ILMOR One-Drive User manual

MARINE ENGINES
ONE-DRIVE
OWNER’S
MANUAL

© 6/2016 Ilmor Marine Engines, Version 1.0
CALIFORNIA PROPOSITION 65 WARNING
Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the
State of California to cause cancer and reproductive harm. Wash hands aer handling.
DISCLAIMERS
All information, illustrations and specications in this manual are based on the latest information available
at the time of publishing. e illustrations used in this manual are intended as representative reference
views only. Moreover, because of our continuous product improvement policy, we may modify information,
illustrations and/or specications to explain and/or exemplify a product, service or maintenance
improvement. We reserve the right to make any change at any time without notice.
ALL RIGHTS RESERVED
No part of this publication may be reproduced or used in any form by any means - graphic, electronic,
or mechanical, including photocopying, recording, taping, or information storage and retrieval systems -
without written permission.

© 6/2016 Ilmor Marine Engines, Version 1.0 i
INTRODUCTION
Ilmor Marine Engines is pleased to welcome you to boating enjoyment
available only through use of the extraordinary Ilmor engines and drives.
Ilmor is a recognized leader in the marine industry, having originated
through championship-caliber, high-performance engines. Our experience
inevitably led to the development of the MV8, oering 6.0 and 6.2 versions,
and the One-Drive sterndrive system. e MV8 and One-Drive together
provide the kind of horsepower necessary to plane with pulse-pounding
quickness while equally ensuring the reliability and smoothness necessary
for just-above-idle investigation of interesting coves and shorelines.
It’s all here.
Ilmor stern-drives are designed for a wide range of applications and are
designed to reduce vibration and make your cruising more pleasurable.
To help you enjoy your Ilmor Marine products for many years to come,
please follow these recommendations:
• Read and understand this Owner’s Manual before you operate
your vessel to ensure that safe operating practices and maintenance
procedures are followed.
• Keep this Owner’s Manual in a convenient place for easy access.
• If this Owner’s Manual is lost or damaged, order a new one from your
authorized Ilmor Marine dealer or distributor.
• Make sure this manual is transferred to subsequent owners. is manual
should be considered a permanent part of the vessel and remain with it.
• Constant eorts are made to improve the quality and performance of
Ilmor products, so some details included in this Owner’s Manual may
dier slightly from your stern-drive. If you have any questions about
these dierences, please consult your authorized Ilmor Marine dealer or
distributor.

ILMOR ONE-DRIVE OWNER’S MANUAL
ii © 6/2016 Ilmor Marine Engines, Version 1.0
RECORD OF OWNERSHIP
Take a few moments to record the information you need when you contact
Ilmor for service, parts or literature.
Stern-Drive Model: ___________________________________________
Stern-Drive Transom Assembly Serial No.: ________________________
Stern-Drive Unit Serial No.: ____________________________________
Stern-Drive Gear Ratio:________________________________________
Date Purchased: ______________________________________________
Engine Model: _______________________________________________
Engine Horsepower: __________________________________________
Propeller Number: ____________________________________________
Propeller Pitch: ______________________________________________
Propeller Diameter: ___________________________________________
Hull Identication Number (HIN): ______________________________
Boat Manufacturer: ___________________________________________
Boat Model: _________________________________________________
Dealer: _____________________________________________________
Dealer Phone:________________________________________________

