Boatmad Workshop Manual Drives 280 285 290

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Contents
Installing the sterndrive .............................................. Models 280 and 285 ............................................... Checking and adjusting controls ...................... Checking the retaining pawl when test running ........................................................ Oil filling ............................................................. Propeller installation ......................................... Installing a `long hub' type of propeller ........ Installing a `short hub' type of propeller ....... The duoprop (earlier model) ....................... Changing the direction of the propeller rotation .............................................................. The electro-mechanical sterndrive tilting device (model 280) .................................. Repair instructions ...................................... Reconditioning the tilting device ................. Model 290, SP and DP ........................................... Adjusting the retaining pawl (model 290) .......
.. Oil filling ............................................................. Propeller installation ......................................... Installing a `long hub' type of propeller ........ Installing a `short hub' type of propeller ....... Changing the direction of the propeller rotation .............................................................. Adjustment of the trim fin ................................... Twin engine installation .................................... Transom shield ............................................................ Changing trim cylinders, model 290, SP and DP ... Chanching steering helmet .................................... Removal ............................................................ Trim system ................................................................. Changing the sending unit ..................................... Changing the trim system gear rack ....................... Changing the trim system gear wheel .................... The power trim pump ......
........................................ Removing the trim pump from the boat ............. Removing the oil reservoir ................................ Replacing filters ................................................ Removing the electric motor ............................. 125 125 127 127 128 128 128 128 129 129 130 130 131 132 137 137 138 138 138 139 140 140 142 142 147 147 150 150 151 153 155 156 156 156 157 Installing the elctric motor ................................. Replacing adapter and pump assembly ........... The relief valve assemblies .............................. Installing the trim pump in the boat ................... Venting system .................................................. Test .................................................................... Adjusting the trim instrument .................................. Checking the trim figure .................................... Adjusting the trim figure .................................... Sterndrive extensions ...........................
..................... Installation instructions for 1" and 4" extensions .... The 4" extension ............................................... The 1" extension ............................................... Welding ......................................................................... Parts that cannot be welded ................................... Parts which can be welded ..................................... Repair instructions .................................................. 157 157 158 158 158 158 158 159 159 160 160 160 161 162 162 162 162

Painting ........................................................................ 163 Preparing the sterndrive ......................................... 163 Painting the underwater hull ................................... 163 Electrical wiring diagrams .......................................... Model 280 Tilting device ......................................... Model 280, Power trim ............................................ Model 290, Power trim (earlier model) ................... Models 290, SP and DP, Power trim (later model) .. 164 164 165 166 167

Technical data ............................................................. Models 280, 280T, 280PT, 285, 285A and 290 ...... Models 280-DP, 280-DP/PT, 290-DP and 290A-DP .......................................................... Models SP-A, SP-A1, SP-A2 and SP-C .................. Models DP-A, DP-A1, DP-A2, DP-B, DP-B1, DP-C and DP-C1 ....................................................

168 168 170 173 174

References to Service Bulletin .................................. 176

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Safety Information
Introduction
The Workshop Manual contains technical data, descriptions, and repair instructions for the designated Volvo Penta products or product versions. Make sure that the correct workshop literature is used. Read the following safety information and the General Information and Repair Instructions in the Workshop Manual carefully before starting service work. As a rule, all service work should be performed on an idle engine. Some work, e.g. certain adjustments, require the engine to be running. Approaching an engine that is running is a safety risk. Remember that loose clothes or long hair can fasten in rotating parts and cause severe injury. A careless movement or dropped tool while working in the vicinity of an engine that is running, can in the worst case lead to injury. Observe caution on hot surfaces (exhaust pipe, turbo, charge air pipe, starter element etc.) and hot fluids in the lines and hoses of an engine that is running, or has just been started. Refit all guards dismantled during service work before start
ing the engine. Make sure that the warning or information decals on the product are always clearly visible. Replace labels that have been damaged or painted over. Never start the engine unless the air filter is fitted. The rotating compressor wheel in the turbo can cause severe injury. Foreign objects in the inlet pipe can also damage the machine. Never use starter spray or the like. Explosion risk in the inlet pipe. Risk of personal injury. Avoid opening the coolant filler cap when the engine is hot. Steam or hot coolant can spray out, and built up pressure will be lost. Open the filler cap slowly and release the overpressure in the cooling system if the filler cap or cock must be opened, or if a plug or coolant pipe must be removed when the engine is hot. Steam or hot coolant can flow out in an unpredicted direction. Hot oil can cause burn injuries. Avoid skin contact with hot oil. Make sure that the oil system is not pressurised before working on it. Never start, or run the engine with the oil filler cap
removed in view of the risk of ejecting oil.

