalent
It is assumed that these personnel are familiar with the Loctite PST Pipe Sealant or equivalent
installation procedures of similar products manufactured
and marketed by Crusader Engines. That they have Mount Adjustment Tool - P/N 22165
been trained in the recommended installation procedures INSTALLATION DRAWINGS
of these products which includes the use of mechanics’
Installation drawings are at the back of this manual.
common hand tools and any recommended tools from
These and archive installation drawings, are also
other manufacturers.
available at crusaderengines.com

L510023-07
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ENGINE AND TRANSMISSION
COMBINATIONS
Engine Rotation:
Engine rotation is indicated by the model number on the
engine serial number plate. Engine rotation is described
by flywheel rotation viewing from the rear of the engine
(transmission end) looking forward to the water pump
end. Refer to the Crusader Model Identification/Advisory
information below.
CRUSADER MODEL IDENTIFICATION /
ADVISORY

MODEL 23 - 6 0 0 V - 0 1 SERIAL 670000

1st - 2nd Space: MANUFACTURING CODE

*SERIAL NUMBER I.D.*
3rd - 5th Space: ENGINE CODE 1st DIGIT INDICATES DECADE ENGINE WAS
810 = 8.1L (496 CID LH MPI) (GM) MANUFACTURED ( 5 = 1990, 6 = 2000, 7 = 2010 )
811 = 8.1L (496 CID LH H.O. MPI) (GM) 2nd DIGIT INDICATES YEAR ENGINE WAS
600 = 6.0L (364 CID LH MPI) (GM) MANUFACTURED.
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)

6th Space: DRIVE CONFIGURATION

blank - Direct Drive
V - V-Drive

7th - 8th Space: SPECIFICATION CODE

Figure 1 Flywheel Showing LH Rotation

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Figure 2 Engine Applications - Typical 8 Degree Down Angle Transmission

Figure 3 Engine Applications - Typical V-Drive Transmission

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 Figure 4 Engine Applications - Typical Remote V-Drive Transmission

TRANSMISSION ROTATION F R
N
Velvet Drive In-Line and V-Drive
Transmission gear ratio (in forward gear) is marked
on the transmission identification plate. Transmission POPPET
output shaft rotation is indicated on a decal on the BALL
transmission case.
IMPORTANT: Use of proper rotation propeller,
indicated by the output flange rotation decal, is
critical as operating the transmission in Reverse to TOWARD
move the boat forward WILL CAUSE transmission FLYWHEEL
failure. The transmission MUST BE operated in FOR
forward gear only to propel the boat forward. FORWARD

Figure 6 Shift Lever Positions - Standard Velvet Drive

PROP SHAFT
ROTATION
DECAL

IDENTIFICATION
TAG

Figure 5 Standard Velvet Drive Identification Plate and

Propshaft Rotation

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Velvet Drive 5000 Series and Hurth
Transmissions
These transmissions are “Full Reversing” with an
8-degree, down-angle output flange. This allows a
standard (LH or CCW) rotation engine to be used
for both propeller shaft rotations. Shaft rotation is
determined by shift cable installation at the remote
control (Figures 7 and 8). Transmission gear ratio
and serial number is marked on the transmission
identification plate.

LH FORWARD
GEAR
FORWARD
GEAR RH

RH PROP SHAFT ROTATION

LH PROP SHAFT ROTATION

VELVET DRIVE 5000

TRANSMISSIONS

Figure 7 Shift Lever Positions - Velvet Drive 5000

RH FORWARD
GEAR
FORWARD
GEAR LH

LH PROP SHAFT ROTATION

RH PROP SHAFT ROTATION

HURTH
TRANSMISSIONS

Figure 8 Shift Lever Positions - Hurth

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GEAR RATIO SELECTION ENGINE RPM CHART
The propeller shaft speed is determined by engine
Minimum
speed and transmission gear ratio. Fast boats operate
Model Full Load Maximum Preferred
best with direct drive or small reductions. Heavier boats
respond best with larger ratios of gear reduction. MP 5.0L 4600 5000 4800
If shaft speeds are too high, a smaller than normal MP 5.7L 4800 5200 5000
propeller must be used resulting in poor performance. MP 6.0L 4800 5300 5200
Conversely, if shaft speeds are too low, a larger than
MP 8.1L STD 4400 4800 4600
normal propeller must be used, again resulting in poor
performance. MP 8.1L HO 4800 5200 5000
PROPELLER SHAFT / COUPLING IMPORTANT NOTICE: Engines equipped with
Installed angle of the engine should not exceed the ECM-07 engine management system incorporate
maximum of 16 degrees from water line. an RPM “MAX Governor” in order to prevent the
engine from over-revving. Engine operation above the
Propeller shaft diameter should be sufficient size for the Maximum RPM listed will appear normal, but will not
type of application. exceed the “MAX Governor” RPM (100 RPM above
Coupling must be keyed to the propeller shaft. The key the Maximum RPM specified for an engine model).
should be a close fit with keyway sides, but should not Operation above the maximum RPM specified for your
touch the top of the keyway in the coupling hub. The engine model is not recommended. If the engine is
coupling should be a light press fit on the shaft. operating above the maximum RPM, a higher pitched
propeller would be required to lower the engine
TRANSMISSION AND PROPELLER maximum RPM to the Preferred RPM specified for your
ROTATION engine model.
For best all-around performance, it is recommended
that the engines be installed so that the propellers turn Minimum
outboard in dual engine applications. Model Full Load Maximum Preferred
NOTICE: Propeller rotation is not necessarily the same Carb. 5.7L 4800 5200 5000
as engine rotation.
PROPELLER SELECTION CAUTION
IMPORTANT: Installed propeller must allow the
engine to run at its specified, Preferred, wide-open- Prolonged WOT operation will shorten the life of your
throttle RPM. engine and could cause premature engine failure.
See Cruising RPM (Max) in the Master Engine
It is the responsibility of the boat manufacturer and/or Specifications. Problems caused by WOT operation
selling dealer to equip the boat with the correct propeller. are considered abuse and are not covered under the
Specified engine WOT RPM is listed in the “Master Crusader Warranty.
Engine Specifications” found within this manual.
Because of many variables of boat designs, only
testing will determine the best propeller for a particular
application. A propeller should be selected that will allow
the engine to operate at or near the recommended WOT
operating range with a normal load. Refer to the engine
RPM chart, right, or the Master Engine Specifications
found in this manual.
In general, a 1 inch change in propeller pitch will result in
a 100 to 200 RPM change in engine speed.

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Single Engine Velvet Drive In-Line Installation
- (1:1, 1.52:1, 2.57:1 or 2.91:1 Ratio)
The transmission output shaft rotation is the same as the
engine rotation. A LH (CCW) rotation engine requires a
LH propeller.

FRONT

LH OR CCW
ENGINE
ROTATION

FLYWHEEL

LH

Figure 9 Single Engine Velvet Drive in-Line Installation

- 1:1, 1.52:1, 2.57:1 or 2.91:1 Ratio

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 INTRODUCTION - 1
Single Engine Velvet Drive In-Line Installation Single Engine V-Drive Installation
- (1.90:1 Ratio) The transmission output shaft rotation is the opposite
The transmission output shaft rotation is the opposite of the engine rotation. A LH (CCW) rotation engine
of the engine rotation. A LH (CCW) rotation engine requires a RH propeller.
requires a RH propeller.

INPUT
GEAR
ROTATION
OUTPUT
FLANGE
ROTATION
FRONT FLYWHEEL

LH OR CCW
LH OR CCW ENGINE
ENGINE ROTATION
ROTATION

FLYWHEEL FRONT

RH
RH

Figure 11 Single Engine V-Drive Installation

Figure 10 Single Engine Velvet Drive in-Line Installation
- 1.90:1 Ratio

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Dual Engine Velvet Drive 5000 and Hurth 630A Dual Engine Velvet Drive 5000 and Hurth 630V
Installation V-Drive Installation
These “Full-Reversing” transmissions rotate equally in These “Full-Reversing” V-Drive transmissions rotate
either direction depending upon shift lever position and equally in either direction depending upon shift lever
desired propeller rotation. position and desired propeller rotation.
Velvet Drive 5000 gear ratios include: 1.50:1, 2.00:1, Velvet Drive 5000 V-Drive gear ratios include: 1.21:1,
2.45:1 or 2.80:1. 1.51:1, 1.99:1 or 2.50:1.
Hurth 630A gear ratios include: 1.50:1, 2.00:1, 2.50:1 or Hurth 630V gear ratios include: 1.30:1, 1.55:1, 2.00:1 or
2.70:1. 2.50:1.

FRONT FRONT

FLYWHEEL FLYWHEEL
LH OR CCW LH OR CCW
ENGINE ENGINE LH OR CCW LH OR CCW
ROTATION ROTATION ENGINE ENGINE
ROTATION ROTATION

FLYWHEEL FLYWHEEL

FRONT FRONT

LH RH LH RH

Figure 12 Dual Engine Velvet Drive 5000 and Hurth Figure 13 Dual Engine Velvet Drive 5000 and Hurth
630H Installation 630V V-Drive Installation

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BOAT CONSTRUCTION 1/2" x 6" LAG SCREW
(MINIMUM LENGTH)
Engine Bed
The engine bed should be a horizontal type and rigid
enough to maintain engine alignment at all times.
Distance between the starboard and port engine mounts ADJUSTING
is 22 1/2 in. (57.15 cm). The engine bed should support SLEEVE
the four (4) engine mounts in such a manner so that a
minimum of 1/4 in. (0.64 cm) up and down adjustment
still exists on all the mounts after the final engine
alignment has been performed. This is necessary to
allow for realigning the engine in the future. STRINGER

Figure 15 Engine Mount Attachment

INSTALLATION REQUIREMENTS
Battery/Battery Cables
IMPORTANT: Boating industry standards (BIA,
ABYC, etc.), Federal standards and Coast Guard
regulations must be adhered to when installing the
battery. Be sure the battery cable installation meets
Figure 14 Engine Bed the pull test requirements and that the positive
battery terminal is properly insulated in accordance
Use adequately sized bolts to attach the engine to the with the regulations.
stringers or mounting plates. It must be remembered IMPORTANT: Engine electrical system is negative
that all the force used to drive the boat through the water (-) ground. It is recommended (required in some
is transferred to the hull through the engine bed. Make states) that the battery be installed in an enclosed
sure there is adequate clearance between the underside case. Refer to the regulations in your area.
of the engine and the hull.
1. Select a battery that meets all of the following
specifications:
A. 12-volt marine type
B. Tapered post connections
C. Reserve capacity rating of at least 100
minutes

MINIMUM 12-VOLT BATTERY SIZE

All Engines 650 CCA 120 Ah

2. Select the proper size positive (+) and negative

(-) battery cables using the chart. Battery should
be located as close to the engine as possible.
3. In twin engine applications, it is recommended
that both engines be grounded together using a
cable of adequate gauge.

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IMPORTANT: Terminals must be soldered to the instrument manufacturer’s name. You may need
cable ends to ensure good electrical contact. Use to install an oil pressure and water temperature
electrical grade (resin flux) solder only. Do not use sender on your engine and use a different engine
acid flux solder as it may cause corrosion and a to boat harness adapter.
subsequent failure. (3) Faulty wire connections at the instrument panel
and/or the old instruments are defective and need
BATTERY CABLES to be replaced.
Cable Length Cable Gauge Refer to pages 20 and 25, for replacement boat
2 harnesses, adapter harnesses, and Sync-N-Cruz Speed
Up to 3-1/2 ft. (1.1 m) 4 (19 mm )
Control Harness + FWMurphy Instrument interface.
3-1/2 - 6 ft. (1.1 - 1.8 m) 2 (32 mm2)
Crusader Engines are equipped with the ECM-07 engine
6 - 7-1/2 ft. (1.8 - 2.3 m) 1 (40 mm2) management system. This system outputs J1939 and
7-1/2 - 9-1/2 ft. (2.3 - 2.9 m) 0 (50 mm2) NEMA 2000 protocol messages that may be utilized by
various manufacturers of multifunction displays; such as,
9-1/2 - 12 ft. (2.9 - 3.7 m) 00 (62 mm2) FWMurphy’s CAN Bus instruments and PowerView and
12 - 15 ft. (3.7 - 4.6 m) 000 (81 mm2) HelmView, which provide expanded display capabilities.
15 - 19 ft. (4.6 - 5.8 m) 0000 (103 mm2) Always check with the manufacturer of the
instrument you are considering, prior to purchase,
for compatibility. These multifunction digital displays
INSTRUMENTATION not only display typical engine data, such as oil pressure,
water temperature, tach, etc., but also provide expanded
CAUTION displays for fuel consumption, ECM-07 diagnostic code
display, and much more.
If a Crusader wiring harness is used, and a fused When replacing or installing the main boat harness,
accessory panel is to be installed (30 amp current route the instrumentation wiring harness back to the
draw maximum), be sure to connect it as shown in engine, making sure that the harness does not rub or get
wiring diagram. Do not connect accessory panel at pinched. If an extension harness is required, be sure to
any other location, as wires in wiring harness may not secure the connection properly. Fasten harness to the
be of sufficient size to handle current load. boat at least every 18 in. (45.72 cm) using appropriate
fasteners.
For ECM-07 equipped engines, instrumentation at
the dash is no longer driven by separate senders TWIN ENGINE SYNCHRONIZATION AND
on the engine. Instrumentation is now driven by the SPEED CONTROL (OPTIONAL)
engine control module (ECM-07) and is just another MY 2007 and newer multi-port fuel injected engines
function of the engine management system. As such, are equipped with the ECM-07 engine management
programming or calibration of the ECM is critical for system. This new system has allowed more features to
proper instrumentation operation. be available than ever before. One of significance is the
The 4 basic gauges which must be used with the engine ability to provide twin engine synchronization and speed
are: control without having to add expensive aftermarket
equipment. This feature is available on all ECM-07
• Tachometer
multi-port fuel injected engine models. Refer to the
• Oil Pressure diagram on page 23 for the accessory harnesses and
• Water Temperature keypad required to enable this feature.
• Voltmeter REQUIREMENTS:
If you experience erroneous instrumentation readings, • Master/Slave Harness - RA121072C
the most common reasons for this condition are: • Sync-N-Cruz Kit - RF152007
(1) The boat is equipped with dual helm NOTE: The Sync-N-Cruz Contorl Panel and harnesses
instrumentation. Verify through your selling are available as separate items for unique installation
distributor/dealer that the calibration in the ECM requirements. Refer to page 23 for harness options.
is for dual helm instrumentation.
IMPORTANT: Sync-N-Cruz harness must be connected
(2) Some instruments may still require instrument to the Master engine.
specific senders to be installed on the engine.
Refer to the Crusader Owners Manual for operating
Contact your selling distributor/dealer with your
instructions for the Sync-N-Cruz system.

