MasterCraft Prostar Series User manual

Welcome Aboard
Congratulations on your choice of the finest
ski boat available! MasterCraft is the recognized
world leader for in-board ski boats today and has been for
more than 35 consecutive years.The quality, innovation,
selection and value are unmatched in the industry.
Please take a few minutes to read this manual
completely before the use of your MasterCraft boat for the
first time. It will help you answer most of the remaining questions
you may have about your new boat. If you still have questions after
reviewing this manual, be sure to contact your MasterCraft dealer.
It is important for you to approach your boating experience with confidence
and as much knowledge as you can.
Every effort has been made to make this manual accurate.
All information is based on the latest product information available at the time of
printing. Because of our policy of continuous product improvement, we reserve the right
to make changes in specifications and models at any time, without notice, and also to discontinue
models.The right is also reserved to change specifications, parts or accessories at any time without
incurring any obligation to equip the same on models manufactured before the date of the change.
The continuing accuracy of this manual cannot be guaranteed.The illustrations used in this manual are
intended only as representative reference views and may not depict actual model component parts.
Information about certain on-board components furnished by suppliers other than MasterCraft
is provided separately.This information is available from your dealer.
Note:The information given in this manual may not be applicable to international waterway rules.
If you have any questions, please contact your local authority.
Visit us on the web at www.mastercraft.com. If you have specific questions about your
MasterCraft boat or trailer, feel free to contact your dealer for additional information and guidance.
MasterCraft Boat Company, 100 Cherokee Cove Drive, Vonore TN 37885
The maintenance, service and repair procedures
described in this Manual should be performed only by
trained and authorized factory personnel or dealer
technicians.To avoid serious injury or damage to the boat or
its components, all steps in each procedure and all safety
recommendations should be strictly observed. Failure to
follow the procedures described will void any and all
warranties and may cause personal injury or damage to
components and adversely affect the operation of the boat.
CONSUMERS SHOULD NEVER ATTEMPT TO UNDERTAKE
THE MAINTENANCE AND REPAIR PROCEDURES
DESCRIBED IN THIS MANUAL.

Dangers, Warnings and Cautions
Throughout this manual the terms “danger,” “warning” and “caution” appear, alerting the boat owner or
operator to dangerous or potentially dangerous situations that may arise. Those terms have the following respec-
tive meanings whenever they appear herein:
Failure to adhere to and comply with the safety dangers, warnings and cautions that appear in this manual can
lead to serious illness, injury or even death and/or damage to your boat or the property of others. Beyond these
warnings, boaters have a personal responsibility to utilize a common sense approach to the boating experience,
including keeping individuals off or near the swim platform and the stern area of the boat during the engine
operation. Personal flotation devices (“PFDs”) save lives and ensure positive experiences. MasterCraft offers many
proactive approaches to the boating experience, but the consumer is ultimately responsible for a positive and safe
involvement in boating.
Be sure to review the Boating Safety section of this manual, which immediately follows this section. Because of
the importance of these dangers, warnings and cautions, they are reprinted here, along with the pages on which
you’ll find them. Please note that the safety information statements presented below are categorized for informa-
tion purposes only, and are not presented in any particular order of importance. Each of the statements refer-
enced below and in the other sections of this manual provide you with important safety-related information and
must be read and followed to avoid injury or damage, as applicable. We strongly encourage your to cross-
reference and read the dangers, warnings and cautions within the context in which they are presented by reading
and reviewing those sections.
1: Failure to comply with safety-related information and instruction may result in serious injury or death to
you and/or others. Always use common sense when operating the boat or participating in any activities
associated with the boat. (Page 1-3)
i
This is the safety alert symbol. It is used to alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid possible injury or death.
DANGER indicates an imminently hazardous situation which,
if not avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation which,
if not avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if
not avoided, may result in minor or moderate injury.
CAUTION used without the safety alert symbol indicates a
potentially hazardous situation which, if not avoided, may
result in property damage.
DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
WARNINGS AND CAUTIONS

2: Gasoline is highly flammable and its vapors may ignite resulting in fire or explosion. Be sure to keep all
sparks and flames well away from the area while inspecting the boat’s fuel system. (Page 17-7)
3: Gasoline is explosive. If you see or smell the presence of gasoline during your inspection, DO NOT
START YOUR ENGINE! Remove your ignition key from the ignition switch and call your MasterCraft
dealer for service. (Page 19-8)
4: Gasoline is extremely flammable and highly explosive under certain conditions. Always stop the engine and
never smoke or allow open flames or sparks within 50 feet of the fueling area when refueling. (Page 8-2)
5: Take care not to spill gasoline. If gasoline is spilled accidentally, wipe up all traces of it with dry rags
immediately and properly on shore. (Page 8-2)
6: Failure to operate the blower as instructed could cause improper ventilation of the boat engine and
bilge areas. Fuel vapors can accumulate in this area and cause a fire or explosion which may result in
serious injury or death! (Page 7-3)
7: To prevent a possible explosion,operate the blower for at least four (4) minutes before starting the engine
and always when at idle or slow-running speed. Explosive gasoline and/or battery fumes may be present in
the engine compartment. Failure to do so may result in serious injury or death! (Page 11-1)
8: Carbon monoxide is a colorless, tasteless, odorless and poisonous gas that accumulates rapidly and can
cause serious injury or death. Exposure to carbon monoxide can be fatal in a matter of minutes.
Exposure to even low concentrations of carbon monoxide must not be ignored because the effects of
expsoure to carbon monoxide are cumulative and can be just as lethal as at high concentrations.
Carbon monoxide from exhaust pipes of inboard or outboard engines may build up inside and outside
the boat in areas near exhaust vents.STAY AWAY from these exhaust vent areas, which are loacted at
the stern of the boat,and DO NOT swim or engage in any watersports or other activties in or near the
stern area of the boat, including, without limitation, the swim platform and the rear sun deck, when the
engine is in operation. Under no circumstances should “teak surfing” or similar activities be performed
during the operation of your MasterCraft boat–such activities are a misuse of this product. (Page 24-1)
9: The safety switch lanyard must be attached to the operator whenever the engine is started. Failure to do
so may result in serious injury or death. (Page 7-3)
10: Never override or modify the engine safety shut-off switch or engine neutral starting safety switch in any
way. (Page 1-3)
11: Before starting the engine, open the engine compartment and check for gasoline fumes, fuel and oil leaks
or the presence of fuel or oil in the bilge. (Page 11-1)
1: DO NOT launch or operate the boat if any problem is found during the Safety Check. A problem could
lead to an accident during the outing, resulting in serious injury or death. Any and all problems should
receive attention immediately. See your MasterCraft dealer for assistance. (Page 9-1)
WARNINGS AND CAUTIONS
ii
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious injury.

WARNINGS AND CAUTIONS
iii
2: Running the engine with the flame arrestor removed increases the possibility of fire or explosion if the
engine should backfire and gasoline fumes are present. If the engine is operated without the flame
arrestor secured, extreme care must be taken to ensure that the engine compartment is well-ventilated
and that no fuel leaks are present. (Page 21-2)
3: Battery electrolyte fluid is dangerous. It contains sulfuric acid, which is poisonous, corrosive and caustic.
If electrolyte is spilled or placed on any part of the human body, immediately flush the area with large
amounts of clean water and seek medical aid. (Page 17-3)
4: When charging, batteries generate small amounts of dangerous hydrogen gas.This gas is highly explo-
sive. Keep all sparks, flames and smoking well away from the area. Failure to follow instructions when
charging a battery can cause an electrical charge or even an explosion of the battery which could cause
serious injury or death. (Pages 17-3 and 17-9)
5: The engine box serves as a machinery guard. The engine must be OFF whenever the box is open.
Clothing or body parts can get caught in moving parts, causing serious injury or death. Keep away from
moving parts! (Pages 17-6, 17-7, 17-8)
6: Before towing this trailer, be sure to read and familiarize yourself with this section of your manual.
(Page 26-2)
7: The total weight of your boat, engine, fuel, water and gear must not exceed the trailer’s maximum
load-carrying capacity. Overloading can cause serious injury or property damage. Note: Maximum
load-carrying capacity is the GrossVehicleWeight Rate (“GVWR”) less the weight of the empty trailer.
