OWNER MANUAL - Berkeley Jet Drive

E NG I NES P E CI F I CA T I O NS MODELS H205,H225, H260, H28OJCt MODELSH225,H260,H280V-Drive 14 tc 1. FlameArrestor 2. Carburetor 3 . Fu el Pum p Vent 4. Fuel Filter 5 " Oil FillerCap 6 . Fu el Line 7. Fuel Pu m p I n l e t 8. Fuel Pu m p 9. Water lnlet 10. Front Mount 11. Rear M o u n t ' t 2. O il Filt e r 13. ExhaustManifold Drain 14. ExhaustRiser 15. ExhaustOutlet 1 9 . E n g i n eSe r i a lN u m b e r 20. Starter 2 1 . O i l D i p sti ck 16. PCV Valve 17. Oil PressureSender 18. Alternator 22. Trans Oil Dipstick 23. Oil Drain Hose 24. Trans Oil Cooler

I E NG I NE S P E CI F I CA T I O NS MODELS H333,H405, V'DT VE MODELS H333, H4O5 JEt 1. FlameArrestor 2. Carburetor 3. F uelP u mpV e n t 4. F uelFi l te r 5. O il F i l l e rC a p 6. F uelL i n e 7. Fuel Pu m p I n l e t 8. Fuel Pu m p 9. Water Inlet 10. Fr ont M o u n t 11. Rear M o u n t 12. O il Filt e r 13.ExhaustManifold 14.ExhaustRiser 15.ExhaustOutlet 16.PCVValve S ender 17.Oi l P ressure 18.Alternator 19.E ngi n eSer ialNum be 20.Starter 21.Oi l D ipst ick 22.Oil DrainHose

E NG I NES P E CI F I CA T I O NS MODELSH260,H280TournamentSkier 1. FlameArrestor 2. Carburetor 3. FuelPumpVent 4. FuelFilter 5. Oil FillerCap 6. FuelLine 7. FuelPumpInlet 8. FuelPump 9. Waterlnlet 10.FrontMount 11.RearMount 12.Oil Filter MODELSH225,H260,H280,H333,H405 InboardFreshWater Gooling 13.ExhaustManifoldDrain 14.ExhaustRiser 15.ExhaustOutlet 16.PCVValve 17.Oil Pressure Sender 18.Alternator 19.EngineSerialNumber 20.Starter 21.Oil Dipstick 22.TrcnsOil Cooler 23.TransOil Dipstick 24.Oil DrainHose 25. HeatExchanger 26.RadiatorCap

ENG I NE S P E CI F I CA T I O NS M O D ELS H333,H405 Inboard lro n MODELS H400, H425,H430 Off Shore 4 8:" \ ,-. 'w i%*-15 2 Carb ur et or ir. Fue l Pum P Vent 4 Fu el Filt er B Fuel P u m P 9 W at e r l n l e t 10. Fr o n t M o u n t 1 1. Rea r M o u n t 5 OlFi ller CaP l ne 6 FLreLt 7 Fue l Pum P lnlet 12 O il F i l t e r 13. Ex h a u s tM a n i l o l d 14 Ex h a u s tR i s e r ( P i P e ) 1 Fla m eAr r es t or 1 5 . E x h a u s tO u t l e t 1 6 .P C V V a l v e 1 7 . O i l P r e s s u r eS e n d e r 1 8 .A l t e r n a t o r 1 9 . E n g r n eS e r r a lN u m b e r 20.Starter 2 '1. O i l D i P S t i c k 2 2 . Tr a n s Oi l D i PSti ck Tr a n s Oi l C o o l e r 2 4 . Oi l D r a i n H o se 2 5 Po w e r Ste e r i n gU n i t 2 6 Oi l C o o l e r 2 7 Th e r m o sta tH o u sl n g