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When installing the Sync-N-Cruz harness, route the making sure that the wires do not rub or get pinched.
harness back to the Master engine, making sure that the Fasten wire(s) to the boat at least every 18 in. (45.72
harness does not rub or get pinched. If an extension cm) using appropriate fasteners.
harness is required, be sure to secure the connection
properly. Fasten harness to the boat at least every 18 • Using existing Round 10-pin BOAT
in. (45.72 cm) using appropriate fasteners. harness connector
Pin-4 = Buzzer
MASTER/SLAVE WIRING CONNECTION
Pin-9 - MIL or Check Engine Lamp
This connection allows the CAN Bus data lines to be
Verify that connections exist at the helm. If not,
joined together for dual engine applications.
two new wires will be required between the helm
The benefits of a Master/Slave connection are: and pins 4 (MIL) and 6 (Buzzer) of the Engine
• Allows for twin engine Sync-N-Cruz operation. harness 8-pin Deutsch connector.
• Electronic Engine Monitor systems installed at • Using existing Rectangular 8-pin BOAT
the helm area may display engine data for both harness connector
engines.
* Requires two additional wires for the MIL and
IMPORTANT: In dual engine applications, the
Buzzer. The MIL is connected to pin-6 and
master/slave wiring harness is used to connect the
the Buzzer is connected to pin-4 of the Engine
engines together. One end of this harness has one
harness, 8-Pin, Deutsch connector.
more wire in it than the other end. The end with the
extra wire is plugged into the Slave engine harness. • Using the Crusader boat harness (P/N
This extra wire is then attached to the ground stud RA121092/RA121092A), the MIL is wired at
on the Slave engine. the helm to the Green/Yellow wire and the
ENGINE WARNING KIT (OPTIONAL) Buzzer is wired to the Tan/Black wire.

An engine warning kit, RK179008, is available. This kit • If previously equipped with the Optional
contains a Check Engine Lamp and Warning Buzzer. Crusader Warning Light Cluster P/N 23505:
It is recommended that the boat be equipped with a
Check Engine Lamp (Malfunction Indicator Lamp - MIL)
and buzzer. These devices warn the boat operator of
potential engine problems.

OIL CHK
PRESS ENGINE

WATER TRANS
TEMP TEMP

Figure 17 Optional Warning Light Cluster - Crusader

Part No. 23505
The Check Engine lamp, of the cluster, and
Figure 16 Optional Warning Light / Alarm - Crusader the existing Buzzer may be used with ECM-07
Part No. RK179008 engine models.
Some boat wiring may already support these devices (1) At each engine, locate the Warning Cluster
and/or they may already be installed at the helm. Harness, 8-pin connector. The wires at Pin-A
Ensure that the new connections match up to the (Orange/Tan wire, Check Engine Lamp) and
existing boat wiring and warning devices. Pin-B (Tan/Red wire, Buzzer) will be the only
Ensure the light and buzzer wires are in the existing boat wires used. Cut the 8-Pin connector off of the
harness, otherwise new wires will have to be run from harness and tape back the wires not used.
the helm to the engine. Use 18 ga minimum wire size,

L510023-07
14
 Buzzer.
CUT 8-PIN 23505
OIL CHK
CONNECTOR Display PRESS ENGINE

ENGINE PIN-A ORANGE/TAN OFF HARNESS 98387/98388

WATER TRANS
PORT/ HARNESS SPLICE TO HARNESS TEMP TEMP

GREEN/YELLOW
SLAVE IN RA121093
ENGINE PIN-B TAN/RED Existing Harness and
SPLICE TO Warning Cluster
TAN/BLACK IN
GND RA121093
Existing Boat
Harness
Part Number -
RA121093
connector. Only, the Check Engine Lamp
pin-B (Tan/Red) to pin-4 of the engine 8-pin
(2) Splice pin-A (Orange/Tan) to pin-6 of the

and alarm buzzer of the warning cluster will be

respective engine 8-pin Deutsch connector and

functional. Refer to the wiring diagram below

for connection/splice options for the MIL and

Master / Slave
Engine Harness
Part Number -
RA121072C

L510023-07
CUT 8-PIN
CONNECTOR
OFF HARNESS 23505
OIL CHK
Display PRESS ENGINE

WATER TRANS
PIN-A ORANGE/TAN TEMP TEMP
98387/98388
Dash Side

ENGINE SPLICE TO
HARNESS

Engine Side
HARNESS GREEN/YELLOW
IN RA121093
PIN-B TAN/RED Existing Harness and
SPLICE TO Warning Cluster
TAN/BLACK IN
RA121093

Existing Boat
Harness
Part Number -
STARBOARD/ RA121093
MASTER
ENGINE

15
 ELECTRICAL SYSTEM PRECAUTIONS
To avoid damage to the electronic fuel injection (EFI)
system, the following precautions must be observed
when adding additional electric accessories.
• DO NOT reverse battery leads.
• DO NOT splice wires into engine electrical harness.
• DO NOT puncture engine wires for testing
(probing).
• DO NOT attempt engine diagnostics without the
proper service tools.
• DO NOT attach any accessory wiring to the ECM
ground location.

TWIN ENGINE
MASTER/SLAVE
CONNECTOR

SLAVE ENGINE 2-PIN BOAT

HARNESS
GROUND TERMINAL CONNECTOR

FUEL TANK
Figure 18 ECM Slave Ground Terminal SOLENOID
CONNECTOR
SPEED CONTROL/
8-PIN BOAT CAN BUS
HARNESS CONNECTOR
CONNECTOR

Figure 20 Electrical System Connectors

TO SLAVE ENGINE
GROUND STUD INSTALLATION NOTE: When installing the
Optional Crusader Sync-N-Cruz system, the speed
control harness (RA121091/RA121091A) MUST be
connected to the Master engine, 20-Pin Speed Control/
CAN Bus Connector and the master/slave harness
(RA121072C) must connect the Master and Slave
engines together. Ensure that the Slave side of the
TO MASTER harness is grounded to the Slave engine.
TO SLAVE ENGINE
ENGINE

Figure 19 Master / Slave Wire Harness

L510023-07
16
 NOTE: ENGINE HARNESS WIRED FOR PANELS USING VOLTMETERS ONLY.
NOTE A : POWER FOR A FUSED ACCESSORY PANEL MAY BE TAKEN FROM
THIS LOCATION. LOAD CANNOT EXCEED 30 AMPS.

2-PIN WIRE HARNESS COLOR CHART ENGINE

CIRCUIT CIRCUIT ENGINE HARNESS HARNESS
NUMBER NAME WIRE COLOR
A 1. VBAT RED/PURPLE
2. GROUND BLACK

8-PIN WIRE HARNESS COLOR CHART

CIRCUIT CIRCUIT ENGINE HARNESS
NUMBER NAME WIRE COLOR
1. (OPEN) CAVITY PLUG
2. TACHOMETER GRAY
3. COOLANT TEMP TAN
4. BUZZER TAN/BLACK
5. IGNITION PURPLE
6. MIL GREEN/YELLOW
7. STARTER YELLOW/RED
8. OIL PRESSURE DARK BLUE

TWIN ENGINE
MASTER/SLAVE
CONNECTOR

2-PIN BOAT
HARNESS
CONNECTOR

FUEL TANK
SOLENOID
CONNECTOR

8-PIN BOAT
HARNESS
CONNECTOR

NOTE: The ‘MIL’ or Malfunction Indicator Lamp may be labeled the “Check SPEED CONTROL/
Engine Lamp” on the instrument panel. Check the boat owners manual for CAN BUS
exact labelling. CONNECTOR

Figure 20A - Electrical System Connectors

INSTALLATION NOTE: When installing the Optional Crusader Sync-N-Cruz system, the speed control harness
(RA121091/RA121091A) MUST be connected to the Master engine, 20-Pin Speed Control/CAN Bus Connector and
the Master/Slave harness (RA121072C) must connect the Master and Slave engines together. Ensure that the Slave
side of the harness is grounded to the Slave engine.

L510023-07
17
CRUSADER CLASSIC 5.7L CARBURETOR CRUSADER CLASSIC ACCESSORIES
- ELECTRICAL SYSTEM PRECAUTIONS Instrument panels, wiring harnesses, propeller shaft
To avoid damage to the electrical system, the following couplers, etc. are available for this product. Contact
precautions must be observed when adding additional your Crusader Engines Distributor or Crusader Engines
electric accessories. Sales Department for a listing of these options. A list of
Distributors is provided at the end of this manual.
• DO NOT reverse battery leads.
• DO NOT splice wires into engine electrical ENGINE INSTALLATION ACCESSORIES
harness. Electric Fuel Solenoid Valve P/N 23532
• DO NOT puncture engine wires for testing Solenoid Valve Power Harness P/N 98452
(probing).
Water Separating Fuel Filter Kit P/N RK080033
• DO NOT attempt engine diagnostics without the
Adapter - Engine to Boat Harness 98218
proper service tools.
10-Pin to 8-Pin Male
• DO NOT attach any accessory wiring to the ECM
Adapter - Engine to Boat Harness R121073
ground location.
10-Pin to 8-Pin Female

NOTE: Twin engine Sync-N-Cruz, multifuction

displays, and CAN-Bus instrumentation options
are not available with the Crusader Classic series
engines.

ENGINE
HARNESS
WIRE HARNESS COLOR CHART
ADAPTER
CIRCUIT CIRCUIT ENGINE HARNESS
NUMBER NAME WIRE COLOR
1. GROUND BLACK
2. TACHOMETER GRAY
3. WATER TEMPERATURE TAN 1
8
4. N/C 2
5. IGNITION PURPLE 9
10
6. BATTERY RED
7. STARTER YELLOW/RED 3 7
8. OIL PRESSURE LT. BLUE
9. N/C
4
5 6
10. N/C

NOTE: ENGINE HARNESS WIRED FOR PANELS USING VOLTMETERS ONLY.

NOTE A : POWER FOR A FUSED ACCESSORY PANEL MAY BE TAKEN A
FROM THIS LOCATION. LOAD CANNOT EXCEED 30 AMPS.

IMPORTANT: Your engine is designed to work with the standard electronics installed in your boat. If you add other
electrical components or accessories, you could change how the overall electrical system functions. Before adding
electrical equipment, consult your dealer. If you don’t, your engine may not perform properly.

CAUTION
Add-on equipment may adversely affect the alternator output or overload the electrical system. Any damage caused
as a result will not be covered by, and may void, your warranty.

L510023-07
18
 10-P IN
E NG INE
BLACK 6 ga
GRD HAR NE S S
RED/WHITE 16 ga
SEN
ALT E R NAT OR EXC PURPLE/WHITE 16 ga
FROM PIN 5
RED 6 ga
BAT

Water

R
T emp

E
WAT E R TAN 14ga
3

D
T E MP
S E NS OR
B attery
- + 60A
RED/WHITE 10ga 125 C
C ircuit 6
B reaker a
g
2
1
B AT T E R Y

RED - 6 ga
E
IT Oil
H
/W
P res s ure
D OIL LT. BLUE 14ga
E P R E S S UR E 8
R
S E NS OR

100A
LIT T LE

F US E

RED - 6 ga
BAT 86 30
T R ANS MIS S ION S tarter
S T AR T E R S
S tarter YEL/RED NE UT R AL YEL/RED
7
12 ga S AF E T Y 12 ga
I FROM R elay S WIT C H
PIN 1

85 87 87A
BLACK 12 ga
Not Us ed
RED - 14ga YELLOW 12 ga
T achometer
GRAY 16ga
2
P UR P LE /
T o - E XC
WHIT E
A lternator
GREEN RED 16 ga 16 ga
12 in. long
BROWN - + Ignition
DIS T R IB UT OR B allas t PURPLE/WHITE
IG NIT ION
R es is tor 14ga
5
(MALLOR Y ) C OIL

RED

PURPLE/WHITE 14 ga
FROM BLACK 14 ga PURPLE/WHITE 14 ga
PIN 1

- +
C AR B UR E T OR
E LE C T R IC
5A
C HOK E
F us e MODULE

Oil P res s ure

DARK RED 14 ga
F uel P ump
GREEN/
YELLOW
Interlock
14 ga S witch
To -
S tarter
To -
R elay
BLACK 14 ga FROM C arburetor
PIN 1 C hoke
G round
T o - E lec . BLACK 10ga
F uel P ump 125 C
1
+ -
E LE C T R IC GROUND
ENGINE BLOCK
F UE L
P UMP LT. Green 14ga

Pigtail connector
near 10-Pin connector
Low Water
Oil P res s ure T emperature
S witch S witch

E NG INE WAR NING C IR C UIT

Figure 20B Typical Engine Wiring w/Mallory Ignition - Crusader Classic 5.7L Carburetor

L510023-07
19
20
Boat Adapter Harnesses

10-Pin
Round Molded
W/VDO Sensor leads
Part Number -
RA121093A
10-Pin
Round Molded
Part Number -
RA121093

8-Pin (F)

L510023-07
Part Number -
RA121094

8-Pin (M)
Dash Side

Engine Side
Part Number -
RA121094A

14-Pin
Merc Style
Part Number -
RA121098
 Engine Boat Harnesses and Accessories

PORT/
SLAVE
All Boat Applications Crusader Instrument Panel
ENGINE BAT / Ground / Starter / Ignition
GND # 22141
Oil Pressure/Coolant Temp Gauges/Buzzer

Replacement Boat Harnesses

Part Number -
Master / Slave RA121092 - 25 FT, Unterminated
Engine Harness RA121092A - 45 FT, Unterminated
Part Number - RA121092B- 25 FT, Terminated 8-Pin Connector
RA121072C RA121092C - 25 FT, W/VDO Sender take-outs
(Requires 2 harnesses - one for each engine.)

L510023-07
RK179008 -
Check Engine Lamp (MIL) Kit -
Lamp and Alarm Buzzer
(Requires 2 kits -
one for each engine.)

Engine Side
Dash Side

STARBOARD/
MASTER
ENGINE

NOTE: The above illustration represents a typical twin engine installation using Crusader harnesses and accessories.

21
 Crusader supplied Boat Extension Harnesses
RA121092 = 25 ft
RA121092A = 45 ft
***Extension harnesses are used to connect engine
wiring to the helm.

Spliced at Helm by Installer

BLK TAN/ GRN/ BLU

BLK YEL

RED GRY TAN PPL YEL/

RED

1 2 2 3 4 5 6 7 8
Battery Ground TACH Coolant Buzzer Ignition Malfunction Starter Oil
(Panel (Panel) Temperature Feed Indicator Circuit Pressure
Power) Sender Lamp (MIL) Sender

Deutsch 2-Way Deutsch 8-Way Connector

Connector P/N - DT04-8PA
P/N - DTP04-2P

RA121092_092A
9-28-06

L510023-07
22
 Engine Speed Control / CAN-Bus Harnesses

SLAVE
OPTIONAL -
Murphy Supplied
PORT/ Equipment
SLAVE See your Distributor/ A B
1
4
2
5
3
ENGINE Dealer for the kit 6

GND you require.