© 6/2016 Ilmor Marine Engines, Version 1.0 iii
TABLE OF CONTENTS
TABLE OF CONTENTS
INTRODUCTION ....................................................................i
RECORD OF OWNERSHIP.....................................................................ii
SAFETY................................................................................ 11
SAFETY PRECAUTIONS .....................................................................12
General Information..........................................................................1-2
Before You Operate............................................................................1-2
During Operation and Maintenance ...............................................1-2
PRODUCT OVERVIEW ..................................................... 21
OVERVIEW..............................................................................................21
Owner/Operator Responsibilities ....................................................2-1
New Stern-Drive Break-In ................................................................2-1
Dealer/Distributor Responsibilities .................................................2-2
COMPONENT IDENTIFICATION.....................................................22
Location of Serial Numbers ..............................................................2-3
CORROSION PROTECTION ...............................................................24
Galvanic Corrosion............................................................................2-4
Corrosion Control .............................................................................2-4
Shore Power........................................................................................2-5
Underwater Drive Coating ...............................................................2-5
Additional Protection........................................................................2-6
Gear Housing Anodic Plates.............................................................2-7
Ventilation Plate Anode ....................................................................2-7
Trim Cylinder Anodes.......................................................................2-7
Propeller Sha Anode .......................................................................2-8
FEATURES AND CONTROLS .............................................................29
Remote Controls ................................................................................2-9
Power Trim .........................................................................................2-9
Stern-Drive Trim Angle ..................................................................2-10
Trim and Tilt/Trailering Switch .....................................................2-10
Electrical System ..............................................................................2-11
Ilmor Cathodic Protection System.................................................2-11
STERNDRIVE OPERATION............................................. 31
PROPELLER SELECTION.....................................................................31
INSTALLING THE PROPELLERS .......................................................32
REMOVING THE PROPELLER ...........................................................33
DAILY CHECKS......................................................................................34
Visual Checks ....................................................................................3-4
Check the Stern-Drive Oil Level ......................................................3-4
Check the Power Trim Pump Fluid .................................................3-7

ILMOR ONE-DRIVE OWNER’S MANUAL
iv © 6/2016 Ilmor Marine Engines, Version 1.0
MAINTENANCE ................................................................. 41
PERIODIC MAINTENANCE ...............................................................41
e Importance of Periodic Maintenance.......................................4-1
Performing Periodic Maintenance...................................................4-1
e Importance of Daily Checks......................................................4-1
Ilmor Replacement Parts...................................................................4-1
Tools Required ...................................................................................4-2
Ask Your Authorized Ilmor Marine Dealer or Distributor
for Help ...............................................................................................4-2
TIGHTENING FASTENERS .................................................................42
TORQUE CHARTS .................................................................................42
Standard Torque Values.....................................................................4-2
Torque Specications.........................................................................4-2
PERIODIC MAINTENANCE TABLE..................................................43
GENERAL INSPECTION ......................................................................44
POWER TRIM PUMP FLUID...............................................................45
PERIODIC MAINTENANCE PROCEDURES...................................45
Weekly .................................................................................................4-5
Aer Initial 50 Hours of Operation.................................................4-6
Every 50 Hours of Operation............................................................4-7
Every 100 Hours of Operation..........................................................4-7
Every 150 Hours of Operation........................................................4-11
Every 250 Hours of Operation........................................................4-11
Every 1000 Hours of Operation .....................................................4-17
Every Year .........................................................................................4-18
Every 2 Years.....................................................................................4-19
TROUBLESHOOTING ....................................................... 51
LONGTERM STORAGE .................................................... 61
COLD WEATHER FREEZING TEMPERATURE,
SEASONAL AND EXTENDED STORAGE.........................................61
Stern-Drive Lay Up............................................................................6-1
Stern-Drive Recommissioning .........................................................6-2
SPECIFICATIONS............................................................... 71

© 6/2016 Ilmor Marine Engines, Version 1.0 1-1
Section 1
SAFETY
Ilmor considers safety of great importance and recommends that anyone
that comes into close contact with its products, such as those who install,
operate, maintain or service Ilmor products, exercise care, common sense
and comply with the safety information in this manual and on the engine
and stern-drive’s safety labels. Keep the labels from becoming dirty or torn
and replace them if they are lost or damaged. Also, if you need to replace
a part that has a label attached to it, make sure you order the new part and
label at the same time.
is safety alert symbol appears with most safety statements. It
means attention, become alert, your safety is involved! Please read
and abide by the message that follows the safety alert symbol.
ADANGER indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
AWARNING indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
ACAUTION indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
NOTICE indicates a situation which can cause damage to the machine,
personal property and/or the environment or cause the equipment to
operate improperly.