(Page 26-2)
8: Trying to tow with water-filled bladder(s) may not only cause the total weight limits for the trailer to be
exceeded but may also result in the improper distribution of the weight on the trailer thereby making
towing difficult and/or causing instability when towing, which can be very dangerous to you and to other
motorists. You should NEVER tow with water in the ballast bladders or tanks! (Page 26-2)
9: Serious injury or death or property damage can result if the total weight on your loaded trailer exceeds
the capacaity of the hitch on your tow vehicle. (Page 26-3)
10: Failure to properly attach the safety cables between your trailer and the tow vehicle can result in a run-
away trailer if the trailer coupler becomes detached from the hitch, which may cause serious injury or
death or property damage. (Page 26-4)
11: Failure to properly engage the hitch ball in the coupler ball socket and to securely lock the coupler latch
mechanism can cause the trailer to become detached from the tow vehicle while traveling, which may
cause serious injury or death or property damage. (Page 26-5)
12: To reduce the risk of serious injury, death or property damage, make certain that all the trailer
lights are in proper working order. (Page 26-5)
13: Maintain the proper torque on the lug nuts attached to the wheel bolts. Failure to do so may result in
serious injury or property damage.Your MasterCraft dealer can provide you with the proper torque
specifications (measured in foot-pounds). (Page 26-5)
14: Also keep the wheel bearings lubricated. Failure to do so may cause failure and possible wheel loss,
which may result in serious injury or death or property damage. (Page 26-6)

15: Keep your tires properly inflated. Failure to maintain the correct pressure may result in tire failure and
loss of control, which may result in serious injury or death or property damage. (Page 26-7)
16: Trailer brakes must be maintained in good working condition.The loss of adequate braking could result
in serious injury or death or property damage. (Page 26-7)
17: Adding additional ballast to your MasterCraft boat is not recommended, and can result in impaired
visibility, diminished handling characteristics and instability when operating your boat, and may result in
potential structural and/or engine damage to your boat, which damage will not be covered by your
warranty. (Page ____)
18: Use of improper parts can cause component or engine failure, which may result in serious injury or
death! (Page 14-1)
19: Do not tow boat with wakeboards or skis left in board and/or ski racks.Doing so may create a hazard for
or cause damage to vehicles following behind you as the boards and/or skis may become disengaged
while traveling,or may result in damage to your vehicle or boat, which damage would not be covered by
your warranty. (Page ___)
1: Some launch ramps may be slippery when wet. Use great care when walking, standing or loading and
unloading boats on or around any launch ramps. (Page 26-10)
2: Wet brakes may not hold and/or may cause brakes to have diminished performance characteristics.A
few braking applications at a slow speed will help to dry them out, but extra care must be used when
braking after brakes have become wet. (Page 26-10)
3: Be sure that all fasteners you use are approved and rated for marine use. Most fasteners used on
MasterCraft boats are stainless steel or specially coated to resist corrosion. (Page 14-1)
4: All replaced fuel system components must meet United States Coast Guard (“USCG”) and American
Boat & Yacht Council, Inc. (“ABYC”) standards, and must be Underwriter’s Laboratory (“UL”)-ap-
proved. Inferior quality components pose a serious safety threat to you and others, and the use of
inferior components may result in serious injury or death. Resulting damage may void your warranty.
(Page 19-8)
5: The use of an unapproved ski pylon extension or extensions is not recommended by MasterCraft on our
products. If you elect to use unapproved merchandise, be aware that these items could create excessive
stress on your boat and could result in damages not covered by your warranty! (Page 1-3)
6: Continuing to operate the boat while the temperature is above normal operating parameters may cause
serious damage to your engine. Damage to your engine resulting from operating the engine in an
overheated condition can be costly to repair. Such damage is not covered by your warranty! (Page 7-2)
7: Do not continue to run the engine if the oil pressure is low. If you do, the engine can become so hot
that it–or surrounding components–could catch fire. Your or others could be burned and the boat
seriously damaged. Check your oil level and add an appropriate amount of approved motor oil before iv
WARNINGS AND CAUTIONS
CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate injury.