+ Battery

Murphy CAN
OR - Ground
Bus Instruments

Murphy HelmView

Murphy PowerView

RA121072C
Murphy CAN

Part Number -

Master / Slave

L510023-07
Engine Harness
Bus Instruments

A B
1
4
2
5
3
6

Engine Side
Dash Side

Crusader Sync-N-Cruz Kit - RF152007

Includes: MASTER
Harness - RA121091 - 25 FT, Engine to Panel + Battery
Control Panel - RA152007
- Ground
Crusader Part Number - Sync Cruise
RPM Cruise Only RA121091 - 25 FT, Engine to Panel
STARBOARD/ Twin Engine Synchronization ON Set (+)/Res + Battery
CAN BUS Displays RA121091A - 45 FT, Engine to Panel
MASTER Syn/Cru Speed Speed
- Ground
ENGINE
OFF Cancel (-)

NOTE: The above illustration represents a typical twin engine installation using Part Number -
Crusader and Murphy harnesses. Original boat harnesses may be used with the RA152007
appropriate adapter and FWMurphy equipment may be used without the use of
the Crusader Speed Control/CAN Bus harness.

23
 Sync/Cruise Switch Panel (RA152007)

5K Circuit
RED/ Sync Resistor Cruise
Board
LED LED
YEL
LT
BLU/
BLK

PPL PPL
ORN

ON SET (+) /
Resume

BRN
Sync/ Speed Speed
Cruise

OFF CANCEL (-)

BLK BLK

BLK PPL

RED/ LT ORN BRN ORN/ ORN/

YEL BLU/ BLU GRN To From
BLK Ground Ignition

8 3 11 12 10 9
Cruise Sync Cruise Sync Speed Speed
LED LED Request Request Set/ Increment/
(Ground) (Ground) Cancel Decrement

Deutsch 12-Way Connector

P/N - DT06-12S

Note: Panel 12-Way connector plugs directly into the following

Crusader supplied Boat Speed Control Harnesses:
RA121091
RA121091A
***See the following pages for schematics of these harnesses.

RA152007
9-28-06

L510023-07
24
Crusader supplied Boat Speed Control Harnesses
RA121091 = 25 ft
RA121091A = 45 ft

Deutsch 3-Way Deutsch 12-Way

Connector Connector
P/N - DT06-3S P/N - DT04-12PA
CAN 1 CAN 1 Speed Speed Cruise Sync
BUS BUS Cruise Set/ Increment/ LED Sync LED
(+) (-) Request Cancel Decrement (Ground) Request (Ground)

A B 11 10 9 8 12 3

Twisted

WHT ORN/ RED/ LT

LT YEL BLU/
BLU BLK
BLK/
WHT
ORN ORN/ BRN
GRN

16 17 8 9 10 11 18 19
CAN 1 CAN 1 Cruise Speed Speed Cruise Sync Sync
BUS BUS Request Set/ Increment/ LED Request LED
(+) (-) Cancel Decrement (Ground) (Ground)

Deutsch 20-Way Connector

P/N - HDP26-18-20SN

RA121091_091A
9-28-06

L510023-07
25
ENGINE COMPARTMENT VENTILATION Air requirements listed are for single engine and
must be doubled for dual engine installations.
USCG & ABYC Standards
The pressure differential (outside engine compartment
United States Coast Guard regulations (33 CFR Section versus inside engine compartment) should not exceed
183, subpart J & K) must be adhered to in any fuel and 2 in. (51 mm) of water (measured with a manometer) at
ventilation system installation. In addition, we strongly wide open throttle.
suggest that ABYC’s recommendations regarding fuel
systems and engine room ventilation be followed. Engine Compartment & Fuel Temperature Testing
capable of operation throughout an ambient (air
Care must be exercised in the design and construction temperature) range from 20° to 150°F (-7° to 65°C)
of the engine compartment. Hatch openings must be without failure. Crusader EFI and associated
located so that any rain water, which may leak through components meet this standard.
the seams, is directed away from the engine. If water
enters the flame arrestor, it can enter the engine and Because electronic fuel injection systems require
cause serious damage to internal engine parts. higher fuel delivery pressures and higher volumes, fuel
temperatures become an issue. Engine compartment
IMPORTANT: Crusader Engines will not honor any temperatures have been measured in excess of 200°F
warranty claim for engine damage as a result of (82°C). High fuel temperatures may lead to excessive
water entry. vapor in the fuel line, particularly when gasoline
Over the past several years, engine compartments have containing alcohol and the newer “reformulated” blends
been made smaller and insulated to be quieter. This are used. A maximum fuel temperature at the fuel
trend, while resulting in quieter boats, has resulted in pump inlet of 105°F (40°C) and an ambient engine room
higher engine compartment temperatures. It is important temperature of 150°F (65°C) must be adhered to.
that attention be given to the air temperatures inside To test for ambient air and fuel inlet temperature
the engine compartment while running and for a period compliance, proceed as follows:
of time after the engine is shut off. This period of time
after shutting off the engines is critical as temperatures The boat being tested should be a standard production
normally rise (heat soak) and can lead to fuel vapor lock boat. The temperature meter used must be of a type
causing the engine startability problems. which can be read with the engine compartment closed.
The engine compartment is to remain closed and no air
Engine compartment must be designed to provide a is to be forced into the engine compartment during the
sufficient volume of air for engine breathing, and must test. The bilge blower should not be running.
vent off any fumes in engine compartment. It should
also be designed to allow heated air to escape and A. Install thermal couples 1 in. (25 mm) above each
maintain low temperatures during engine operation. flame arrestor for air temperature measurement.
Cool air should enter the engine compartment as low as B. Tee another thermal couple into the fuel line(s)
possible and heated air should be vented from as high a at the fuel pump inlet for measuring fuel
point as possible. temperature.
IMPORTANT: The size of ventilation opening must C. Operate the engine(s) until engine and bilge
be increased if any auxiliary equipment, such as temperatures are stabilized. This usually
generators, is located in the engine compartment. occurs when operating the engine under cruise
ENGINE AIR REQUIREMENTS conditions for a minimum of one hour.
AT WIDE-OPEN-THROTTLE D. Shut engine(s) off and monitor temperatures
for an additional hour. Air temperature should
Model Volume
not exceed 150°F (65°C) and fuel temperature
MP 5.0L 670 ft3/min (0.320 m3/sec) should not exceed 105°F (40°C) at any time,
MP 5.7L 670 ft3/min (0.320 m3/sec) either during engine operation or engine off (hot
soak).
MP 6.0L 670 ft3/min (0.320 m3/sec)
E. After the one hour hot soak test, start the
MP 8.1L STD 697 ft3/min (0.329 m3/sec) engine and let it idle (in neutral) for 20 minutes.
MP 8.1L HO 697 ft3/min (0.329 m3/sec) Continue to record temperatures for another 20
minutes.
If temperature limits are exceeded at any time during
this test, it is necessary to reevaluate the fuel system
and/or bilge ventilation and take appropriate measures
to maintain temperatures at or below the specified limits
at all times.

L510023-07
26
FUEL SUPPLY AND RETURN 2. Dual installations; it is best to use a fuel pickup
CONNECTIONS and supply line for each engine. If a single
pickup and line is used, fittings and line must
USCG & ABYC Standards not be smaller than 1/2 in. (13 mm) I.D.
United States Coast Guard regulations (33 CFR Section 3. Fuel tanks must have at least 1/2 in. (13 mm)
183, subpart J & K) must be adhered to in any fuel and shut-off valves and fittings on the fuel supply line
ventilation system installation. In addition, we strongly and 3/8 in. (10 mm) shut-off valves and fittings
suggest that ABYC’s recommendations regarding fuel on the fuel return line.
systems and engine room ventilation be followed.
4. There must be free flow into the top of the tank
for the return fuel line. There must not be a “dip
CAUTION tube” extending into the tank.
5. On installations requiring long lines or numerous
Using Loctite Pipe Sealant with Teflon, lightly coat all fittings, larger size lines (than previously
threads of the fuel fittings used at the tank, fuel filter, specified) should be used.
fuel pumps, etc. DO NOT use Teflon tape.
6. Fuel line should be installed free of stress,
A flexible fuel line must be used to connect fuel line and firmly secured to prevent vibration and/or
to and from the engine to absorb deflection when the chafing.
engine is running. The accompanying drawing illustrates 7. Sharp bends in fuel lines should be avoided.
the typical location on the engine for connection of fuel
8. A flexible fuel line must be used to connect fuel
supply and return lines. Remove shipping plugs and
line to the engine fuel pump to absorb deflection
connect fuel lines to the locations shown.
when engine is running.
1. Fuel pickup should be at least 1 in. (25 mm) from
9. Route all fuel lines as low in the bilge as
the bottom of the fuel tank to prevent picking up
possible to take advantage of the cooler ambient
impurities.
temperatures found there.

FUEL TANK FILL

FUEL TANK
VENT ANTI-SIPHON
VALVE OR SOLENOID
FUEL FEED LINE
FUEL TANK
PICK UP FUEL RETURN
LINE
WATER
SEPARATING
FUEL FILTER

FUEL
CONTROL
CELL

"NOT" ACCEPTABLE ACCEPTABLE

LOW-PRESSURE
FUEL PUMP

RETURN FUEL LINE TO FUEL TANK CONNECTION

Figure 21 Engine and Fuel Line Installation

L510023-07
27
FUEL INLET RESTRICTION Recommended minimum size fuel line:
The maximum allowable inlet restriction at the electric • 1/2” (13 mm) I.D. supply side
fuel pump inlet is 2 in. Hg (6.75 kPa) at 40 GPH (151 • 3/8” (10 mm) I.D. return side. (If required.)
LPH) flow (typical idle flow rate). To test this, tee a
digital vacuum gauge into the fuel supply line at the Fuel lines should be secured per ABYC
inlet to the low pressure fuel pump and read the gauge recommendations. In addition, the following steps
at engine idle. If fuel inlet restriction exceeds the should be followed to minimize fuel temperature:
maximum, the following is recommended: A. Route all fuel lines as low in the bilge as
A. Use supply side fuel lines including valves possible to take advantage of the cooler ambient
and fittings with at least 1/2 in. (13 mm) I.D. temperatures found there.

B. DO NOT install any additional fuel filters B. Keep the use of brass fuel elbows and fittings
between the fuel tank and the fuel pump inlet. to an absolute minimum. Brass is a good
conductor of heat. Tests have shown that fuel
C. Avoid using crossover valves unless may begin to vaporize when passing through
absolutely necessary. a 90 degree brass elbow at only 85°F (29°C)
D. If an anti-siphon valve(s) is required, it is ambient temperature.
recommended to use an electric solenoid C. Maintain adequate engine compartment
shut-off valve. ventilation.
IMPORTANT: The electric fuel pump on the engine
TEE FITTING has been designed to function with a fuel/water
separator, with 10 micron filter capability and a
minimum of 90 gallons per hour flow rate, between
the pump and fuel source. Crusader DOES NOT
recommend the use of any additional filters installed
by the OEM or boat dealer. The use of additional
filters which do not meet the requirements stated
above, can cause one or more of the following:
FUEL INLET • Fuel Vapor Locking
in
Hg
• Difficult Warm-Starting
ON
OFF
Z ERO
STOR
E
• Poor Drivability
HOLD
MEM
ORY
UNITS

• Piston Detonation Due to Lean Fuel Mixture

LOC

DIG
ITA
L-
MA
NO
ME
TER

FUEL SYSTEM PRESSURE CHECK

VACUUM GAUGE Connect a fuel pressure tester to the test valve on the
Figure 22 Checking Fuel Inlet Restriction fuel rail. Start and run the engine at idle and note the
fuel pressure reading. Verify reading meets or exceeds
FUEL LINES minimum pressure (if shown) listed in the following chart.
IMPORTANT: Current or proposed legislation may
require the use of low permeation fuel lines when Minimum WOT
re-powering. This type fuel line will be marked with Engine Pressure Pressure
the ‘Type A1-15’ designation. Check your local and MP 5.0L Master Specs. Master Specs.
state regulations regarding the required use of this
MP 5.7L Master Specs. Master Specs.
type of fuel line.
MP 6.0L Master Specs. Master Specs.
IMPORTANT: Return fuel must flow back to the tank
from which it was drawn to prevent over-filling and MP 8.1L STD Master Specs. Master Specs.
fuel spills through the vent system. MP 8.1L HO Master Specs. Master Specs.
IMPORTANT: Prior to engine installation, fuel lines Carb. 5.7L Master Specs. Master Specs.
should be inspected for compatibility with ethanol
blended fuel. IMPORTANT: Fuel pressure MUST be taken at wide-
open-throttle conditions in order to ensure that the
Replacement fuel line should be USCG Approved,
correct fuel pressure is present at all times.
Marine Grade fuel line for use with ethanol blended
fuels. See MASTER SPECIFICATIONS at the end of this
manual for specifications not shown on the chart.

L510023-07
28
GASOLINE REQUIREMENTS GASOLINE CONTAINING ALCOHOL
The implementation of ethanol-based fuel is spreading
CAUTION
rapidly throughout the United States. As such, Crusader
Fire and Explosion Hazard - Gasoline is extremely Engines provides the following information regarding the
flammable and highly explosive, and , if ignited, use of this fuel.
can cause serious bodily injury or death. Careful This information addresses the use of ethanol fuels in
inspection of the entire fuel system including, but CRUSADER ENGINES ONLY. It does not address the
not limited to, fuel tanks, fuel lines, fuel filters and use of ethanol fuels in vessel related components such
all fittings is mandatory, especially after periods as boat gas tanks, boat fuel lines, etc.
of storage. Replace any component that shows
Ethanol blended fuel rated E10 or less is acceptable
signs of leakage, corrosion, deterioration, swelling,
to use. Fuels rated higher than E10 SHOULD NOT
hardening or softening.
BE USED. Ethanol fuels rated higher than E10 could
WARRANTY NOTICE: Damage caused to the engine potentially damage the engine and/or present an
through the use of improper gasoline, low-quality or unsafe boating condition. Damage to the engine
gasoline with an octane rating below the minimum resulting from the use of ethanol fuel rated higher
requirements listed below, is considered misuse of the than E10 IS NOT covered by the warranty.
engine. Such damage is not covered by the Crusader
Marine Engines warranty. CAUTION
The ignition timing set by the factory requires the use
Do Not use any gasoline that contains
of a high-quality lead-free regular gasoline with the
METHANOL. This fuel is very corrosive and will
following octane specification.
create unsafe operating conditions. Serious
Pump Octane Number (R+M/2) (PUMP) - 87 damage will result from the continued use of fuel
containing METHANOL. Any resulting engine
damage will not be covered by the warranty.
ED
AD If ethanol blended fuel rated E10 or less is used, or
U NLE $ D if the presence of alcohol is uncertain, more frequent
DE
LEA R
UN GULA
RE inspections and service of the complete fuel system are
87 MINIMUM OCTANE RATING
required. Any sign of fuel leakage or deterioration must
R + M/2 METHOD be repaired immediately before further engine operation.
It is important to note that ethanol blended fuel will act

E10 87 as a solvent and will attract and hold moisture. Without

proper fuel stabilization and fuel filtration, ethanol
blended fuel may cause the following:
• Excessive moisture (water) may cause lean
operation to include hard starting and operating
difficulties such as, vapor lock, low speed

E10 •
stalling, and shortened fuel shelf life.
Acting as a solvent, ethanol blended fuel may
cause gum, sediment, sludge, and other particles
to be loosened and carried through the fuel
Figure 23 Fuel Requirements system to the engine.
NOTICE: Most Crusader Fuel Injected engines are Fuel system or engine damage caused by
calibrated to operate on 87 octane fuel and maximum contamination from water, foreign particles, sludge,
performance is obtained when using this fuel. Some or gums entering or forming in the fuel system is not
applications may require a higher octane fuel. These covered by the Crusader Limited Warranty.
particular applications will be noted.
FUEL STABILIZER RECOMMENDATIONS
If a slight pinging is heard during acceleration and the
proper octane fuel is being used, it is considered normal.
FOR ETHANOL BLEND FUEL
If a constant, heavy knock occurs, the engine should The use of a commercially available fuel stabilizer, such
be evaluated by a Crusader Marine Engines service as STA-BIL®, is recommended when storing ethanol-
technician. blended fuel for more than 2 weeks.