SECTION 1 ILMOR ONE-DRIVE OWNER’S MANUAL
1-2 © 6/2016 Ilmor Marine Engines, Version 1.0
SAFETY PRECAUTIONS
General Information
ere is no substitute for common sense and careful practices. Improper
practices or carelessness can cause burns, cuts, mutilation, asphyxiation,
other bodily injury or death. is information contains general safety
precautions and guidelines that must be followed to reduce risk to personal
safety. Special safety precautions are listed in specic procedures. Read and
understand all of the safety precautions before operation or performing
repairs or maintenance.
Before You Operate
WARNING!
• Never permit anyone to install or operate the engine
or stern-drive without proper training.
• Read and understand this Owner’s Manual before
you operate or service the engine or stern-drive to
ensure that you follow safe operating practices and
maintenance procedures.
• Safety signs and labels are additional reminders for
safe operating and maintenance techniques.
• Consult your authorized Ilmor Marine dealer or
distributor for additional training.
During Operation and Maintenance
ADANGER! FIRE HAZARD! Ensure that appropriate fire
detection and extinguishing equipment are installed
and checked periodically for proper operation.
ADANGER! CRUSH HAZARD!
• Always use lifting equipment with sufficient capacity
to lift the stern-drive.
• Never stand under a hoisted stern-drive. If the hoist
mechanism fails, the stern-drive will fall on you,
causing serious injury or death.
• Never support the stern-drive with equipment not
designed to support the weight of the stern-drive
such as wooden pieces, blocks or by only using a
jack.

© 6/2016 Ilmor Marine Engines, Version 1.0 1-3
SAFETY
WARNING! EXPLOSION HAZARD! While the engine
is running or the battery is charging, hydrogen gas
is being produced and can be easily ignited. Keep
the area around the battery well-ventilated and keep
sparks, open flame and any other form of ignition out
of the area.
WARNING! FIRE HAZARD! Undersized wiring systems
can cause an electrical fire.
WARNING! SEVER HAZARD!
• Never service the stern-drive while under tow or if
the engine is running at idle speed. The propeller
may rotate under these circumstances.
• If the vessel has more than one engine, never
service a stern-drive if either of the engines are
running. In multi-engine configurations, the
propeller for an engine that is shut down may rotate
if any of the other engines are running.
• Rotating parts can cause severe injury or death.
Never wear jewelry, unbuttoned cuffs, ties or loose-
fitting clothing, and always tie long hair back when
working near moving/rotating parts such as the
flywheel or PTO shaft. Keep hands, feet and tools
away from all moving parts.
• To prevent accidental equipment movement, never
start the engine in gear.
• Before starting the engine, always make sure that all
bystanders are clear of the area. Keep children and
pets away while the engine is operating.
• Always remove any tools or shop rags used during
maintenance from the area before operation.
• Stop the engine before you begin to service the
stern-drive and secure the propeller so it will not
turn.
WARNING! ALCOHOL AND DRUG HAZARD! Never
operate the engine while under the influence of
alcohol or drugs or when feeling ill.