OPERATING INSTRUCTIONS DO NOT OPERATESTARTERFORMORETHAN 15 SECONDSWITHOUT PAUSINGTO ALLOW STARTERMOTOR TO COOL FOR 2 MINUTES. FILLINGTHE FUELTANK CAUTION:GASOLINEVAPORSARE EXPLOSIVE. ALWAYSUSE SAFETYMEASURES WHENFUELING ANDSTARTING YOURENGINE. B. Boatr equlppedwith Foot Throtlle 1. Insurethat all electricalequipmentis turnedoff. 2. Extinguish all openflameand all smokingmaterial. 3. Thef illerhosenozzleshouldbein contactwiththefill pipeto prevent sparks. BEFORESTARTING '1. Gheckengine,transmission or outdrivefor properoil level. 2. Checkfuel supply. 3. Operatebilge blowerfor at least4 minutesprior to crankingthe engineto removeany possiblegasolinefumeslrom the engine compartment. 4. Checkthat all the engineandexhaustmanifolddrainplugson the engineare closedtight. STARTING A. Boals equlppedwlth slngle leyercontrol such aBMorse"MV-J" 1. Placeleverin neutraldetent. 2. Pull buttonout or pull outwardon leverto disengageshifter. 3. Pumpthrottleby movingshift leverfull foruardand returntwo or threetimesto primea coldengine.Do notpumpthrottleif engineis hot. Throttleshouldbe at idlewhen startingengine. 4. Turn ignitionkey to startand as soonas enginestarts,releasekey and allowswitchto returnto run position. 10 1. Placeshift leverin approximate neutralandplaceonehandon lever whilestarting.Thiswill enableyouto keepthe boatin neutralwhen the enginestarts. 2. Pumpthrottleas in an automobileto startcold engine. 3. Usestarterlimitationas listedpreviously. AFTERENGINESTARTS '1. Checkoil pressure - lt shouldbeat or above10lbs.at idleRPMon a cold engine. 2. Runengineat closeto idleuntila risein temperature canbedetected guage. on the temperature 3. Placethrottlein neutralandpushbuttonin to engageshiftcable.You are now readyto get underway. 4. Moveshift leverforwardto placedrivein forwardandas levercontinuesto moveforward,throttlewill be advanced. JETDRIVEENGINES MAYBERUNWITHBOATOUTOFWATER ONLY IF WATERIS SUPPLIED TO THE INLETWATERHOSEFORENGINE COOLING.DO NOT RUN OVER2OOO RPM OR FOR MORETHAN 1 MINUTEOR DAMAGEMAYOCCURIN THESEALAREAOF THEJET DRIVE.IF WATERIS NOT SUPPLIED TO THE ENGINEIT MAY BE STARTED, BUT SHOULDONLYBE ALLOWEDTO RUN FORA FEW SECONDS. DO NOTSTARTV-DRIVE, I/O ORDIRECTDRIVEENGINES WITHOUTA WATERSUPPLYAS DAMAGEMAY BE DONETO THE WATERPUMP.

OPERATING INSTRUCTIONS AWAY CAUTION: KEEP PASSENGERS FROM HEADERAT ALL TIMES. INJURY' lN SEVERE ieriune ro Do so couLD RESULT headersto keep ln short, allow only enough water to pass through blueing' from the rest of the chrome headerand engine at al Keep belongingsanctpassengersaway from times. Headers C. Boats equipped with Water lniected The Gate Valve: t. that you can regulatethe fn" g"t" u"fu" (see fig. 8) is necessaryso headers' the passes through amoJnt of water that Operatingthe Gate Valve: to headers' A. Turn valve clockwise to allow more water the amount of water restrict to clockwise counter valve Turn B. to headers. C.Ge ne ral r ulet olollow: Thef as t er t heboat s p e e d 't h e m o r e slower the boat the valve should be turned clockwise' The counter clockspeed, the more the valve should be turned wise. nose of boat is elevated' 3. When running boat on trailer, make sure this Procedure: Always follow OFF WATER' STOP START ENGINE,TURN ON WATER.TURN ENGINEON JE TS O NLY. equipped with an engine driven 4. For V-Drive engines or engines water PumPfollow this Procedure: TURN OFF TURN ON WATER,START ENGINE.STOP ENGINE, WATER. are also hot Water inlected headersare DRY and HOT at idle They f ittingand the the f irst'6 inchesout from the headto the water inlet chrome will blue to this Point' could Failureto do any of above,or if systemis not workingcorrectly o. DAMAGE' ENGINE result in SEVERE Figure 8 11 Gate V al v e