L510023-07
29
FUEL FILTER RECOMMENDATIONS FOR Upon initial installation or service of the fuel/water
ETHANOL BLEND FUEL separator, the filter element should be pre-filled with
fresh fuel prior to mounting the element to the head.
Because ethanol will act as a solvent and will attract Pre-filling the filter element, with fresh fuel, will reduce
and hold moisture, Crusader Engines has removed the the time required to prime/re-prime the fuel system after
Primary Fuel Filter or Fuel Pre-Filter and in its place a a service interval.
fitting will be provided for connection to a spin-on type
fuel/water separator. Refer to the diagram below for height, width, depth,
and the minimum under bowl clearance for service
A spin-on type fuel/water separator filter, of 10 micron dimensions for the RA080033 fuel/water separator.
filtering capability with a minimum rating of 90 gallons
per hour is required between the low pressure fuel pump RA080033 - Fuel / Water Separator Assembly
and the fuel source. Crusader Engines recommends the R080033 - Fuel / Water Separator Replacement
use of Crusader part number RA080033. This is a 3- Element
piece, RACOR, fuel/water separator. This unit allows for
RK080033 - Fuel / Water Separator Kit, Includes
the easy draining of water and contaminate inspection
RA080033 Assembly plus 1/2” hose barb
between service intervals, without the need to replace
fittings for Low Pressure Fuel Pump and
the filter element during an inspection.
Separator Assembly.
Crusader Engines recommends that the fuel/water
separator be mounted as low as possible, relative to the
fuel source, away from heat, such as exhaust runs, and
in an easily accessed and serviceable area.

FUEL NOTE: Not all fuel systems use a return to tank fuel line.
SUPPLY Do not install a return to tank fuel line if your fuel system
LINE was not originally equipped with one.

FUEL
RETURN
LINE
5.0/5.7L
ONLY

TO
FUEL
TANK

FROM
FUEL
TANK
RA080033
FUEL
CONTROL
CELL
LOW-PRESSURE
FUEL PUMP Height: 11.0 inches
Width: 4.2 inches
Depth: 4.5 inches

Under Bowl Clearance:

1.0 inch Minimum

Figure 24 Fuel / Water Separator Installation

L510023-07
30
EXHAUST SYSTEM 3. Engine Operation - You should never start
the engine just for the sake of warming it
IMPORTANT: It is the responsibility of the boat
when not being used. This does not get the
manufacturer, or the installing dealer, to properly
manifolds up to temperatures needed to burn off
locate the engine and install the exhaust system.
condensation. This will get worse with colder
Improper installation may allow water to enter the
inlet water temperatures.
exhaust manifolds and combustion chambers, and
severely damage the engine.
Damage caused by water entering the engine through EXHAUST RISERS
the exhaust system WILL NOT be covered by Crusader
To determine if exhaust risers are required, make the
Engines Warranty, unless the damage is the result of
following measurements. With the boat in the water and
defective part(s).
maximum load onboard, make measurements “A” and
When designing and installing the exhaust system, it “B” (Figure 22). Subtract measurement “B” from “A.” If
is very important that the following points be taken into the difference between the two measurements is less
consideration. than specified on the drawing and chart below, it will be
1. A water lift muffler, or collector, mounted necessary to add exhaust risers as required to correctly
close to the exhaust outlets - These position the exhaust elbow.
components hold hot water. Once the engine
is shut off, this sets up a “sauna” effect. “A” minus “B” must be this
Condensation will form and enter the exhaust Engine Models distance or more
manifolds and run into the cylinders in some
cases. Always try to install these components All Engines 12 in. (304.80 mm)
as far away from the exhaust outlets as possible.
2. Not enough drop in the exhaust hose - The
most aggressive drop between the exhaust
outlet and the muffler, or collector, will aid in
preventing condensation from forming and
working its way back into the exhaust manifold(s)
and elbow(s).

A -- FROM WATERLINE TO REFERENCE POINT

B -- FROM HIGHEST POINT ON EXHAUST ELBOW TO SAME REFERENCE POINT

Figure 25 Proper Exhaust Elbow Location

L510023-07
31
Exhaust Systems without Water-Lift Mufflers 4. Exhaust outlet(s) should be slightly above the
water line with the boat at rest in the water, and
a full load onboard. Exhaust outlet(s) must be
WARNING equipped with an internal shutter and/or exhaust
flapper to prevent seawater from running back
Boating industry standards (BIA, ABYC, etc.), Federal into the exhaust system.
standards, and Coast Guard regulations must be
adhered to when designing and installing exhaust
systems.

1. System layout and construction must prevent

cooling system discharge water from flowing
back into the engine, and also must prevent
seawater from entering the engine via the
exhaust system.
2. The exhaust hoses and pipes must not be higher
than the exhaust elbow outlets at any point. HOT SPOT
3. The exhaust system (for routing exhaust to
outside of boat) must be located so that a
minimum of 1 in. per foot (83.31 mm per meter)
downward pitch exists in the exhaust hose or
pipe from the engine exhaust elbow to the outlet,
with a minimum drop of 4 in. (100 mm) overall
(this is an ABYC recommendation). The drop
must be constant so that a low spot does not
exist at any point in the exhaust hose or pipe.
INCORRECT CORRECT

Figure 26 Exhaust Hose Connections

Figure 27 Typical Inline Muffler Exhaust Layout

L510023-07
32
 5. System must not cause excessive back 6. Exhaust hoses must be connected to the engine
pressure. Back pressure MUST NOT exceed 4 exhaust elbows so that they do not restrict the
in. (10.16 cm) of mercury when measured with flow of discharge water from the elbow.
a mercury manometer at the exhaust elbow If hoses are connected incorrectly, a hot spot in the hose
outlets. Minimum exhaust hose sizes are given can occur, and eventually burn through.
in the chart below.

MINIMUM EXHAUST HOSE SIZE

Engine Single Dual
MP 5.0L 4 in. (102 mm) 3 in. (76 mm)
MP 5.7L 4 in. (102 mm) 4 in. (102 mm)
MP 6.0L 4 in. (102 mm) 4 in. (102 mm)
MP 8.1L STD 4 in. (102 mm) 4 in. (102 mm)
MP 8.1L HO 4 in. (102 mm) 4 in. (102 mm)
Carb. 5.7L 4 in. (102 mm) 4 in. (102 mm)

L510023-07
33
 Figure 28 Typical Water-Lift Muffler Exhaust Layout

Exhaust Systems with Water-Lift Mufflers flapper to prevent seawater from running back
into the exhaust system.
5. System must not cause excessive back
WARNING
pressure. Back pressure MUST NOT exceed 4
in. (10.16 cm) of mercury when measured with
Boating industry standards (BIA, ABYC, etc.), Federal
a mercury manometer at the exhaust elbow
standards, and Coast Guard regulations must be
outlets. Minimum exhaust hose sizes are given
adhered to when designing and installing exhaust
in the chart on page 26.
systems.
6. Exhaust hoses must be connected to the engine
exhaust elbows so that they do not restrict the
1. System layout and construction must prevent flow of discharge water from the elbow.
cooling system discharge water from flowing
back into the engine, and also must prevent NOTICE: There have been instances where the use
seawater from entering the engine via the of water-lift mufflers, installed close to the engine, have
exhaust system. caused water to be drawn back into the engine under
certain operating conditions. Crusader has in-line
2. The exhaust hoses and pipes must not be higher damper valve assemblies available to help prevent water
than the exhaust elbow outlets at any point. ingestion problems.
3. The exhaust system (for routing exhaust to
outside of boat) must be located so that a
In-Line Exhaust Damper Valve Kit P/N RK012023
minimum of 1 in. per foot (83.31 mm per meter)
downward pitch exists in the exhaust hose LH Damper Tee Assembly
or pipe from the engine exhaust elbow to the (4X4X5 in.) P/N 22920
muffler inlet, and from the muffler outlet to the RH Damper Tee Assembly
exhaust outlet, with a minimum drop of 4 in. (100 (4X4X5 in.) P/N 22921
mm) overall (this is an ABYC recommendation).
The drop must be constant so that a low spot
does not exist at any point in the exhaust hose If you have questions regarding the use of water-lift
or pipe. mufflers, contact Crusader Engines for clarification.
4. Exhaust outlet(s) should be slightly above the
water line with the boat at rest in the water, and
a full load onboard. Exhaust outlet(s) must be
equipped with an internal shutter and/or exhaust

L510023-07
34
THROTTLE/SHIFT REMOTE CONTROL AND
CABLES
1.25 in (3.17 cm)
Shift control and shift cable MUST position transmission INLET HOSE
shift lever EXACTLY as stated in this manual or CONNECTION
transmission failure may occur. Damage caused
to transmission as a result of improper shift lever
positioning WILL NOT be covered by transmission
manufacturer’s warranty. SEACOCK
IMPORTANT: To ensure proper shift and throttle
operation, control must provide a shift cable travel
of 2-3/4 in. (6.99 cm).

NEUTRAL

REVERSE
GEAR WATER PICKUP

BOAT MOVEMENT WATER FLOW

IN FORWARD GEAR
FORWARD
GEAR
Figure 30 Water Pickup and Seacock

SEACOCK SIZE RECOMMENDATION

Seacock used must have an internal cross-sectional
area equal to, or greater than, the hose to prevent
restricting water flow. Install the valve in an area where
it will be easily accessible and supported adequately to
Figure 29 Shift Control prevent hose fatigue. A minimum 1-1/4 in. (3.17 cm)
brass ball or gate valve is recommended.
SEAWATER PICKUP CONNECTION
SEA STRAINER RECOMMENDATION
Seawater Pickup and Hose
Strainer used must be of sufficient size to ensure that an
Water pickup must be large enough to permit sufficient
adequate supply of water will be maintained for cooling
water flow to the engine seawater pickup pump for
the engine. A minimum of 30 gallons per minute (114
adequate engine cooling [30 gallons per minute (114
liters per minute) flow rate is required.
liters per minute) minimum]. Pickup must supply a
positive head while underway. Water pickup should CRANKCASE OIL DIPSTICK RELOCATION
be located as close to the seawater pickup pump inlet
All Transmissions Except Hurth and Velvet
as possible and in an area where an uninterrupted,
solid stream of water will flow past, when the boat is Drive 5000 Series
underway. Engine crankcase oil dipstick and tube can be located
Connect the water pickup to the seawater pickup pump on either the starboard or port side of the engine to suit
inlet with 1-1/4 in. (3.17 cm) I.D. wire reinforced hose installation requirements. To move the dipstick and tube
of adequate wall thickness to prevent it from collapsing to the opposite side of the engine, if necessary, do the
from the pump suction. Be sure to secure the hose following:
connections with hose clamps. 1. Lift the engine with a suitable sling and loosen
IMPORTANT: DO NOT install the water pickup the dipstick fitting on the oil pan. Drain the oil
directly in line with the propeller, as the pickup into a clean, approved container for reuse.
may create turbulence and allow air to flow
into the “propeller slipstream.” This will cause
propeller ventilation and will adversely affect boat
performance.

L510023-07
35
 2. Remove the bolt retaining the dipstick mounting PRELIMINARY ENGINE ALIGNMENT
clamp. Then, remove the dipstick fitting at the (Mount Adjustment Tool - P/N 22165)
oil pan. Loosen the center bolt and rotate the oil
pan fitting. 1. Remove the lag screws holding the engine to
the shipping pallet. Attach a suitable sling to the
3. Put sealer on the dipstick fitting threads and lifting eyes on the engine. Lift the engine from
reinstall into the oil pan fitting. Mount and attach the pallet with an overhead hoist.
the dipstick in the same manner as it was
removed from the other side. 2. Check the tightness of the engine mounts and
re-torque the mount attaching bolts to 45-50 lb-ft
4. Fill the engine with oil. (61-68 N.m), if necessary.
IMPORTANT: Engine mounts must be adjusted
as explained in Steps 3 and 4 to center mount
adjustment and establish a uniform height on all
DIPSTICK mounts.
TUBE
3. Check all four (4) engine mounts to ensure that
the distance from the bottom of the mount to
CLAMP the bottom of the trunnion is as shown. If not,
turn the nylon adjusting sleeve in the direction
required to obtain the proper dimension.
4. Loosen the trunnion clamping bolt and nut on
all four (4) engine mount brackets to ensure the
following:
a. Large diameter of the mount trunnion is
OIL PAN extended as shown.
FITTING b. Each mount base is downward. Tighten the
trunnion clamping bolts and nuts slightly to
prevent moving in or out. Mounts must be
Figure 31 Oil Pan and Dipstick Fittings free to pivot when installing the engine.

Engines Equipped with Hurth and Velvet Drive

0.5 in.
5000 Series Transmissions (12.5 mm)
Engine crankcase oil dipstick can be located either port
or starboard side of the engine, depending on installation
requirements. To move the dipstick, reverse the dipstick LAG
and rubber caps on the dipstick tubes. BOLT

ENGINE INSTALLATION
NOTICE TO INSTALLER BEFORE STARTING
INSTALLATION: Read “General Information” and
“Installation Requirements” completely.
3/8 in.
TORQUE SPECIFICATIONS (9.5 mm)

NOTICE: Tighten ALL fasteners (not listed) securely.

Engine Mount Attaching Bolts 45 lb-ft (61 N.m)

TRUNNION
Fuel Line Inlet Fitting Securely BOLT
Trunnion Clamping Bolt and Nut 45 lb-ft (61 N.m)
Propeller Shaft Coupling Bolt and
Nut 50 lb-ft (68 N.m) Figure 32 Preliminary Engine Mount Extension

Exhaust Manifold Bolt 20 lb-ft (27 N.m)

L510023-07
36
Velvet Drive and Hurth 8 Degree Down Angle All Transmissions
Transmissions IMPORTANT: The engine bed must position the
5. Lift the engine into the boat and position it on engine so that a minimum of 1/4 in. (6 mm) up-and-
the engine bed so that the transmission and down adjustment still exists on all four (4) mounts
propeller shaft couplings are visibly aligned (no after performing final adjustment. This is necessary
gap can be seen between the coupling faces to allow for realigning the engine in the future.
when butted together). Adjust the engine bed 6. Check all four (4) mounts to ensure that they are
height, if necessary, to obtain proper alignment. still positioned properly, then fasten the mounts
DO NOT use mount adjustments to adjust to the engine bed with 1/2 in. (1.27 cm) diameter
engine position at this time. lag bolts (of sufficient length). Tighten the lag
bolts securely.
7. Disconnect the overhead hoist and remove the
sling.