SECTION 1 ILMOR ONE-DRIVE OWNER’S MANUAL
1-4 © 6/2016 Ilmor Marine Engines, Version 1.0
WARNING! EXPOSURE HAZARD! Always wear personal
protective equipment including appropriate clothing,
gloves, work shoes, eye and hearing protection as
required by the task at hand.
WARNING! ENTANGLEMENT HAZARD!
• Never leave the key in the key switch when servicing
the engine or stern-drive. Someone may accidentally
start the engine and not realize you are servicing it.
• Never operate or service the engine while wearing
a headset to listen to music or the radio because it
will be difficult to hear the warning signals.
WARNING! BURN HAZARD! Some of the engine and
stern-drive surfaces become very hot during operation
and shortly after shutdown. Keep hands and other
body parts away from hot surfaces.
WARNING! EXHAUST HAZARD!
• Never block windows, vents, or other means of
ventilation if the engine is operating in an enclosed
area.
• All internal combustion engines create carbon
monoxide gas during operation and special
precautions are required to avoid carbon monoxide
poisoning.
WARNING! ELECTRICAL SHOCK HAZARD!
• Always turn off the battery switch (if equipped)
or disconnect the negative battery cable before
servicing the equipment.
• Always keep the electrical connectors and terminals
clean. Check the electrical harnesses for cracks,
abrasions, and damaged or corroded connectors.
ACAUTION! POOR LIGHTING HAZARD! Ensure that the work area
is adequately illuminated. Always install wire cages on portable
safety lamps.
ACAUTION! TOOL HAZARD! Always use tools appropriate for
the task at hand and use the correct size tool for loosening or
tightening machine parts.

© 6/2016 Ilmor Marine Engines, Version 1.0 1-5
SAFETY
ACAUTION! FLYING OBJECT HAZARD! Always wear
eye protection when servicing the stern-drive or when
using compressed air or high-pressure water. Dust,
flying debris, compressed air, pressurized water or
steam may injure your eyes.
ACAUTION! SLIPPING AND TRIPPING HAZARD!
• Ensure that adequate floor space is set aside for servicing the
stern-drive. The floor space must be flat and free of holes.
• Keep the floor free of dust, mud, spilled liquids and parts to help
prevent slipping and tripping.
NOTICE: It is important to perform the daily checks as listed in this
Owner’s Manual.
NOTICE: Periodic maintenance prevents unexpected downtime,
reduces the number of accidents due to poor engine or stern-drive
performance and can help extend the life of the engine and
stern-drive.
NOTICE: Always be environmentally responsible.
Follow the guidelines of the EPA or other governmental
agencies for the proper disposal of hazardous materials
such as lubrication oil, diesel fuel and engine coolant.
Consult the local authorities or reclamation facility.
NOTICE: Never dispose of hazardous materials by dumping them into a
sewer, on the ground or into ground water or waterways.
NOTICE: Before operating the engine, check stern-drive oil level.
NOTICE: If the stern-drive oil temperature is too high, stop engine
immediately and check the stern-drive oil level and check the oil cooler
for proper coolant and water flow.
Always tighten components to the specified torque. Loose parts can
cause equipment damage or cause it to operate improperly.
NOTICE: Only use replacement parts specified. Other replacement
parts may affect warranty coverage.

SECTION 1 ILMOR ONE-DRIVE OWNER’S MANUAL
1-6 © 6/2016 Ilmor Marine Engines, Version 1.0
NOTICE: Never attempt to modify the stern-drive’s design or safety
features.
Failure to comply may impair the stern-drive’s safety and performance
characteristics and shorten the stern-drive’s life.Any alterations to this
stern-drive may affect the warranty coverage of your stern-drive.
NOTICE: Never use the stern-drive lifting eye to lift the engine and
stern-drive as an assembly. Use the engine lifting eyes to lift the engine
and stern-drive. Only use the stern-drive lifting eye to lift the stern-drive
as a separate component.
NOTICE: The anode of the stern-drive is only calculated for the stern-
drive. Changing the material of the propeller may require additional
anodes to be installed on the stern-drive.
NOTICE: Anytime the boat is left in the water and the engine is not
running, the drive must be left in the fully down position.This will keep
the anodes in the water and will keep the exhaust pipe engaged with
the exhaust port of the drive.