OPERATING INSTRUCTIONS OPERATING HINTSFORBOATOWNERS A. When launching your boat, do not back the trailer in at a fast pace and "hit the brakes" to "shoot the boat off the trailer". This launching tech nique could force water up the exhaustport and into the enginewhich could cause severedamage to the engine. The flappers in the exhaust ports and the risers on the exhaust manifold are designed to prevent this from happeningunder normal use. (Seefigure 9). B. lf your boat is a low profiletype boatwith an openenginecompartment, you should be awareof the "followingwake" of your boat when you are slowing down and the boat setiles back into the water as it comes off plane. A little nudge of power from your enginejust as the wake ap proachesthe stern of your boat will preventwater from splashingover the transom and into the engine compartment. C. Beforeturning your engine off, insurethe following: 1. The boatspeedis below2 MpH. Thiswillhelppreventthe,,following wake" from forcing water up the exhaust ports. 2. The engine is at idle. This will preventexhaustwater from being drawn into the manifoldsby a coastingengine. D. At full throttle and top boat speed a jet obtains water from 2" below the bottom of the boat. However, if full throtfle is suddenly applied at zero boat speed,a jet is capableof pulling in water and debrisfrom up to 6 feet below the jet intake.This is especiallytrue when operatingin reverse.Thereforewhen maneuveringyour jet boat in shallowwater (6 feet or less) do not use a large burst of power (above 1500RpM) unless you are gettingunderway.For propellerdriveboats,be sureto maintain an adequatedepth to preventfouling the propeller. FIG.9 NOTE: lf the engine should develop a hydro-static lock (water drawn into the cylinderthroughthe exhaustsystem)the followingsteps should be taken: 1. Loosenthe connectionbetweenthe exhaustriser and the exhaust manifold.This will allow any waterthat is trappedinsidethe exhaust chamberto drain out. Retightenthe riser. 2. Removeall spark plugs,removethe centerwireof the coil,and crank engine for 15 seconds. 3. Squirt approximately1 teaspoonof motor oil in each cylinderand crank engine again for 1Sseconds. 4. Replacespark plugs, re-installthe coil wire, and start engine. lf engine does not sound normal,do not continueto operateyour "-' engine until your Hardin Marine Dealer has checked it out thoroughly. 1T

OPERATING INSTRUCTIONS of the 10 hour break in period' 8. Change oil and filter at the end 9. Change fuel filter' P E R IOD ENG I N E1 OH O U RB R E A K -IN the factoryfor a short ne1i9O.ot All Hardinenginesnave beentest run at the systems'This is not to be all out time to make adjustmentsand check break-inis essentialto proper The engine. the of break-in considereda performanceand engine maximum and assumeminimumoil consumptio-n servlce. .10 checkfor oil pressure'leaks'proper 1. First minutes- ldle RPM and adiustment' control proper cooling, and RPM ' 2. Ne xt 15 minu tes- M inim um planning no sudden acceleration" with RPM 4O0O to 3. Next 35 minutes- Up to maximum RPM momentarily' up RPM Varied minutes 60 Next 4. with no sudden accelerations' of your engine'slile vary the 5. For the remainderot the first 10 hours accelerations throttle full RPM with no . in accordancewithnor6. Conduct 10 hour checkand operateengine l f ( a f t e r i n i t i a b r e a k - i n p e r i o d ) y o u w i s h t o o p e r a te yo u r e n g i n e a to r n e a the craft mav become Rpru'. in rough watei ionditions wherein r;-i;;; thata RPMLimiterbe installedon temporarilyair-borne,it is recommended RPM Limiterthat is available your engineto proteclVoutinu"ltt"nt' The RPM'This is onlyto preRated Maximum at is set i; ;;;t HardinDealer the enginesuddenly sho-uld RPM's vent the enginefrom go'ng ; e*ti"te a governorand the same be to designed not is unload under fullthrottle-it should be observed' RPM limitationsfor normal operation BE T I M E S H OYL D TH E EN GIN E CAUTION FOR HIGH RPM: AT NO ENRATING' MAXIMUM RPM OPERATEDBEYOND THE SPECITIED HIGH RPMWILL OF EXCESSIVELY NESUiT IJN WHICH FAILURE GINE WARRANTY. THE UNDER r.IOiAE REPAIRED ISAS FOLLOWS: MAXIMUM RECOMMENDEDRPM RPM H405-5000 RPM H205-4600 RPM H225-4400 mal Procedures' H26O-4400RPM H280-5000 RPM CAUTION: UNDERHEAVYLO A D S D U R I N G D O N OT PUL L SKIERSO RO PERATE PERI oD' inr ro Hou R BREAK - I N DURING BREAK'IN PERIOD OBSERVE INSTRUMENTSCAREFULLY npM n"iz-o- 'otio nisi-aooo npN'l npft'f Ff OO-SOOO RPM H425-5200 H43O-5200RPM INSTRUMENTS your enginegauge::Y:lll": A good habit to form is that of checking on the performanceol information of source minutes.They are the best your engine. oF ENGINE' oPERATIoN iol.rsune PRoPER Oil PressureGauqe 7. Also check for: a. Correct oil level b. ProPercooling c. Oil, water or fuel leaks d. Abnormalvibrationor noise nuts and clamps e. Loose mountings,fittings' bolts' eachtimethe engineis startedandat snoutooE-cnecked Oil pressure 3G40 is between Normaloil pressure timesdurinj operation' intermittent the engineis when RPM 900 at PSI at 1500nprr,t.rvriniirll'oiift"t"u'" throughlywarmis 10 PSI' 13