FINAL ENGINE ALIGNMENT

IMPORTANT: Engine alignment MUST BE
RECHECKED with the boat in the water, fuel tanks
filled, and with normal load onboard.
OFFSET ANGULAR You MUST allow 24 hours from the time the boat is
MISALIGNMENT MISALIGNMENT launched until the final engine alignment is checked.
This allows the boat hull to settle into the position
that the engines will run in.
Engine must be aligned so that the transmission and
propeller shaft coupling center lines are aligned and
coupling faces are parallel within 0.003 in. (0.07 mm).
This applies to installations with solid couplings, as
PERFECT ALIGNMENT well as flexible couplings.
COUPLING FACES ARE PARALLEL 1. Check the mating faces on the transmission and
WITH DISTANCE BETWEEN FACES propeller shaft couplings to make sure they are
EXACTLY THE SAME AT ALL POINTS clean and flat.

Figure 33 Coupling Flange Alignment

Velvet Drive and Hurth V-Drive Transmissions

5. Lift the engine into the boat and position it
on the engine bed so that the propeller shaft
protrudes thru the transmission output flange
coupling. Install the propeller shaft coupling and
then position the engine so that the couplings are
visibly aligned (no gap can be seen between the
coupling faces when butted together). Adjust the
engine bed height, if necessary, to obtain proper
alignment. DO NOT use mount adjustments to
adjust engine position at this time.

Figure 34 Shaft Mating Surface Check - 8 Degree Down

Angle

L510023-07
37
 Figure 35 Shaft Mating Surface Check - V-Drives Figure 37 Centering Propeller Shaft - V-Drives

2. Center the propeller shaft in the shaft log as 3. Check that the coupling center lines align by
follows: butting the propeller shaft coupling against the
transmission coupling. The shoulder on the
A. Push down and then lift the propeller shaft as
propeller shaft coupling face should engage
far as it will move, then place the shaft in the
recessed on the transmission coupling face, with
middle of the movement.
no resistance.
B. Move the shaft to the port and then to the
NOTICE: Some propeller shaft couplings may not have a
starboard as far as the shaft will move,
shoulder on the mating surface. On these installations,
then place the shaft in the middle of the
use a straight edge to check the centerline alignment.
movement.
4. Check for any angular misalignment. Hold
C. With the propeller shaft in the middle of the
coupling faces tightly together and check for a
shaft log, align the engine to the shaft.
gap between the coupling faces, with a 0.003 in.
(0.07 mm) feeler gauge, at 90-degree intervals.

Figure 36 Centering Propeller Shaft - 8 Degree Down

Angle Figure 38 Angular Alignment - 8 Degree Down Angle

L510023-07
38
 B. LEFT or RIGHT ADJUSTMENT: Loosen the
trunnion clamping bolt and the nut on all
four mounting brackets. Move the engine to
the left or right, as necessary, to obtain the
proper alignment.
IMPORTANT: The large diameter of the mount
trunnion MUST NOT extend over 1.0 in. (25.4 mm)
from the mounting brackets on any of the mounts.

1.0 in. MAX

(25 mm)

LAG
BOLT

Figure 39 Angular Alignment - V-Drives

5. If the coupling center lines are not aligned, or if

the coupling faces are more than 0.003 in. (0.07
mm) out of parallel, adjust the engine mounts as
follows:
A. UP or DOWN ADJUSTMENT: Loosen the
lag bolt 1/4 turn. Use the mount adjusting
tool or a 3/8 in. (0.95 cm) or 1/2 (1.27 TRUNNION
cm) diameter rod through both sides of the BOLT
adjusting sleeve to turn. Turn the adjusting
Figure 41 Engine Extension
sleeve in the direction required to raise or
lower the engine. After the adjustment is
6. After the engine has been properly aligned,
complete, tighten the lag bolt.
secure the engine mounts.
7. Connect the propeller shaft coupling to the
transmission coupling. Tighten the coupling
attaching bolts and nuts to the correct
specifications.
ROD
THROTTLE/SHIFT CABLES
Lubricate the cable ends, then attach to the engine and
transmission.
LOWER Attaching/Adjusting Throttle Cable
ENGINE
RAISE Your new engine is equipped with an electronic sensor,
ENGINE the Throttle Control Position sensor, which is used
to command the throttle plate to the desired throttle
position. The TCP sensor is a spring loaded device,
when the throttle cable is disconnected the TCP will
return to its Idle or zero position at rest on the TCP
bracket idle stop. There are two critical positions that
Figure 40 Engine Mount Adjustment
need to be checked when ensuring proper throttle cable
adjustment.
IMPORTANT: Both the front mount (or rear mount)
adjusting sleeves must be turned equally to keep the 1. Place the remote control throttle lever in the idle
engine level from side to side. position.

L510023-07
39
 2. Install the throttle cable hub into the throttle Attaching/Adjusting Shift Cable - Velvet Drive
cable retaining clip and secure with the cable In-Line and V-Drive Models
clip.
IMPORTANT: Velvet Drive Transmission Warranty
3. Thread the ball joint clevis onto the throttle cable is jeopardized if the shift lever poppet ball or
as far as necessary to line up the ball joint stud spring is permanently removed, if the shift lever
mounted on the TCP throttle arm. The TCP is repositioned or changed in any manner or if
arm should be on the idle stop by its own return the linkage between the remote control and the
spring pressure with no additional pressure transmission shift lever does not have sufficient
supplied by the throttle cable. Tighten the clevis travel in both directions.
jam nut when positioned correctly.
1. Place the remote control shift lever and
transmission shift lever in neutral position.
2. Install the shift cable hub onto the shift cable
retaining bracket and lock the cable clip.
3. Thread the clevis pin onto the shift cable until
the clevis lines up with the stud attached on the
transmission shift lever.
Pivot and Clip should be
centered so no tension is
placed on the bracket. 4. Retract the spring lock on the clevis pin and
attach the shift cable to the ball joint stud.
5. Place the remote control lever in the forward
gear position and check the transmission shift
lever position. Lever must be positioned as
shown for full engagement.

F N R
4. Retract the spring lock on the clevis pin and
attach the throttle cable to the ball joint stud.
5. Place the remote control throttle lever in the full POPPET
throttle position. The TCP arm should be near BALL
or just touch the WOT stop of the TCP bracket.
IMPORTANT: It is not necessary for the arm to
touch the bracket stop to achieve 100% throttle.
Check the throttle cable and TCP linkage for any TOWARD
binding. Return the throttle lever to the neutral FLYWHEEL
or idle position. FOR
FORWARD
BALL JOINT

CABLE
CLIP
Figure 43 Shift Lever Positions - Standard Velvet Drive
6. Place the remote control lever in the reverse
gear position and check transmission shift lever
position. The lever must be positioned as shown
for full engagement.
7. If the transmission shift lever is positioned
properly in one gear but no the other, recheck
the shift cable adjustment. If the transmission
shift lever is not properly positioned in either
LUBRICATION gear, readjust the shift cable and recheck for
POINTS correct shift engagement. If correct positioning
is still not achieved, the remote control does
Figure 42 Typical Throttle Cable Installation not provide sufficient shift travel and must be
replaced.

L510023-07
40
 8. Shift remote control lever from forward to
reverse and make sure cable moves freely and
no binding occurs.
LH FORWARD
GEAR
FORWARD
GEAR RH

PROP SHAFT
ROTATION
DECAL
RH PROP SHAFT ROTATION
LH PROP SHAFT ROTATION

VELVET DRIVE 5000

TRANSMISSIONS
IDENTIFICATION
TAG

Figure 44 Forward Gear Prop Shaft Rotation - Standard Figure 46 Velvet Drive 5000 Shift Lever Movement vs.
Velvet Drive Output Flange Rotation

CABLE CLIP

BALL JOINT
BALL JOINT

CABLE CLIP

Figure 45 Typical Shift Cable Installation

Attaching/Adjusting Shift Cable - Velvet Drive
5000 Series Transmissions Figure 47 Shift Cable Installation - Velvet Drive 5000
These model transmissions are full reversing
transmissions. Rotation of the output flange and 1. Place the remote control shift lever and
propeller shaft is determined by the hookup of the shift transmission shift lever in neutral position.
cable at the remote control before starting the installation
2. Install the shift cable hub into the shift cable
and adjustment procedures.
retaining bracket and lock the cable clip.
For left-hand (LH) shaft rotation - the transmission shift
3. Thread the clevis pin onto the shift cable until
lever must move TOWARD the engine (flywheel) when
the clevis lines up with the stud attached to the
the remote control shift handle is placed in the forward
transmission shift lever.
position.
4. Retract the spring lock on the clevis pin and
For right-hand (RH) shaft rotation - the transmission shift
attach the shift cable to the ball joint stud.
lever must move AWAY from the engine (flywheel) when
the remote control shift handle is placed in the forward
position.

L510023-07
41
 5. Place the remote control shift lever in the forward Attaching/Adjusting Shift Cable - Hurth 630
gear position and check the transmission shift Series Transmissions
lever position. Lever must be positioned as
These model transmissions are full reversing
shown for full engagement.
transmissions. Rotation of the output flange and
6. Place the remote control shift lever in the reverse propeller shaft is determined by the hookup of the shift
gear position and check the transmission shift cable at the remote control before starting the installation
lever position. Lever must be positioned as and adjustment procedures.
shown for full engagement.
For left-hand (LH) shaft rotation - the transmission shift
7. If the transmission shift lever is positioned lever must move AWAY the engine (flywheel) when
properly in one gear, but not the other, recheck the remote control shift handle is placed in the forward
the shift cable adjustment. Readjust the shift position.
cable and recheck for correct shift engagement.
For right-hand (RH) shaft rotation - the transmission shift
NOTICE: If correct positioning is still not achieved, the lever must move TOWARD from the engine (flywheel)
remote control does not provide sufficient shift travel and when the remote control shift handle is placed in the
must be replaced. forward position.
8. Shift the remote control lever from forward to
reverse and make sure cable moves freely and
no binding occurs.
RH FORWARD
GEAR
FORWARD
GEAR LH

LH PROP SHAFT ROTATION

RH PROP SHAFT ROTATION

HURTH
TRANSMISSIONS

IDENTIFICATION Figure 50 Hurth Shift Lever Movement vs. Output

LABEL Flange Rotation
Figure 48 Forward Gear - LH Prop Shaft Rotation -
Velvet Drive 5000 CABLE CLIP
BALL
JOINT

IDENTIFICATION
LABEL
Figure 49 Forward Gear - RH Prop Shaft Rotation -
Velvet Drive 5000 Figure 51 Shift Cable Installation - Hurth

L510023-07
42
 1. Place the remote control shift lever and
transmission shift lever in neutral position.
2. Install the shift cable hub into the shift cable
retaining bracket and lock the cable clip.
3. Thread the clevis pin onto the shift cable until
the clevis lines up with the stud attached to the
transmission shift lever.
4. Retract the spring lock on the clevis pin and
attach the shift cable to the ball joint stud.
5. Place the remote control shift lever in the forward
gear position and check the transmission shift
lever position. Lever must be positioned as
shown for full engagement.
6. Place the remote control shift lever in the reverse
gear position and check the transmission shift
lever position. Lever must be positioned as
shown for full engagement.
7. If the transmission shift lever is positioned
Figure 53 Forward Gear - RH Prop Shaft Rotation
properly in one gear, but not the other, recheck
- Hurth
the shift cable adjustment. Readjust the shift
cable and recheck for correct shift engagement.
NOTICE: If correct positioning is still not achieved, the AUDIO ALARM SYSTEM
remote control does not provide sufficient shift travel and
must be replaced.
WARNING
8. Shift the remote control lever from forward to
reverse and make sure cable moves freely and
The buzzer is not external-ignition protected.
no binding occurs.
Therefore, DO NOT mount buzzer in the engine or
fuel compartments.

1. Select a location for the audio warning buzzer

which meets all of the following requirements:
a. A location where the buzzer can be easily
heard, yet is out of sight
b. A location which is easily accessible for
installation and maintenance.
c. A location where the buzzer will not get wet.
2. Mount the buzzer in desired location.
3. Attach the buzzer to any 12-volt source on
switched side of the ignition switch. TERMINAL
TO WHICH WIRE IS ATTACHED MUST
HAVE NO VOLTAGE WHEN THE IGNITION
SWITCH IS IN THE “OFF” POSITION. Tighten
the connection securely, and coat with liquid
neoprene.
4. Connect tan/blue wire in the instrumentation
Figure 52 Forward Gear - LH Prop Shaft Rotation wiring harness to the buzzer.
- Hurth

L510023-07
43
EXHAUST SYSTEM CONNECTION CLASSIC 5.7L CARBURETOR -
1. Exhaust hoses must be connected to the ENGINE HARNESS CONNECTION
exhaust elbows so that they do not restrict the Install the main engine electrical harness plug and clamp
flow of discharge water from the elbow. If the as shown. Tighten the clamp securely.
hoses are connected incorrectly, a hot spot in
the hose can occur, and can eventually burn
through.
2. Exhaust hoses should be secured at each
connection with at least two (2) adequate hose
clamps.

HARNESS
CLAMP

HOT SPOT

BATTERY CONNECTION
IMPORTANT: Engine electrical system is negative (-)
ground.
1. Connect the engine positive (+) battery cable
(usually red) to the positive (+) battery terminal.
INCORRECT CORRECT 2. Connect the engine negative (-) battery cable
(usually black) to the negative (-) battery
Figure 54 Exhaust Hose Connections terminal.
3. Make sure that all the battery terminal
ENGINE HARNESS CONNECTION connections are tight. Then, coat the
Install the main engine electrical harness at the 2-Pin connections and terminals with a battery terminal
and 8-Pin Deutsch connectors. anti-corrosion spray to help retard corrosion.