operating again or have your boat serviced by your local MasterCraft dealer. Note that damage to
your engine from englected oil problems can be costly to repair. Such damage is not covered by your
warranty. (Page 7-2)
1: To ensure proper break-in and lubrication, boat owners should not remove the factory break-in oil until
after the initial ten (10) hours of operation. At that time, an oil change should be performed by an
authorized MasterCraft service technician/your local MasterCraft dealer. (Page 10-1)
2: DO NOT use the ski pylon for lifting. It is NOT designed as a central lifting point. Also, DO NOT use
the stern ski tow as a lifting ring.The deck will be damaged. See the Storage Cradle sub-section of the
Lifting the Boat section of this Manual. Also never lift a boat with a large amont of water in the bilge
or containing a water-filled device such as a Fat Sac or ballast system. The extra stress will put an
excessive load on the hull and lifting equipment that may seriously damage the boat and void your
warranty. (Page 13-1)
3: Continued operation after the warning light has illuminated may cause severe engine damage.This will
void your warranty. (Page 11-3)
4: Because of the complexity of preparing your boat for proper winter storage, as well as the possibility of
extreme damage to the engine if a preparation error was made during winterization, MasterCraft recom-
mends that you schedule an appointment with your local MasterCraft dealer and permit the dealer to
perform the winterization procedures. (Page 21-1)
5: 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. (Page 17-3)
6: Ignoring elevated temperatures on a temperature gauge or any other evidence of the engine operating at
temperatures above recommended levels can result in serious damage to the engine. Any resulting
damage will not be covered by, and may void, your warranty! (Page 17-5)
7: Failure to follow the engine oil recommendation listed in the manual can cause additional engine wear
and increase the possibility of engine component failure. Damage to your engine due to incorrect oil
usage can be costly to repair, and is not covered by your warranty! (Pages 10-2 and 18-3)
8: Failure to maintain your coolant at the proper level can cause engine damage.Your warranty will not cover
engine damage due to overheating or any other cause associated with improper coolant levels. (Page 17-2)
9: Do not operate the starter motor continuously for more than fifteen (15) seconds without at least a two
(2) minute “cool-down” period. Failure to do so may cause the starter to overheat, resulting in damage.
Failure to release the ignition key after the engine has started may cause damage to the starter motor and
drive. (Page 11-2)
10: Damage to the engine by use of low-quality gasoline or gasoline with an octane rating below the
minimum level listed will void the warranty on your boat. (Page 8-1)
11: Fuels that are blended to contain methanol or wood alcohol are not to be used in MasterCraft engines.
These fuels can corrode some metal parts in your fuel system and engine. Damage caused by the use of
unapproved fuels is not covered by warranty. (Page 8-2)
WARNINGS AND CAUTIONS
v
CAUTION used without the safety alert symbol indicates a
potentially hazardous situation which, if not avoided, may
result in property damage.

WARNINGS AND CAUTIONS
vi
12: Extended storage with fuel in the system can affect the fuel’s stability and may require system inspection
and fuel filter replacement when the unit is placed back into service. (Page 8-2)
13: Lifting slings must never contact shafts, struts or hardware protruding from the hull. Damage caused by
slings will void your warranty. (Page 13-1)
14: When your boat is out of the water, it is important to support the hull correctly to avoid any hull
damage that will void your warranty. (Page 13-1)
15: Crossing cables or jumper cables can result in damage to the electrical components due to incorrect
battery connections. Such damages are not covered by your warranty. (Page 17-4)
16: Attention must be paid to any leakage occurring in the propeller shaft log area.Water intrusion into the
transmission, which can happen if excessive leakage is occurring, can cause serious damage and void
your warranty. (Page 17-7)

BOATING SAFETY ---------------------------------------- 1-1
RULES OF THE OPEN WATER --------------------------- 2-2
NAUTICAL TERMINOLOGY ------------------------------ 3-2
MASTERCRAFT DESIGN PROCESS ----------------------- 4-1
INDIVIDUAL MODELS ------------------------------------ 5-1