© 6/2016 Ilmor Marine Engines, Version 1.0 2-1
Section 2
PRODUCT OVERVIEW
OVERVIEW
Owner/Operator Responsibilities
e operator must, and assumes all responsibility to:
• Read and understand the operation manual prior to operating the stern
drive;
• Perform all safety checks as necessary to ensure safe operation;
• Comply with and follow all lubrication and maintenance instructions
and recommendations; and
• Have an authorized Ilmor Marine dealer/distributor perform periodic
checkups.
Conducting normal maintenance service and replacing consumable parts
as necessary is the responsibility of the owner/operator and necessary to
provide the best durability, performance and dependability of the stern
drive while keeping your overall operating expenses to a minimum.
Individual operating habits and usage may increase the frequency of
performing maintenance service condition. Monitor conditions frequently
to determine if the maintenance intervals suggested in the manual are
frequent enough for stern drive.
NOTICE: The anode of the stern-drive is only calculated for the stern-
drive. Changing the material of the propeller may require additional
anodes to be installed on the stern-drive.
New Stern-Drive Break-In
• On the initial engine start-up, allow the engine to idle for approximately
15 minutes while you check for proper stern-drive function and stern-
drive oil leaks.
• During the break-in period, carefully observe stern-drive indicators (if
any) for proper stern-drive function.
• During the break-in period, check the stern-drive oil levels frequently.

SECTION 2 ILMOR ONE-DRIVE OWNER’S MANUAL
2-2 © 6/2016 Ilmor Marine Engines, Version 1.0
Dealer/Distributor Responsibilities
In general, a dealer’s responsibilities to the customer include predelivery
inspection and preparation such as:
• Ensure that the vessel is properly equipped.
• Prior to delivery, make certain that the Ilmor stern-drive and other
equipment are in proper operating condition.
• Make all necessary adjustments for maximum eciency.
• Familiarize the customer with the on-board equipment.
• Explain and demonstrate the operation of the stern-drive and vessel.
COMPONENT IDENTIFICATION
Steering system
location
Transom assembly
Drive unit
Antiventilation
plate
Trim cylinder
I-CaPS electrode
Figure 2-1

© 6/2016 Ilmor Marine Engines, Version 1.0 2-3
PRODUCT OVERVIEW
Location of Serial Numbers
e serial numbers are the manufacturer’s keys to numerous engineering
details which apply to your Ilmor stern-drive. When contacting Ilmor
about service, always specify model and serial numbers.
Transom assembly serial number
Drive unit
serial
number
Figure 2-2

SECTION 2 ILMOR ONE-DRIVE OWNER’S MANUAL
2-4 © 6/2016 Ilmor Marine Engines, Version 1.0
CORROSION PROTECTION
Galvanic Corrosion
Galvanic corrosion results whenever two or more dissimilar metals (like
those found on the stern-drive) are submerged in a conductive solution,
such as saltwater, polluted water or water with a high mineral content
because a chemical reaction takes place causing electrical current to ow
between the metals. e electrical current ow causes the metal that is
most chemically active, or anodic, to erode. If not controlled, galvanic
corrosion may corrode stern-drive components.
NOTICE: The anode of the stern-drive is only calculated for the stern-
drive. Changing the material of the propeller may require additional
anodes to be installed on the stern-drive.
Corrosion Control
It is the boat designer’s responsibility and/or the re-powering engineer’s
responsibility to design the proper systems and equipment to control and
reduce the possibility of galvanic corrosion.
To help control the eects of galvanic corrosion, Ilmor Marine One-Drive
stern-drives come with several anodes and an electronic anticorrosion
system (I-CaPS) that protect the stern-drive in moderate corrosive
conditions. However, it is essential that the owner/operator frequently
monitor the anodes for wear, inspect the stern drive for corrosion and
replace the anodes oen enough to provide a sacricial surface for the
electrical current to attack. Galvanic isolators are also available from
the aermarket (not supplied by Ilmor) to block stray current while still
providing a path to ground for dangerous shock currents.
e rate of corrosion depends on numerous factors, such as:
• e number, size and location of anodes on the stern-drive and vessel;
• e marina environment such as stray current in the water, fresh or salt
water and use and isolation of shore power;
• Improper application of marine paint or antifouling paint;
• Failure to repaint damaged areas; and
• How the vessel is bonded.
Please check with the boat builder, dealer or other professional to
determine if your vessel and/or stern drive is adequately protected from
galvanic corrosion.
If anodes erode quickly or if signs of corrosion are evident, the owner
should take immediate corrective action. Ilmor recommends consulting
an engineer specializing in marine electricity and corrosion control to
determine the best way to correct the rapid erosion of the anodes.