TWIN ENGINE NEGATIVE (-)

MASTER/SLAVE
CONNECTOR POSITIVE (+) CONNECTION
CONNECTION

2-PIN BOAT
HARNESS
CONNECTOR

FUEL TANK
SOLENOID
CONNECTOR
SPEED CONTROL/
8-PIN BOAT CAN BUS
HARNESS CONNECTOR
CONNECTOR

Figure 55 Typical Main Engine Electrical Harness

Connection
NOTE: Refer to page 20 for Adapters to
mate to existing boat harnesses. Figure 56 Battery Terminal Connections

L510023-07
44
 CRUSADER MASTER ENGINE SPECIFICATIONS - 2007
MODEL MP 5.0L MP 5.7L MP 8.1L (STD) MP 8.1L (HO) MP 6.0L Carb 5.7L
(Horsepower) (275 HP) (330 HP) (385 HP) (425 HP) (375 HP) (300 HP)

Displacement 5.0L (305 CID) 5.7L (350 CID) 8.1L (496 CID) 8.1L (496 CID) 6.0L (364 CID) 5.7L (350 CID)

Bore 3.75 in. (95.0 mm) 4.0 in. (101.6 mm) 4.25 in. (107.95 mm) 4.25 in. (107.95 mm) 4.0007 in. (101.618 mm) 4.0 in. (101.6 mm)

Stroke 3.48 in. (88.3 mm) 3.48 in. (88.3 mm) 4.370 in. (111.0 mm) 4.370 in. (111.0 mm) 3.622 in. (92.0 mm) 3.48 in. (88.3 mm)

Compression Ratio 9.4:1 9.4:1 9.1:1 9.1:1 9.4:1 9.4:1

Compression Pressure 130 - 215 psi 130 - 215 psi 130 - 175 psi 130 - 175 psi 130 - 215 psi 130 - 215 psi

WOT Operating RPM 4600-5000 (**5100) 4800 - 5200 (**5300) 4400 - 4800 (**4900) 4800 - 5200 (**5300) 4800 - 5300 (**5400) 4800 - 5200
Preferred WOT RPM 4800 5000 4600 5000 5200 5000

Cruising RPM (Max) 3800 4000 3800 4000 4000 4000

Idle RPM (In Gear) 650 (Not Adjustable) 650 (Not Adjustable) 650 (Not Adjustable) 700 (Not Adjustable) 650 (Not Adjustable) 750

Oil Pressure @ 25 - 60 psi 25 - 60 psi 25 - 60 psi 25 - 60 psi 25 - 80 psi 25 - 60 psi

2000 RPM (172 - 414 kPa) (172 - 414 kPa) (172 - 414 kPa) (172 - 414 kPa) (172 - 552 kPa) (172 - 414 kPa)

Minimum Oil Pressure 10 psi (69 kPa) 10 psi (69 kPa) 10 psi (69 kPa) 10 psi (69 kPa) 10 psi (69 kPa) 10 psi (69 kPa)
at Idle at Idle at Idle at Idle at Idle at Idle

L510023-07
Spark Plug P/N R030010 R030010 R030009 R030009 R030011 R030010
Spark Plug Gap 0.060 in. 0.060 in. 0.060 in. 0.060 in. 0.060 in. 0.060 in.

Firing Order 1-8-4-3-6-5-7-2 (LH) 1-8-4-3-6-5-7-2 (LH) 1-8-7-2-6-5-4-3 (LH) 1-8-7-2-6-5-4-3 (LH) 1-8-7-2-6-5-4-3 (LH) 1-8-4-3-6-5-7-2 (LH)
1-2-7-5-6-3-4-8 (RH) 1-2-7-5-6-3-4-8 (RH) NA NA NA 1-2-7-5-6-3-4-8 (RH)

Thermostat FWC 170˚F (76.7˚C) FWC 170˚F (76.7˚C) FWC 170˚F (76.7˚C) FWC 170˚F (76.7˚C) FWC 170˚F (76.7˚C) FWC 170˚F (76.7˚C)

Over-Temperature 220° F (104.8° C) 220° F (104.8° C) 220° F (104.8° C) 220° F (104.8° C) 220° F (104.8° C) 210° F (100° C)

Electrical System 12 Volt Negative (-) 12 Volt Negative (-) 12 Volt Negative (-) 12 Volt Negative (-) 12 Volt Negative (-) 12 Volt Negative (-)
Ground Ground Ground Ground Ground Ground

Alternator Rating 70 / 100 Amps 70 / 100 Amps 70 / 100 Amps 70 / 100 Amps 70 / 100 Amps 70 / 100 Amps

Ignition Timing Not Adjustable Not Adjustable Not Adjustable Not Adjustable Not Adjustable 26º @ 4000 RPM

CAM Retard 0-4 degrees 0-4 degrees Not Adjustable Not Adjustable Not Adjustable Not Adjustable

Battery Rating 650 CCA (Minimum) 650 CCA (Minimum) 650 CCA (Minimum) 650 CCA (Minimum) 650 CCA (Minimum) 650 CCA (Minimum)
120 Ah 120 Ah 120 Ah 120 Ah 120 Ah 120 Ah

45
 CRUSADER MASTER FUEL PRESSURE SPECIFICATIONS - 2007

46
MODEL MP 5.0L MP 5.7L MP 8.1L (STD) MP 8.1L (HO) MP 6.0L Carb 5.7L
(Horsepower) (275 HP) (330 HP) (385 HP) (425 HP) (375 HP) (300 HP)
Fuel Pressure FCC 57-62 psi @ WOT 57-62 psi @ WOT 57-62 psi @ WOT 57-62 psi @ WOT 59-62 psi @ WOT
Fuel Pressure - FCC
Returnless Fuel System 57-62 psi @ WOT 57-62 psi @ WOT 66-69 psi @ WOT 66-69 psi @ WOT 66-69 psi @ WOT
w/mounted LPFP
Fuel Pressure mounted 7 - 9 psi 7 - 9 psi 7 - 9 psi 7 - 9 psi 7 - 9 psi
LPFP (WOT) (WOT) (WOT) (WOT) (WOT)
Fuel Pressure - FCC
Returnless Fuel System 57-62 psi @ WOT 57-62 psi @ WOT 63-68 psi @ WOT 63-68 psi @ WOT 63-68 psi @ WOT
w/Remote mount LPFP

Fuel Pressure remote 4 - 7 psi 4 - 7 psi 4 - 7 psi 4 - 7 psi 4 - 7 psi 4 - 7 psi

LPFP (WOT) (WOT) (WOT) (WOT) (WOT) (WOT)
IMPORTANT: FUEL PRESSURE MEASUREMENT MUST BE MADE WITH THE ENGINE UNDER LOAD.
CRUSADER MASTER WARNING/ALARM SPECIFICATIONS - 2007
MODEL MP 5.0L MP 5.7L MP 8.1L (STD) MP 8.1L (HO) MP 6.0L Carb 5.7L
(Horsepower) (275 HP) (330 HP) (385 HP) (425 HP) (375 HP) (300 HP)

Coolant 220° F (104.8° C) 220° F (104.8° C) 220° F (104.8° C) 220° F (104.8° C) 220° F (104.8° C) 210° F (100° C)
Over-Temperature M.I.L. - DTC 116 M.I.L. - DTC 116 M.I.L. - DTC 116 M.I.L. - DTC 116 M.I.L. - DTC 116 Check Gauges Lamp
Sensor Check Engine Lamp Check Engine Lamp Check Engine Lamp Check Engine Lamp Check Engine Lamp and/or Buzzer

L510023-07
and/or Buzzer and/or Buzzer and/or Buzzer and/or Buzzer and/or Buzzer

Transmission 235° F ± 10° F 235° F ± 10° F 235° F ± 10° F 235° F ± 10° F 235° F ± 10° F 235° F ± 10° F
Over-Temperature M.I.L. - DTC 1542 M.I.L. - DTC 1542 M.I.L. - DTC 1542 M.I.L. - DTC 1542 M.I.L. - DTC 1542 Check Gauges Lamp
Switch Check Engine Lamp Check Engine Lamp Check Engine Lamp Check Engine Lamp Check Engine Lamp and/or Buzzer

Exhaust 248° F ± 5° F 248° F ± 5° F 248° F ± 5° F 248° F ± 5° F 248° F ± 5° F

Over-Temperature M.I.L. - DTC 2428 M.I.L. - DTC 2428 M.I.L. - DTC 2428 M.I.L. - DTC 2428 M.I.L. - DTC 2428 N/A
Switch Check Engine Lamp Check Engine Lamp Check Engine Lamp Check Engine Lamp Check Engine Lamp
and/or Buzzer and/or Buzzer and/or Buzzer and/or Buzzer and/or Buzzer

Low Oil < 10 psi < 10 psi < 10 psi < 10 psi < 10 psi < 10 psi
Pressure Sensor or M.I.L. - DTC 524 M.I.L. - DTC 524 M.I.L. - DTC 524 M.I.L. - DTC 524 M.I.L. - DTC 524 Check Gauges Lamp
(Switch-5.7L carb only) Check Engine Lamp Check Engine Lamp Check Engine Lamp Check Engine Lamp Check Engine Lamp and/or Buzzer
and/or Buzzer and/or Buzzer and/or Buzzer and/or Buzzer and/or Buzzer

**IMPORTANT NOTICE: Crusader engines incorporate an RPM “MAX GOVERNOR” in order to prevent the engine from over-revving.
Engine operation above the Maximum RPM listed will appear normal, but will not exceed the (**MAX Governor) RPM listed. This is not
recommended. If the engine is operating above the maximum RPM listed, a higher pitched propeller would be required to lower the engine
maximum RPM to the Preferred RPM listed in the chart above. Engine Specs
NOTE: FOR NEW BOAT PROPPING, IT IS RECOMMENDED THAT OEMS PROP TO THE MAXIMUM RPM LISTED. 07/07
 CRUSADER MASTER ENGINE SPECIFICATIONS - 2007 - SN 671344 and higher
MODEL MP 5.0L MP 5.7L MP 8.1L (STD) MP 8.1L (HO) MP 6.0L Carb 5.7L
(Horsepower) (275 HP) (330 HP) (385 HP) (425 HP) (375 HP) (300 HP)

Displacement 5.0L (305 CID) 5.7L (350 CID) 8.1L (496 CID) 8.1L (496 CID) 6.0L (364 CID) 5.7L (350 CID)

Bore 3.75 in. (95.0 mm) 4.0 in. (101.6 mm) 4.25 in. (107.95 mm) 4.25 in. (107.95 mm) 4.0007 in. (101.618 mm) 4.0 in. (101.6 mm)

Stroke 3.48 in. (88.3 mm) 3.48 in. (88.3 mm) 4.370 in. (111.0 mm) 4.370 in. (111.0 mm) 3.622 in. (92.0 mm) 3.48 in. (88.3 mm)

Compression Ratio 9.4:1 9.4:1 9.1:1 9.1:1 9.4:1 9.4:1

Compression Pressure 130 - 215 psi 130 - 215 psi 130 - 175 psi 130 - 175 psi 130 - 215 psi 130 - 215 psi

WOT Operating RPM 4600-5000 (**5100) 4800 - 5200 (**5300) 4400 - 4800 (**4900) 4800 - 5200 (**5300) 4800 - 5300 (**5400) 4800 - 5200
Preferred WOT RPM 4800 5000 4600 5000 5200 5000

Cruising RPM (Max) 3800 4000 3800 4000 4000 4000

Idle RPM (In Gear) 650 (Not Adjustable) 650 (Not Adjustable) 650 (Not Adjustable) 700 (Not Adjustable) 650 (Not Adjustable) 750

Oil Pressure @ 25 - 60 psi 25 - 60 psi 25 - 60 psi 25 - 60 psi 25 - 80 psi 25 - 60 psi

2000 RPM (172 - 414 kPa) (172 - 414 kPa) (172 - 414 kPa) (172 - 414 kPa) (172 - 552 kPa) (172 - 414 kPa)

Minimum Oil Pressure 10 psi (69 kPa) 10 psi (69 kPa) 10 psi (69 kPa) 10 psi (69 kPa) 10 psi (69 kPa) 10 psi (69 kPa)
at Idle at Idle at Idle at Idle at Idle at Idle

L510023-07
Spark Plug P/N R030010 R030010 R030009 R030009 R030011 R030010
Spark Plug Gap 0.060 in. 0.060 in. 0.060 in. 0.060 in. 0.060 in. 0.060 in.

Firing Order 1-8-4-3-6-5-7-2 (LH) 1-8-4-3-6-5-7-2 (LH) 1-8-7-2-6-5-4-3 (LH) 1-8-7-2-6-5-4-3 (LH) 1-8-7-2-6-5-4-3 (LH) 1-8-4-3-6-5-7-2 (LH)
1-2-7-5-6-3-4-8 (RH) 1-2-7-5-6-3-4-8 (RH) NA NA NA 1-2-7-5-6-3-4-8 (RH)

Thermostat FWC 170˚F (76.7˚C) FWC 170˚F (76.7˚C) FWC 170˚F (76.7˚C) FWC 170˚F (76.7˚C) FWC 170˚F (76.7˚C) FWC 170˚F (76.7˚C)

Over-Temperature 220° F (104.8° C) 220° F (104.8° C) 220° F (104.8° C) 220° F (104.8° C) 220° F (104.8° C) 210° F (100° C)

Electrical System 12 Volt Negative (-) 12 Volt Negative (-) 12 Volt Negative (-) 12 Volt Negative (-) 12 Volt Negative (-) 12 Volt Negative (-)
Ground Ground Ground Ground Ground Ground

Alternator Rating 70 / 100 Amps 70 / 100 Amps 70 / 100 Amps 70 / 100 Amps 70 / 100 Amps 70 / 100 Amps

Ignition Timing Not Adjustable Not Adjustable Not Adjustable Not Adjustable Not Adjustable 26º @ 4000 RPM

CAM Retard 0-4 degrees 0-4 degrees Not Adjustable Not Adjustable Not Adjustable Not Adjustable

Battery Rating 650 CCA (Minimum) 650 CCA (Minimum) 650 CCA (Minimum) 650 CCA (Minimum) 650 CCA (Minimum) 650 CCA (Minimum)
120 Ah 120 Ah 120 Ah 120 Ah 120 Ah 120 Ah

47
 CRUSADER MASTER FUEL PRESSURE SPECIFICATIONS - 2007 - SN 671344 and higher

48
MODEL MP 5.0L MP 5.7L MP 8.1L (STD) MP 8.1L (HO) MP 6.0L Carb 5.7L
(Horsepower) (275 HP) (330 HP) (385 HP) (425 HP) (375 HP) (300 HP)
Fuel Pressure FCC 57-62 psi @ WOT 57-62 psi @ WOT 57-62 psi @ WOT 57-62 psi @ WOT 59-62 psi @ WOT
Fuel Pressure - FCC
Returnless Fuel System 57-62 psi @ WOT 57-62 psi @ WOT 66-69 psi @ WOT 66-69 psi @ WOT 66-69 psi @ WOT
w/mounted LPFP
Fuel Pressure mounted 7 - 9 psi 7 - 9 psi 7 - 9 psi 7 - 9 psi 7 - 9 psi
LPFP (WOT) (WOT) (WOT) (WOT) (WOT)
Fuel Pressure - FCC
Returnless Fuel System 57-62 psi @ WOT 57-62 psi @ WOT 63-68 psi @ WOT 63-68 psi @ WOT 63-68 psi @ WOT
w/Remote mount LPFP

Fuel Pressure remote 4 - 7 psi 4 - 7 psi 4 - 7 psi 4 - 7 psi 4 - 7 psi 4 - 7 psi

LPFP (WOT) (WOT) (WOT) (WOT) (WOT) (WOT)
IMPORTANT: FUEL PRESSURE MEASUREMENT MUST BE MADE WITH THE ENGINE UNDER LOAD.
CRUSADER MASTER WARNING/ALARM SPECIFICATIONS - 2007 - SN 671344 and higher
MODEL MP 5.0L MP 5.7L MP 8.1L (STD) MP 8.1L (HO) MP 6.0L Carb 5.7L
(Horsepower) (275 HP) (330 HP) (385 HP) (425 HP) (375 HP) (300 HP)