PROSTAR 190 ------------------------------------------- 5-2
PROSTAR 197 ------------------------------------------- 5-3
PROSTAR 209 ------------------------------------------- 5-4
PROSTAR 205 V-DRIVE ---------------------------------- 5-5
MARISTAR 210 ------------------------------------------ 5-6
MARISTAR 230 ------------------------------------------ 5-7
MARISTAR 280 ------------------------------------------ 5-8
X-2 ---------------------------------------------------- 5-9
X-7 -------------------------------------------------- 5-10
X-9 -------------------------------------------------- 5-11
X-10 ------------------------------------------------ 5-12
X-30 ------------------------------------------------ 5-13
X-Star ----------------------------------------------- 5-14
ENGINE &PROPELLER SPECIFICATIONS --------------- 6-1
CONTROLS AND INDICATORS --------------------------- 7-1
FUELING ------------------------------------------------- 8-1
SAFETY CHECKS AND SERVICES ------------------------- 9-1
NEW BOAT BREAK-IN --------------------------------- 10-1
STARTING AND BASIC OPERATIONS ------------------ 11-1
OPERATIONAL HINTS --------------------------------- 12-1
LIFTING THE BOAT ------------------------------------ 13-1
CORROSION ------------------------------------------- 14-1
CLEANING --------------------------------------------- 15-1
SCHEDULED MAINTENANCE CHECKS &SERVICES --- 16-1
BEFORE EACH USE
TRANSMISSION COOLER -------------------------------- 17-1
COOLANT LEVEL -------------------------------------- 17-1
ALTERNATOR BELT ------------------------------------- 17-2
BATTERY CONNECTIONS AND HOLD-DOWNS ---------- 17-3
LOOSE OR MISSING HARDWARE ------------------------ 17-4
CABLE KINKS, WEAR AND INTERFERENCE -------------- 17-4
IMPELLER ---------------------------------------------- 17-5
PROPELLER SHAFT LOG -------------------------------- 17-6
FUEL SYTEM LEAKS ------------------------------------ 17-7
EXHAUST SYSTEM LEAKS ------------------------------- 17-8
FULLY CHARGED BATTERY ------------------------------ 17-9
ENGINE OIL LEVEL ------------------------------------- 17-9
TRANSMISSION FLUID LEVEL --------------------------- 17-10
QUARTERLY MAINTENANCE
ENGINE STARTER GEAR AND SHAFT LUBRICATION ------ 18-1
CHANGE ENGINE OIL --------------------------------- 18-1
ANNUAL MAINTENANCE
CLEAN ENGINE FLAME ARRESTOR ---------------------- 19-1
REPLACE RAW WATER PUMP IMPELLER ------------------ 19-3
ENGINE TUNE-UP ------------------------------------- 19-3
CHANGE TRANSMISSION FLUID ------------------------- 19-3
CHECK ENGINE MOUNTS ------------------------------ 19-4
CHECK PROPELLER SHAFT COUPLING ALIGNMENT ------ 19-5
Table of Contents
INSPECT EXHAUST FLAPS ------------------------------ 19-5
LUBRICATE STEERING SYSTEM -------------------------- 19-5
LUBRICATE SHIFT AND THROTTLE SYSTEM --------------- 19-6
BALLAST PUMP IMPELLER ------------------------------- 19-7
INSPECT COMPLETE FUEL SYSTEM FOR LEAKAGE -------- 19-7
EMISSIONS --------------------------------------------- 20-1
STORAGE/WINTERIZATION ---------------------------- 21-1
GENERAL PREPARATION -------------------------------- 21-1
FUEL SYSTEM TREATMENT ------------------------------ 21-1
ALL ENGINES ------------------------------------------ 21-2
RAW-WATER COOLED ENGINES ------------------------ 21-2
FRESH-WATER COOLED ENGINES ----------------------- 21-3
DRIVE TRAIN PREPARATION ----------------------------- 21-3
GENERAL POWER PACKAGE PREPARATION ------------- 21-3
OTHER WINTERIZATION PREPARATION ------------------ 21-3
BALLAST SYSTEM PREPARATIONS ------------------------ 21-4
REACTIVATING AFTER STORAGE ------------------------- 21-4
UNSCEDULED MAINTENANCE
CHECKING/REPAIRING PROPELLERS --------------------- 22-1
CHANGING PROPELLERS ------------------------------- 22-1
CHECKING SPEEDOMETER CALIBRATION ---------------- 22-1
TROUBLESHOOTING ---------------------------------- 23-1
THE COMMON SENSE APPROACH -------------------- 24-1
LIMITED WARRANTY STATEMENT --------------------- 25-1
MASTERCRAFT TRAILERS
TRAILERING AND LAUNCHING ------------------------- 26-1
APROPER MATCH ------------------------------------- 26-2
LOAD-CARRYING CAPACITY ---------------------------- 26-2
WEIGHT DISTRIBUTION -------------------------------- 26-2
TRAILER HITCH ---------------------------------------- 26-2
SAFETY CABLES ---------------------------------------- 26-3
TRAILER WINCH ASSEMBLY ----------------------------- 26-4
WARNINGS ON PIVOT TONGUE ------------------------ 26-4
MASTER CYLINDER LEVEL ------------------------------ 26-4
TRAILER COUPLING ------------------------------------ 26-4