EN GIN E INSTRUMENTS WaterTemperatureGauge Tachometer The water temperature should be observedclosely during the break-in period. Normal operatingrange is from 120oFto180"F.Maximumoperation temperatureis 195oF. During break-inperiodspecialattentionshould be given to engine temperature at idle. lf necessary,idle the new engine higher than normal to provideadequatecooling during break-inperiod. This indicatesthe RPM at which the engine is running.A decreasein maximum RPM indicatesa loss of horsepowerf rom the engine and may be an indicationof needfor a tune.up.An increasefrom the normalmaximum RPMwould be an indicationthat the jet drive or V-drivemay not be f unctioning properly. Ammeter The ammeter indicatesthediflerence betweenalternatoroutput and current "draw". Should the ammeter indicate discharge when the engine is running above 1000RPM, haveyour dealercheck the circuit as soon as possible. Normal ammeter reading at averagecurrent draw is 20 amps at 1500RPM. Higher readingswill be seen if the battery has avery low charge. Voltmeter The Yourboatmaybeequippedwith a voltmeterin placeol anammeter. voltmeterindicatesbatteryand alternatorconditions.Withswitchon,the of 11to12volts.Duringnormalopvoltmeter indicates batteryconditions erationthe voltmetershouldindicate12.5to 14volts.Duringstarting,9.5 voltsis normal.Shouldvoltagedropto 7 whilecrankingor remainat 12 volts during normaloperationsee your HardinDealerfor an electrical checkup. 14 1 . Oil Pressure 2. Wator Tempoaature 3. Tachomatel 4. Ammeler or Voltmeter 5. Fuel Guage

-l EN GIN E L U B R ICATIO N E N G INEO IL Method A: Remove Oil Through the Oil Pan Drain Use only SF engineoil (SF oil meetsquality standardGM-6163GMand FMC-M2C101-C).lt is recommendedthat SAE 30 be usedat all times.The oil changeintervaland the new enginewarrantyare basedon the useof oil which meetsthese requirements.Oil conformingto thesestandardscontain detergentanti-wearadditives. 1. With coolantwater flowing through the engineand transmissionor jet drivein neutral:startengineand allowto reachnormaloperating temperaturebut do not run longerthan 5 minutes.Shut off engine. 2.Removeoil drain plug locatedin enginecrankcaseoil pan and drain oil in suitablecontainer.Replacedrain plug. NOTE: lf you are unableto drain the oil through the oil pan drain plug: removethe oil dip stick and pump the oil out of the enginevia a plastictube insertedin the dip stick tube. (See Figure 10) NON DETERGENTAND LOW QUALITY OILS ARE SPECIFICALLYNOT R E C OMMENDED.THE USE O F PRO PER ENG I NE O I L A N D O I L CHANGE INTERVALS IS EVEN MORE IMPORTANT IN A MARINE ENGINE DUE TO THE HIGHERLOADS AND RPM THAT CAN BE AP PLIED TO THE ENGINE FOR EXTENDEDPERIODSOF TIME. The oil and f ilter that were installedat the factoryshouldbe changedat the 10 hour inspection.Oil and filter changesshould be made every 50 hours of operationor every 60 days thereafter,whicheveroccurs first. ENG I N EO I L D R A IN IN GP R OC E D U R E There are two basic procedureswhich can be used for draining or removing oil from the engine'scrankcase. 15 N O T E : B e g i n n i n gi n 1 9 8 5a l l H a r d i nE n g i n e swi l l b e e q u i p p e dw i th a n o i l drain hose.To drain the oil on these enginessimply removethe brasscap at the end of the hose and drain in to a suitablecontainer. 3. Removethe oi I f ilter.Coatsealon f aceof newli lterwith cleanengine oil and installnew filter. Tighten 2/3turn past finger tight. 4. Pour fresh oil into engine through filler cap on top of engine (sAE 30) 5. Startengineand tu rn on water.Checkfor oil pressure and run at idle for 2 minutes.Check for leaks. 6. Stop engineand checkoil levelwith oil dip stick.Add oil if necessar to bring level up to the full mark. When checking oil level,the engine should be near level,the dip stick pusheddown fully and sufficienttime should be allowedfor the oilto drain back into the oil pan area.