Coolant 220° F (104.8° C) 220° F (104.8° C) 220° F (104.8° C) 220° F (104.8° C) 220° F (104.8° C) 210° F (100° C)
Over-Temperature M.I.L. - DTC 116 M.I.L. - DTC 116 M.I.L. - DTC 116 M.I.L. - DTC 116 M.I.L. - DTC 116 Check Gauges Lamp
Sensor Check Engine Lamp Check Engine Lamp Check Engine Lamp Check Engine Lamp Check Engine Lamp and/or Buzzer

L510023-07
and/or Buzzer and/or Buzzer and/or Buzzer and/or Buzzer and/or Buzzer

Transmission 235° F ± 10° F 235° F ± 10° F 235° F ± 10° F 235° F ± 10° F 235° F ± 10° F 235° F ± 10° F
Over-Temperature M.I.L. - DTC 1542 M.I.L. - DTC 1542 M.I.L. - DTC 1542 M.I.L. - DTC 1542 M.I.L. - DTC 1542 Check Gauges Lamp
Switch Check Engine Lamp Check Engine Lamp Check Engine Lamp Check Engine Lamp Check Engine Lamp and/or Buzzer

Exhaust 248° F ± 5° F 248° F ± 5° F 248° F ± 5° F 248° F ± 5° F 248° F ± 5° F

Over-Temperature M.I.L. - DTC 2428 M.I.L. - DTC 2428 M.I.L. - DTC 2428 M.I.L. - DTC 2428 M.I.L. - DTC 2428 N/A
Switch Check Engine Lamp Check Engine Lamp Check Engine Lamp Check Engine Lamp Check Engine Lamp
and/or Buzzer and/or Buzzer and/or Buzzer and/or Buzzer and/or Buzzer

Low Oil < 10 psi < 10 psi < 10 psi < 10 psi < 10 psi < 10 psi
Pressure Sensor or M.I.L. - DTC 524 M.I.L. - DTC 524 M.I.L. - DTC 524 M.I.L. - DTC 524 M.I.L. - DTC 524 Check Gauges Lamp
(Switch-5.7L carb only) Check Engine Lamp Check Engine Lamp Check Engine Lamp Check Engine Lamp Check Engine Lamp and/or Buzzer
and/or Buzzer and/or Buzzer and/or Buzzer and/or Buzzer and/or Buzzer

**IMPORTANT NOTICE: Crusader engines incorporate an RPM “MAX GOVERNOR” in order to prevent the engine from over-revving.
Engine operation above the Maximum RPM listed will appear normal, but will not exceed the (**MAX Governor) RPM listed. This is not
recommended. If the engine is operating above the maximum RPM listed, a higher pitched propeller would be required to lower the engine
maximum RPM to the Preferred RPM listed in the chart above. Engine Specs
NOTE: FOR NEW BOAT PROPPING, IT IS RECOMMENDED THAT OEMS PROP TO THE MAXIMUM RPM LISTED. 07/07
DELIVERY PREPARATION IMPORTANT: If the engine is to be tested on land,
water must be supplied to the seawater pickup
NOTICE: Before starting the pre-delivery, read “General
pump. DO NOT run engine above 1500 RPM.
Information” and “Installation Requirements” completely.
Test Running the Engine

WARNING

If the engine is to be tested on land, propeller must

be removed.

Pre-Delivery Checklist
Check for Bulletins Belt and Pulley: Inspect
for Damage
Engine Oil: Check All Drain Plugs: Confirm
Proper Installation
Drive Lube: Check All Fuel Lines:
Confirm No Leaks
Type Information
Battery Rating, Charge, and Level: All Oil Lines:
Check Confirm No Leaks
Control Adjustments: All Water Lines:
To
Confirm Proper Operation
Prevent Confirm No Leaks
Gauges: Check for Electrical Wiring: Check
Proper Operation for Proper Installation
Processing Delay
Record Propeller Size, Rotation and WOT - Port
WOT RPM_________Diameter_________ Pitch_________Rotation__________
Record Propeller Size, Rotation and WOT - Stbd
WOT RPM_________Diameter_________ Pitch_________Rotation__________
Port - Starboard -
Record Fuel Pressure, WOT ______ Record Fuel Pressure, WOT ______
Dealer Reviewed Warranty Trouble Codes Checked
with Owner Trouble Codes Cleared

NOTICE: The following pages contain detailed steps in order to successfully perform the “Crusader
Pre-Delivery Inspection Procedure.” These steps should be read carefully and completely prior to
performing the inspection.

L510023-07
49
 Pre-Delivery Inspection
REFERENCES: • Crusader Owner’s Operation and Maintenance
Manual
• Crusader Master Engine Specifications Sheet
• Boat Owner’s Manual

The Pre-Delivery Inspection ensures the safety and reliability of the Crusader
product. It is necessary that the inspection procedures be performed in the order
given. Crusader recommends that the inspection be accomplished in a timely
manner, allowing time for repairs that may be necessary, prior to the boats delivery
to the customer.
The inspection is laid out in two (2) stages. Stage One is a static, pre-operational
inspection. Stage Two is an operational/sea-trial inspection. After completion of the
Pre-Delivery Inspection you will have the information necessary to accurately and
completely fill out the Pre-Delivery Checklist portion of the Warranty Registration
Form.

Stage 1 - Static Pre-Operational Inspection

1. Engine and Transmission Identification.
(Refer to the Crusader Owner’s Operation and Maintenance Manual for Engine
and Transmission Identification location.)
Locate the engine identification tag and record the model and serial number in
the space provide. The Crusader model identification provides you with valuable
information concerning the engine you are working on. Information includes
raw/fresh water cooling, engine rotation, engine type, drive type and function,
propeller shaft rotation, gear ratio, and ignition and fuel type. Also the engine
serial number. This information will be needed for the next step in this procedure
so you can narrow your search for Service Updates to only those associated
with the engine you are preparing to put into service. PORT STBD
ENGINE MODEL NO.
ENGINE SERIAL NO.
Locate the transmission identification tag and record the model and serial
number in the space provide on the inspection procedure.
TRANS. MODEL NO.
TRANS. SERIAL NO.
2. Service Update Check
Once you have located the Engine and Transmission Model and Serial numbers
you need to review the Service Updates for any which may apply to the
engine(s) you are preparing for delivery.
Check Crusader Service Updates for USCG Safety Recall and product
enhancement bulletins. Correct any condition that may be discovered, before
proceeding with the Pre-Delivery Inspection Procedure. Note Service Update
number(s) in the space provided and check the compliance box.
SERVICE UPDATE #

SERVICE UPDATE(S) INSTALLED:

L510023-07
50
 3. Propeller Identification and Inspection
(Refer to the Crusader Owner’s Operation and Maintenance Manual and the
Crusader Master Engine Specification Sheet for operational parameters based on
propeller selection.)
• Proper boat performance is dependent upon boat design, engine power
and a properly sized propeller. The size markings will be needed if a
performance issue is raised.
• Prior to installation of the propellers, locate the size and rotation markings on
the propeller(s).
• Record the markings, Diameter, Pitch, and Rotation in the space provided
and compare to known standards. If you are unsure of the proper propeller
size, contact the boat manufacturer for the information necessary to
determine the proper size for the boat. Correct any deficiency. PORT STBD
Diameter:
Pitch:
Rotation:
NOTICE: The boat manufacturer and/or the dealer selects and installs
the propeller(s). Problems that are associated with the propeller(s) or its
installation should be corrected at the direction of the boat manufacturer
and/or installer and are not a Crusader Warranty item.
4. Static Leak Check of Fuel and Oil Lines PORT STBD
Check all fuel and oil lines for leaks. Using your hand check each and every
fuel line and oil line to and on the engine for leaks. Note the location of any
leaks found. Correct any deficiency. Check the compliance box.

NOTICE: The boat manufacturer and/or the dealer selects and installs the
fuel lines from the fuel tank to the engine. Problems associated with this
fuel line or its installation should be corrected at the direction of the boat
manufacturer and/or installer and are not a Crusader Warranty item.
5. Engine Wiring Inspection PORT STBD
Do a visual inspection to insure that all plug-in connectors of the engine wiring
harness are plugged into their proper devices. Check to insure that the boat
harness is plugged completely and correctly into the engine harness. Correct
any deficiencies found and check the compliance box.
6. Static, Prelaunch Fluids Check PORT STBD
• Engine and transmission oil levels must be verified prior to engine operation.
These levels will again be checked after operation. Normal levels for both
the engine and transmission should be between the Low and Full marks on
the dipstick. Oil levels must be at least to the low oil level mark at this
time.
• With the boat resting close to its in-the-water position, remove the engine(s)
dipstick(s) and wipe the dipstick(s) clean of oil and insert the dipstick into the
dipstick tube. Be sure that the dipstick bottoms out in the tube.
• Remove the dipstick and note the oil level. Correct any deficiency for each
engine.
• Remove the dipstick from each transmission, wipe the dipstick clean of oil
and insert the dipstick into the dipstick opening. Be sure that the dipstick
bottoms out on case (Velvet Drive) or to the threads (Hurth - Note: do not
screw the dipstick in when checking fluid levels.).
• Remove the dipstick from the transmission and note the oil level. Correct
any deficiency. NOTE: Oil levels slightly above the full mark, at this
time, would be normal. Do Not remove fluid at this time.

L510023-07
51
 7. Check Water & Exhaust Hoses for Proper Connection PORT STBD
• Attach hoses removed for winterization.
• Inspect each hose for leaks, routing, rubbing and cuts or abrasions. Correct
any deficiency.
• If equipped, check to insure that the strainer is not damaged and seal is
secure. Correct any deficiency.
• If equipped, check to insure that the hull inlet valve is turned to its OPEN
position.
• Check Fresh Water Cooling to insure that the coolant level is proper. Coolant
level in the Degas Bottle should be at the ‘MAX’ line on the bottle.
IMPORTANT: The addition of accessories, either by the Dealer or Boat
Manufacturer, i.e. a hot water heater or heater, to the engine’s freshwater
coolant system, increases the volume of the engine’s coolant system and will
require additional coolant to be added. Be sure to use Dex-Cool™ extended
life coolant when topping off the Fresh Water Cooling System.
NOTICE: The boat manufacturer/dealer selects and installs the water/exhaust
hoses and accessories to the engine. Problems associated with these hoses,
accessories, or their installation should be corrected at the direction of the
boat manufacturer and/or installer and are not a Crusader Warranty item.
8. Install and Tighten all Drain Plugs PORT STBD
• The drain plugs have been removed for shipping or winterization. Before the
engine may be safely started the drain plugs must be installed.
• Insert a plug of the proper size coated with PST (Pipe Sealant with Teflon by
Loctite or equivalent) into each drain location.
• Tighten each drain plug securely. Caution ! Do Not Over Tighten Or Damage
Could Occur.
• Check the compliance box on the procedure.
9. Visual Check of Belt And Pulley Alignment PORT STBD
NOTE: All Crusader engines currently use a serpentine belt at the front of the
engine. This belt has a self-tensioning system which is non-adjustable.
• Check belt for cuts or other damage. Correct any deficiency.
• Check the pulleys for damage. Correct any deficiency.
• Visually inspect for pulley and belt alignment. Correct any deficiency.

L510023-07
52
 10. Check Battery Installation And Charge Level PORT STBD
• Check battery(s) cold cranking amps against the minimum recommended
Cold Cranking Amps listed on the Master Engine Specification Sheet.
Correct any deficiency.
• Check for a properly connected power cable(s) (Red) and ground cable(s)
(Black), at the engine, terminal block/isolator, charger, house battery,
and battery switch(s). Correct any deficiency.
• Check the electrolyte level (as required) and battery(s) charge. Correct any
deficiency.
• Always connect the positive (+) cable to the battery(s) first and tighten
securely.
• Connect the negative (-) cable to the battery(s) and tighten securely.
• After following boat manufacturer’s pre-start procedures, turn the Ignition
Switch(s) to the ON position and verify battery voltage on the instrument
panel and remaining gauge cluster reads normal for Key On Engine Off.
Turn the Ignition Switch(s) to the OFF position. DO NOT START THE
ENGINE AT THIS TIME.
• Check the compliance box on the procedure.
NOTICE: Problems that are associated with the battery(s) or installation
should be corrected at the direction of the supplier and/or installer and are
not a Crusader Warranty item.
11. Check Control Adjustment, Direction and Travel PORT STBD
The boat manufacturer and/or the dealer selects and installs the control cables
and control head. Check both the throttle and shift cable in-accordance-with
the boat manufacturers and/or installers instructions.
A minimum inspection of the control cables would include the following: (1)
Throttle and shift in neutral, (2) Shift in forward, throttle in neutral or idle
position, (3) Shift in reverse, throttle in neutral or idle position, and (4) Throttle
at the wide-open-throttle (WOT) position.
When the control is in the neutral position, inspect that the throttle linkage is at
its zero or detent position, with no additional pressure supplied by the throttle
cable to the TCP sensor (SUC-1006-01). Verify that the transmission shift arm
is in its neutral position. With the control moved to its in gear and zero throttle
position, the transmission shift arm should be to its full in gear position (both
forward and reverse positions need to be checked) and the throttle linkage
should still be at its zero throttle position or detent position.
With the throttle at its WOT position the verify the TCP arm is near or just
touches the WOT detent. Adjustments should be made as necessary and in
accordance with the boat manufacturer’s / installer’s instructions and SUC-
1006-01.
Check the compliance box on the procedure.
NOTICE: Improper adjustment of the control cables can cause engine
and/or transmission damage. Control cables, their adjustment, or engine/
transmission damage resulting from improper adjustment are not a Crusader
Warranty item.

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 Stage 2 - Operational / Sea-Trial Inspection
Boat-in-the-Water Tests PORT STBD
IMPORTANT: Engine alignment MUST BE CHECKED at this time, with the boat
in the water, fuel tanks filled, and with a normal load onboard.

WARNING

DO NOT leave the helm unattended while performing any tests.

1. Test Equipment Connection

• With the boat in the water and secured in her slip, locate the Data Link
Connector (DLC) on the engine and connect the Diacom cable from your
computer to the engine.
Note: On twin engine applications, Diacom can only read the engine data from
the engine it is connected to. You must disconnect from the current engine
and reconnect to the other engine when you are instructed.
Verify that the Master/Slave Wiring Harness is installed between engine #1 and
engine #2’s Engine Wiring Harnesses.
PORT STBD
• Install the fuel pressure gauge onto the fuel rail or FCC fuel pressure fitting.
(NOTE: For twin engine applications, you will be instructed on when to
connect the fuel pressure gauge to the second engine.) Readings should
be made with the gauge positioned at the same height as the fitting to which
it is attached. Consult the Master Engine Specification Sheet for the proper
pressures for the engine being tested.
Check the compliance box.
2. Priming the Fuel System and Check for Fuel Leaks
• Turn the Ignition Switch to the ON position (for the engine that the fuel
pressure gauge is currently connected to.) to allow the fuel pumps to run until
they shut off, then turn the Ignition Switch to the OFF position (Ignition switch
must remain in the OFF position for a minimum of 5 seconds in order to reset
the engine’s ECM and allow another pump cycle to occur.). This procedure
may have to be repeated 1-3 times to prime the fuel system. Repeat as
necessary to build fuel pressure to the specification of this engine. Check for
fuel leaks at the fuel pressure gauge connection and all fuel fittings. Correct
any leaks before proceeding.
• When the fuel pressure is at the specified level, stop cycling the pumps and
allow the engine to sit for one minute while observing the fuel pressure reading
on fuel gauge. Pressure must remain constant when the fuel pumps are not
operating.
NOTE: While the pumps are operating fuel pressure should be within the
Master Engine Specification range for WOT pressure; after the pumps cut
off pressure will drop slightly but remain constant. If proper pressure is
not displayed or does not remain constant, correct this condition before
proceeding.
• Check for signs of fuel in the engine compartment and all fuel lines for leaks
before starting the engine. Correct any deficiency prior to proceeding.
• For twin engine applications: Relieve the fuel pressure and disconnect
the fuel gauge from engine #1, connect the fuel gauge to engine #2 and
repeat the priming and fuel leak check for engine #2.
Check the compliance box.