LIGHTS ------------------------------------------------ 26-5
WHEELS AND HUBS ----------------------------------- 26-5
LUG NUTS OR WHEEL BOLTS --------------------------- 26-6
LUBRICATION ------------------------------------------ 26-6
WHEEL BEARINGS AND BRAKING SYSTEM -------------- 26-7
TIRES -------------------------------------------------- 26-7
BRAKES ----------------------------------------------- 26-7
TRAILER JACKS ----------------------------------------- 26-8
TIE-DOWNS ------------------------------------------- 26-8
HITCHING UP ----------------------------------------- 26-8
TRAILER TECHNIQUES ---------------------------------- 26-9
LAUNCHING ----------------------------------------- 26-10
STORAGE --------------------------------------------- 26-10
TRAILERING TIPS --------------------------------------26-11
TRAILERING CHECKLIST ------------------------------- 26-11
GMP PRODUCTS --------------------------------------- 27-1
WARRANTY TRANSFER -------------------------------- 28-1
TEAM MASTERCRAFT ---------------------------------- 29-1

BOATING SAFETY
1-1
Boating Safety
Your safety, as well as the safety of others with and around you, is a direct result of how you operate and
maintain your boat. Read and comprehend this manual. Make sure that you understand all the controls and
operating instructions before attempting to operate the boat. Improper operation is extremely dangerous!
The basic safety rules are outlined in this section of the manual. Additional precautions throughout the
manual are noted by the following symbols:
The precautions listed in this manual and on the boat are not all-inclusive. If a procedure,
method, tool or part is not specifically recommended by MasterCraft, using it may place you and
others in an unsafe situation; as well, you may render your warranty void. Remember: Always use
common sense when operating, servicing or repairing the boat!
In addition to everyday safety, failure to observe the safety recommendations may result in
severe personal injury or death to you or to others. Use caution and common sense when operat-
ing your boat. Don’t take unnecesssary chances!
Be certain that all boat operators are aware of this infor-
mation and conform to boat safety principles.
General Precautions
Boating safety starts with a thorough understanding of op-
eration. In addition to careful review of this manual, you should
be aware as well that there are many sources of information
available. MasterCraft urges you to pursue additional trainining.
The following is a listing of just some of the agencies and
organizations that offer safety training or information.
AMERICAN RED CROSS, NATIONAL HG
8111 GATEHOUSE ROAD, 6TH FLOOR
FALLS CHURCH VA 22042
[phone]
www.redcross.org
This is the safety alert symbol. It is used to alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid possible injury or death.
DANGER indicates an imminently hazardous situation which,
if not avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation which,
if not avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if
not avoided, may result in minor or moderate injury.
CAUTION used without the safety alert symbol indicates a
potentially hazardous situation which, if not avoided, may
result in property damage.
MasterCraft
President and CEO
John Dorton
prepares for a run
during an INT event
while wearing his
own PDF.

BOATING SAFETY
1-2
USA WATER SKI ASSOCIATION
1251 HOLY COW ROAD
POLK CITY FL 33868
[phone]
http://usawaterski.org
BOAT OWNERS ASSOCIATION OF THE UNITED STATES
880 SOUTH PICKETT STREET
ALEXANDRIA VA 22304
[phone]
http://boatus.com
NATIONAL SAFE BOATING COUNCIL
2550 MSTREET NW, SUITE 425
WASHINGTON DC 20037
[phone]
www.safeboatingcouncil.org
U.S. COAST GUARD AUXILARY
2100 SECOND STREET SW
WASHINGTON DC 20593-0001
[phone]
http://uscg.mil
Safety Equipment
Federal law requires certain
safety equipment to be on-board
at all times. In addition, respon-
sible boaters carry other equip-
ment in case of emergency.
Check with the local boating au-
thorities for any additional re-
quirements over and above the
federal stipulations.
Required Equipment
Your MasterCraft has been
equipped at the factory with most
of the federally required safety
equipment for inland waters (Class
I, 16-foot-to-26-foot watercraft).
This equipment includes:
• ABYC-approved marine mufflers
with water injection
• USCG-approved marine flame
arrestor
• USCG-approved engine box ven-
tilation with spark-less power
blower
• ABYC-approved electric horn
sound-warning device
• USCG-approved inland lighting.