Important
The following special warning symbols are used in the Workshop Manual and on the product. WARNING! Warns of risk of bodily injury, serious damage to product or property, or that a serious malfunction can occur if the instructions are not followed. IMPORTANT! Used to attract attention to things that can cause damage or malfunction to product or property. NOTE! Used to attract attention to important information, to simplify work procedures or handling. The following list provides an overview of the risks and cautionary procedures that should always be observed. Prevent the engine from being started by disconnecting the power with the main switch (switches) and locking it (them) in disconnected mode before the service work is begun. Attach a warning sign in the cabin.

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General Information
Stop the engine and close the bottom valve before working on the cooling system. Only start the engine in a well-ventilated area. Exhaust fumes and crankcase gases should be led out of the engine compartment or workshop when working in closed environments. Always use protective glasses for work where there is a risk of splintering, sparks, or splashing of acid or other chemicals. The eyes are extremely sensitive, and an injury can cause blindness! Avoid skin contact with oil! Prolonged or frequent skin contact with oil can degrease the skin, resulting in irritation, drying out, eczema, and other skin complaints. Used oil is more dangerous than new oil from the health care point of view. Use protective gloves and avoid oil drenched clothes and rags. Wash your hands regularly, especially before meals. Use special hand cream to counteract drying out, and to simplify cleaning the skin. The majority of chemicals intended for the product (e.g. engine and timing gear oils, glycol, petrol and diesel oil) or chemical
s for workshop use (e.g. degreasing agent, enamels and solvents) are hazardous to health. Read the instruction on the pack carefully. Always follow the given safety instructions (e.g. the use of breathing protection, protective glasses, or gloves, etc.) Make sure that other personnel are not exposed to hazardous substances, e.g. by inhaling the air. Make sure there is adequate ventilation. Handle consumed and surplus chemicals in the prescribed manner. Observe extreme caution when tracing fuel leaks in fuel systems and when testing fuel nozzles. Wear protective glasses. The jet from a fuel nozzle has a very high pressure and penetrating force. The fuel can penetrate deeply into bodily tissue and cause serious injury. Risk of blood poisoning. All fuels, in similarity with chemicals, are inflammable. Make sure that naked flames, or sparks, cannot lead to ignition. Petrol, certain thinners, and hydrogen from batteries, are extremely inflammable and explosive when mixed with air. Smoking is prohibited! Ventilate
well and take the necessary precautions before conducting welding or grinding work in the immediate vicinity. Always have a fire extinguisher handy in the workshop. Make sure that rags drenched in oil and petrol, including old fuel and lubricant filters, are stored safety. Oil drenched rags can in certain conditions self-ignite. Old fuel and oil filters are environmentally hazardous waste, and together with spent lubricant, contaminated fuel, paint residue, solvent, degreasing agent and suds, should be handed in to a waste handling unit for destruction. Batteries must never be exposed to naked flames or electrical sparks. Never smoke in the vicinity of batteries. Hydrogen develops when batteries are charged, which in combination with air forms an explosive gas. This gas is highly inflammable and very explosive. One spark from connecting the batteries incorrectly is sufficient to cause the battery to explode and cause injury. Do not touch the connection when starting (risk of spark) and do not lean over the
batteries. Never confuse the plus and minus terminals when fitting the batteries. This can cause serious damage to the electrical equipment. Check the wiring diagram. Always use protective glasses when charging and handling batteries. The battery electrolyte contains strongly corrosive sulphuric acid. On skin contact, wash with soap and plenty of water. If battery acid gets into the eyes, rinse immediately with water, and contact a doctor without delay. Stop the engine and switch off the power with the main switch (switches) before working on the electrical system. Adjustment of the clutch should be conducted when the engine is idle.

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