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 3. Engine at Idle Check PORT STBD
Follow boat manufacturer’s starting procedures regarding the blower, etc.
Start the engine.
WARNING! If fuel and/or oil leaks are present shut off the engine(s)
immediately.
• Check to insure that the raw water pump is pumping water( both engines)
then allow the engine(s) to idle for approximately one minute. Shut the
engine(s) off. Check each fuel line and fitting for leaks by running your
clean, dry hand along and under every fuel line and fitting. Correct any
deficiency prior to proceeding.
• With clean dry hands, check each oil line and fitting for leaks by running
your clean, dry hand along and under every oil line and fitting. Correct any
deficiency prior to proceeding.
• With clean dry hands, check each water hose and fitting for leaks by running
your hand along and under every water hose and fitting. Correct any
deficiency prior to proceeding.
• Start the engine(s), then check each exhaust hose and fitting for leaks by
running your hand along and under every engine exhaust outlet hose and
fitting. Correct any deficiency prior to proceeding.
• Check each engine’s pulleys for wobble. Correct any deficiency.
• Cycle each transmission, at idle RPM, from Neutral-Forward-Neutral-
Reverse-Neutral.
• Shut the engine(s) off and leave the test equipment attached to the engine.
NOTE: Immediately proceed to the Transmission Fluid check after
shutting the engines off. False fluid readings can be obtained as the
fluid returns to the transmission from the oil cooler and its lines.
Check the compliance box. PORT STBD
4. Engine and Transmission Fluid Check
Transmission:
• On each transmission, wipe the dipstick clean of oil and insert the dipstick
into the dipstick opening. Be sure that the dipstick is fully inserted into the
case (Velvet Drive) or inserted to the threads, but not screwed in (Hurth).
• Remove the dipstick from the transmission and note the oil level. Correct
any deficiency.
• Correct any low oil deficiency by adding the proper amount of oil, that meets
the specification stated on the engine specification decal, to bring the oil to
the full mark. Correct an over-filled condition by removing oil until the level
reading on the dipstick is at the full mark. PORT STBD
Engine:
• On each engine remove the dipstick and wipe the dipstick clean of oil, then
insert the dipstick into the dipstick tube. Be sure that the dipstick bottoms
out in the tube.
• Remove the dipstick and note the oil level. Correct any deficiency.
• Correct a low oil level condition by adding the proper amount of oil, that
meets the specification stated on the engine specification decal, to bring the
oil to the full mark. Correct an over-filled condition by removing oil until the
level reading on the dipstick is at the full mark.
Check the compliance box.

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 5. ECM-07 System Check PORT STBD
A check of the engine management system is done to insure that the EFI
system has not been damaged or modified since shipment from Crusader.
• With the Diacom loaded and set to Crusader’s standardized screen, turn the
ignition switch(s) to the ‘ON’ position (Do Not start the engine(s)) and check
the engine(s) for codes. If codes are present, make a note of them, in the
space provided on the Pre-Delivery Inspection Procedure, and then erase the
codes using the ‘Pencil with Eraser’ icon button on the Diacom screen.
• If any code returns after the erase procedure is performed, the problem is still
in the circuit indicated by the code and must be corrected by the technician
before proceeding.
NOTES: CODES:

• When the system tests code-free, you may proceed to start the engine(s).
NO CODES:
• **ECM-07 Engines: After starting the engine(s), for 5.0L and 5.7L engines
only, CAM Retard must be checked, using Diacom, and verified to be
between 0 to 4 degrees. If CAM Retard is not between 0 to 4 degrees
it must be set to the proper specification. Consult Crusader Service
Update # SUC-0706-01 for the procedure to be used to correct CAM
Retard.
For Twin Engine Applications, disconnect Diacom from the current engine and
connect Diacom to the other engine. Repeat the CAM Retard check/adjustment for
the other engine.

CAM RETARD:
Check the compliance box.
6. Instrumentation Check PORT STBD
• The gauges on the boat’s instrument panel are the operator’s insight into
the engine’s vital signs. Constant monitoring of the gauges is necessary to
insure that abnormal conditions are recognized as soon as possible to prevent
engine damage and/or dangerous conditions from occurring.
• Allow the engine(s) to come up to normal operating temperature.
• Verify coolant flow and level at the Degas Bottle on the engine(s). Correct any
deficiency. Caution! The Degas Bottle operates under pressure. Allow
the engine to cool sufficiently before removing the Degas Bottle Cap to
add fluid.
• Check and verify proper operation of all gauges. Correct any deficiency.
NOTICE: The boat manufacturer and/or the dealer selects and installs the
instrument panel and gauges. Problems associated with the instrument panel
and gauges or their installation should be corrected at the direction of the boat
manufacturer and/or installer and are not a Crusader Warranty item.
Check the compliance box.

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 7. Engine Performance Test
• All gauges and test equipment should be observed as frequently as possible
to allow the operator to react quickly to any discrepancy displayed. The
operator must also listen for unusual sounds, feel for unusual vibrations,
smell for signs of fuel, smoke, etc. and look for any sign of abnormal
operational characteristics.
• Verify normal operation and readings on all gauges.
• When conditions permit, accelerate to bring the boat on plane and to a
cruising speed of 3600 RPM. While frequently observing the gauges,
operate the boat at this speed for five minutes.
• After five minutes at 3600 RPM, move the throttle to wide-open-throttle
(WOT) and run at this speed (not to exceed 30 seconds) until the RPMs
have stopped increasing. Note and record the WOT RPM and fuel pressure
at WOT. Reduce the throttle to 3600 RPM.
• Operate the engine(s) at 3600 RPM for an additional 10 minutes while
frequently observing the gauges.
• Return to idle.
• For twin engine applications: Shut off both engines, then relieve the
fuel pressure and disconnect the fuel gauge from engine #1, connect
the fuel gauge to engine #2, re-start the engines, then as conditions
permit, accelerate to bring the boat on plane and to a cruising speed
of 3600 RPM. Operate the boat at this speed for approximately one
minute, then move the throttle to wide-open-throttle (WOT) and run at
this speed (not to exceed 30 seconds) until the RPMs have stopped
increasing. Note and record the fuel pressure at WOT for engine #2. PORT STBD
• Return to idle.
WOT RPM:
FUEL PRESSURE - WOT:
8. Diacom Record of Engine Performance (Optional) PORT STBD
• Record the following water test for your records, using the Diacom ‘Record’
feature. This recording is to be made after all defects, if any are found, have
been corrected. The record time for this procedure will easily fit on a 3 1/2”
floppy disk making it easily accessible for future retrieval, reference and
storage.
NOTE: 2007 Engines: For Twin engine applications, Diacom will have to be
connected to the other engine and the procedure repeated so you
will have a recording of both engine’s parameters.
1. Start the Diacom record function.
2. Idle for 10 seconds.
3. Run at 1,000, 2,000, 3,000, and 4,000 RPMs for 10 seconds each.
4. Return to idle for 10 seconds.
5. Accelerate to 3600 RPM and run @ 3600 RPM for 30 seconds.
6. Accelerate to WOT and run at WOT until the RPM’s stop increasing (not to
exceed 30 seconds).
7. Return the throttle(s) quickly to idle and allow the engine(s) to idle for 10
seconds, then stop the recording.
8. Save the recording, using the engine(s) serial number as the file name.
• Return to the dock, check the engine(s) for leaks (water, oil and fuel) and
correct any leaks noted. Turn off the engine(s), recheck the fluid levels in
the transmission(s) and engine(s) and correct as necessary.
• Review the test data and compare the results to the Master Engine
Specification Sheet. If defects were noted, correct all, then retest the boat.
• Disconnect the test equipment and prepare the boat for customer delivery.
Check the compliance box.

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 9. Lay-Up Engine (OPTIONAL)
CAUTION

If the engine will not be used for an extended period of time, or will be exposed
to freezing temperatures, drain the water from the cooling system, as explained
in the “Owner’s Operation and Maintenance Manual.” Water MUST BE drained
to prevent corrosion and freeze damage to the engine.

CAUTION

If the new engine is test run and actual customer usage is not anticipated with
a seven-day period, the engine must be put back into a preserved state by
fogging the cylinders with rust-preventive oil. See the “Owner’s Operation and
Maintenance Manual.” PORT STBD
Check the compliance box.

10. Complete the Pre-Delivery Checklist

Obtain the Crusader Warranty Registration Form that came with the engine.
Using the data obtained and recorded on the Pre-Delivery Inspection Procedure
complete the following blocks on the Warranty Registration Form:
Complete the Pre-Delivery Checklist by checking each box and filing in the
required data to signal compliance.
Engine Model No. (Port and Starboard)
Engine Serial No. (Port and Starboard)
Transmission Serial No. (Port and Starboard)
Check for Bulletins
Engine Oil: Check
Drive Lube: Check
Battery Rating, Charge, and Level: Check
Control Adjustments: Confirm Proper Operation
Gauges: Check for Proper Operation
Record Propeller Size, Rotation, and WOT:
Port: WOT RPM Diameter Pitch Rotation
Stbd: WOT RPM Diameter Pitch Rotation
Record Fuel Pressure:
Port: WOT
Stbd: WOT
Belt and Pulley: Inspect for Damage
All Drain Plugs: Confirm Proper Installation
All Fuel Lines: Confirm No Leaks
All Oil Lines: Confirm No Leaks
All Water Lines: Confirm No Leaks
Electrical Wiring: Check for Proper Installation
Trouble Codes Checked / Trouble Codes Cleared
Your Diacom recording and these Pre-Delivery procedure sheets can be
archived either by engine serial number, owner’s name, or both for future
reference by the technician.

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11. Register the Engine with Crusader PORT STBD
When the boat is sold, you will complete the remaining blocks of the Warranty
Registration Form. Completely fill in the required information.
Owner’s Name Date of Sale
Address Selling Dealer
City, State, Zip Address
Boat Make, Length, Type
You should review the Crusader 2 Year Transferable Limited Warranty with the
new owner. Upon completion of the warranty review, you will complete the
remaining dealer portion of the Crusader Warranty Registration form by filling
in the following blocks.
Dealer Reviewed Warranty with Owner (the last block of the Pre-Delivery
Checklist)
Dealer Signature: (By signing this form, the dealer certifies that he has
checked the installation and operation of the engine(s) and
finds them to be performing properly.)
Owner’s Signature and Date
Give the customer their copy of the completed Crusader Warranty Registration
form along with the copy of the Warranty Statement. Affix proper postage and
send the pre-addressed card to Crusader. This completes the registration of a
new Crusader engine.

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 EXHAUST INSTALLATION GUIDELINES
The top of the exhaust riser must be a minimum of 12 inches above the water line
with the boat at rest and a full load aboard. It is recommended by the ABYC, and
a Pleasurecraft Engine Group requirement, that there be a drop in the exhaust run
between the engine and exhaust outlet of a minimum of 1 inch per foot of run, with a
minimum of four (4) inches drop overall. The drop must be constant so that no low
spots exist at any point in the exhaust hose. The above are minimum guidelines for
installation, however, meeting the minimum guidelines will not necessarily insure
no water intrusion under all operating conditions. It is the responsibility of the boat
builder to confirm, for each model, that under any and all running angles and other
conditions of operation, no water ingestion will occur.

EXHAUST OUTLET MUST HAVE B

INTERNAL SHUTTER AND/OR
EXHAUST FLAPPER INSTALLED

EXHAUST SYSTEM DROP MUST BE

1" PER FOOT OR MINIMUM 4" TOTAL

A - B = 12" MINIMUM

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 CRUSADER MARINE ENGINES
DISTRIBUTORS

Marysville
Marine
Engine Distributors Inc.
Engine 400 University Court
Distributors
Blackwood, NJ 08012
Jaime Cummins
Engine
Distributors
Phone: 800-220-2700
Fax: 856-228-5657 - Parts
Engine Fax: 856-228-5531 - Sales
Distributors II
jcummins@edi-dist.com
Trans Pacific
Engine Distributors -
Engine Distributors Inc.
Jacksonville 41 Pope Road
Engine Distributors -
Holliston, MA 01746
AER Supply Ft. Lauderdale Jaime Cummins
Phone: 800-220-2700
Fax: 856-228-5657 - Parts
Fax: 856-228-5531 - Sales
Marysville Marine Distributors jcummins@edi-dist.com

Trans Pacific Distributors

Marysville Marine Engine Distributors Inc. II
Distributors 303 Interstate Dr.
AER Supply
282 Progress Way Archdale, NC 27263-3148
Sun Prairie, WI 53590 Jaime Cummins
Engine Distributors Inc.
Brian Hunter Phone: 800-220-2700
Phone: 608-825-3878 Fax: 856-228-5657 - Parts
Fax: 608-825-2790 Fax: 856-228-5531 - Sales
marysvillemarine.com jcummins@edi-dist.com

Trans Pacific Distributors Marysville Marine Engine Distributors -

1941 Walters Court Distributors Jacksonville
Fairfield, CA 94533 1551 Michigan Avenue 259 Ellis Road South
Henry Bramhall - Owner Marysville, MI 48060 Jacksonville, FL 32254
Arley Harty Steve Riehl Jaime Cummins
Phone: 800-688-6208 Phone: 810-364-7653 Phone: 800-220-2700
Fax: 707-426-0206 Fax: 810-364-4112 Fax: 856-228-5657 - Parts
sales@marinegate.com marysvillemarine.com Fax: 856-228-5531 - Sales
jcummins@edi-dist.com

AER Supply Marysville Marine Engine Distributors - Ft.

2301 NASA Road One Distributors Lauderdale
PO Box 349 127 Industrial Dr. 2917 SW 2nd Avenue
Seabrook, TX 77586 White House, TN 37188 Ft. Lauderdale, FL 33315
Richard Miller Randy Hall Jaime Cummins
Phone: 800-767-7606 Phone: 615-672-1142 Phone: 800-220-2700
Fax: 281-474-2714 Fax: 615-672-8084 Fax: 856-228-5657 - Parts
aersupply.com marysvillemarine.com Fax: 856-228-5531 - Sales
jcummins@edi-dist.com

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