© 6/2016 Ilmor Marine Engines, Version 1.0 2-5
PRODUCT OVERVIEW
Shore Power
Vessels that are connected to shore power require additional protection
to prevent destructive low voltage galvanic currents from passing through
the shore power ground wire. Galvanic isolators are available from the
aermarket (not supplied by Ilmor) to block these currents while still
providing a path to ground for dangerous shock currents.
NOTICE: If the AC shore power ground is not isolated from the boat
ground, the I-CaPS and anodes may be unable to neutralize the
increased galvanic potential. Corrosion damage that results from the
improper system design or application is not covered by the Ilmor
limited warranty.
Underwater Drive Coating
e lower gear case coating may be damaged when hit by objects in the
water, or when having deposits removed from it. e underwater coating
must be inspected at least once per year and when it is believed that an
object was hit that may have caused damage. Repair and repaint damaged
areas immediately.
Observe the following precautions when applying antifouling or marine
paint to the transom of the boat hull:
• Always follow the paint/coating manufacturer’s directions for surface
preparation and application.
• Always use a high quality primer and topcoat paint specically designed
for aluminum outboards or stern-drives.
• Never paint the anodes installed on the stern-drive.
• Never paint the I-CaPS reference electrode and/or anode.
• Never wash the stern-drive with a high pressure washer. is could
damage the coating on the reference wire.
• Never paint the stern-drive with a material that contains copper or tin.
• Never paint over drain holes, anodes, I-CaPS or other items specied by
the anode manufacturer.
Consult your authorized Ilmor Marine dealer or distributor for assistance.
NOTICE: Galvanic corrosion damage, normal maintenance and
consumable parts are not covered by the Ilmor limited warranty.

SECTION 2 ILMOR ONE-DRIVE OWNER’S MANUAL
2-6 © 6/2016 Ilmor Marine Engines, Version 1.0
Additional Protection
In addition to the corrosion protection devices, take these steps to inhibit
corrosion:
1. Paint the stern-drive. See Touching-Up the Stern-Drive Paint and Spray
with Corrosion Guard on page 4-11.
2. Spray stern-drive components on the inside of the vessel annually
with corrosion guard to protect the nish from dulling and corrosion.
External stern-drive components may also be sprayed.
3. Keep all lubrication points, especially the steering system, shi and
throttle linkages, well-lubricated.
4. Flush the coolant system periodically, preferably aer each use.
NOTICE: Replace anodes if eroded 50 percent or more.
NOTICE: Anytime the boat is left in the water and the engine is not
running, the drive must be left in the fully down position.This will keep
the anodes in the water and will keep the exhaust pipe engaged with
the exhaust port of the drive.
Trim cylinder anodes
I-CaPS
electrode
Ventilation
plate anode
Propeller shaft
anodes
Gear
housing
anodic
plates
Figure 2-3

© 6/2016 Ilmor Marine Engines, Version 1.0 2-7
PRODUCT OVERVIEW
Gear Housing Anodic Plates
e gear housing anodic plates (Figure 2-4, 1) are installed on the
underside of the antiventilation plate.
1
Figure 2-4
Ventilation Plate Anode
e ventilation plate anode (Figure 2-5, 1) is installed on the front of the
drive sha housing on top of the ventilation plate.
1
Figure 2-5
Trim Cylinder Anodes
e trim cylinder anodes (Figure 2-6, 1) are installed on each trim cylinder.
1
Figure 2-6

SECTION 2 ILMOR ONE-DRIVE OWNER’S MANUAL
2-8 © 6/2016 Ilmor Marine Engines, Version 1.0
Propeller Shaft Anode
e propeller sha anode (Figure 2-7, 1) is located behind the a
propeller.
1
Figure 2-7