ENGINE LUBRICATION OIL PAN PLUGSMUSTBE TORQUEDTO 25 FT. LBS.TO PREVENTWATER D I L UT IONOF OIL . Figure 1 0 Figure1 1 Method B: Remove Oil Through Oil PressureFitting at Front of Engine '1.With coolantwaterflowingto engineand transmissionor let drivein neutral:start engineand allow to reach normal operatingtemperature, but not longer than 5 minutes.Shut off engine. 6. Removeoil f ilter.Coat sealon face of new f ilterwith cleanengineoil or greaseand installnew filter.Tighten2/3Iurn pastf ingertight.Reinstalloil pressurefitting. 7 . P o u r f r e s h o i l i n t o e n g i n e t h r o u g h f i l l e r c a p o n to p o f e n g i n e (SAE 30) 2. Removeoil pressuresender from engine block. 3. Installa threaded nipple into the senderfitting. (see Figure 11) B.Startengineand turn on water.Check for oil pressureand run at idle f o r 2 m i n u t e s .C h e c k f o r l e a k s . 4. Installrubber hose over nipple and placeother end into an oil drain oan. 5. Start engineand run at 1000RPM until oil stops runningout rubber hose.Normally,this takesabout 25seconds.In all cases,do not run enginefor more than 60 secondswith oil pressuresenderremoved. A n o p t i o n a lo i l f i l t e r r e l o c a t o rw h i c h a i d s i n t h e r e m o va lo f th e o i l fi l te r a n d a n o i l d r a i n k i t a r e a v a i l a b l eA. s k y o u r H a r d i nD e a l e r fo r tu r th e r d e ta i l s. N O T E : Ru nn ingpro ce du r ef or J et Dr iv e Engines : S T ARTENGINE,TURNO N W ATER.TURNO FFW ATERS , TOP E NGINE. 16 N O T E :R u n n i n gp r o c e d u r ef o r V - D r i v e 'Ou t D r i veo r En g i n eD r i ve n Wa t e r P u m P E n g i n e s . T U R N O N WA T E R ,S T A R TE N G I N E.SIOP EN GIN E,TU R NOFF WA T E R .

ENG INE LUBRICATION valve rocker cover. Should this filter become plugged, blow-by fumes would be condensedin the crankcase,resultingin the formationof acid s l u d g e b u i l d - u p ,o i l d i l u t i o n ,o i l b l o w - b y ,h i g h ero i l co n su m p ti o na n d r u st Any of these conditionscould shortenthe life of your Hardinengine.To preventthis, removethe filter at each oil changeand wash in solvent,re-oi lightly with clean engine oil and replace. U N IVER SALJOINT Use a hand greasegun at the Zerk fittingson each crossof the universal joint. Do not overgreasethese as the seals may be damagedby excess grease. Use a .l50 weight EP2 automotive chassistype grease,but do not use a high pressuregun such as that used in a servicestation. Figure 12 Figure13 Figure 14 Figure 15 THROTTLECABLE PCVValve SprayWD40or light weight oil on exposedend of the th rottlecableat the engine end and work the cable in and out to lubricate. A positivecrankcaseventi

1. Check for oil, fuel or water leaks. 2. Drain oil and replace f ilter.(see oil change). pg. 15-17 3. Check and re{ighten engine mount bolts. 4. Check fuel line f ittings for tightness. 5. Check hose clamPs and hoses. 6. Check the alternator belt for correct tension' 7. Check throttle linkage. B. Check the flame arrestor' 9. Check the fuel .