Federal law also requires at
least one Type I, II or III Personal
Flotation Device (PFD) for each person on-board or be-
ing towed on water skis or other recreational equipment.
In addition, one throwable Type IV PFD must also be on
board. As the owner, obtaining the appropriate PFDs is
your responsiblity. Your MasterCraft dealer can–and will
be–happy to assist you.
Note: Requirements for coastal waters and in-
land waters differ. Check with the local authori-
ties for more information.
Recommended Equipment
A smart boat owner will avoid potential problems
on an outing by having additional equipment on board.
Normally, the decision regarding which equipment to
take is dependent on the body of water and the length
of the trip. We suggest the following as a minimum.Your
MasterCraft dealer can also assist you with additional
recommendations.
• An anchor with at least 75 feet of line
• A manual bailing device for removing water
• A combination oar/boat hook
• A day-and-night visual distress signal

BOATING SAFETY
1-3
Failure to comply with safety-related information and instruction
may result in serious injury or death to you and/or others. Always
use common sense when operating the boat or participating in any
activities associated with the boat.
Never override or modify the engine safety shut-off switch or
engine neutral starting safety switch in any way.
• A first aid kit and manual
• An airway breathing tube
• A waterproof flashlight
• A horn or whistle, non-electric
• A set of local navigational charts
• Mooring lines and fenders
• Extra engine oil
• A tool kit
• A portable, battery-operated AM/FM radio
Safety Afloat
Boating-related accidents are generally caused by
the operator’s failure to follow basic safety rules or
written precautions. Most accidents can be avoided if
the operator is completely familiar with the boat, its
operation, and can recognize potentially hazardous situ-
ations before an accident occurs.
• Improper operation is extremely dangerous. Opera-
tors must read and understand all operating manu-
als supplied with the boat, before operation.
• On-board equipment must always conform to the
governing federal, state and local regulations.
• Always attach the engine safety shut-off lanyard to a
part of your clothing, such as a belt loop,when oper-
ating the boat.
• Never operate the boat while under the influence of
alcohol or drugs.
• Never stand or allow passengers to stand in the boat–
or sit on the motor box–while underway. You or
others may be thrown from the boat.
• Prior to starting the engine, you must open the en-
gine box and check the engine compartment and
bilge for gasoline and oil vapors.You must also oper-
ate the blower for at least four minutes. Failure to do
so may result in fire or explosion.
• Never remove or modify any components of the
fuel systems,except for maintenance and repair per-
formed by qualified MasterCraft personnel. Tam-
pering with fuel components may cause a hazard-
ous situation and voids warranty.
• Never allow any type of spark or open flame on board.
It may result in fire or explosion.
• Prior to starting the engine, you must open the en-
gine box and check the engine compartment and
bilge for gasoline and oil vapors.You must also oper-
ate the blower for at least four minutes. Failure to do
so may result in fire or explosion.
• Never remove or modify any components of the
fuel systems,except for maintenance and repair per-
formed by qualified MasterCraft personnel.Tamper-
ing with fuel components may cause a hazardous
situation and voids warranty.
• Never allow any type of spark or open flame on board.
It may result in fire or explosion.
Skiing & Wakeboarding Safety
Skiers and wakeboarders are obligated to be as aware
of the fundamental safety rules as operators must be. If
you are new to water skiing, seek certified training be-
fore starting. You will find it especially helpful to join a
local ski club and the USWSA, when possible.
Always remember that the majority of water-
skiing and wakeboarding injuries are the result of
impacts with other objects, so always look where
you are going and be aware of what is going on
around you.
Never put your arm, head or any other part of
your body through the handle/bridle of the ski
line nor wrap the line around any part of the
body at any time.
• Never ski at night, or directly in front of
other boats.
• Never jump from a boat that is moving at
any speed, nor enter or exit the water when
the engine is running (ON).

1-4
BOATING SAFETY
The use of an unapproved ski pylon extension or extensions is not
recommended by MasterCraft on our products. If you elect to use
unapproved merchandise, be aware that these items could create ex-
cessive stress on your boat and could result in damages not covered by
your warranty!
• Make sure that everyone knows and uses approved skiing hand signals and common skiing
courtesy.
• Never ride on the ski platform or hold on to the platform while in the water during engine
operation, including at idle. Carbon monoxide fumes are expelled from the lower transom area
of a boat and can cause serious illness or even death.
• The above recommendations are not all-inclusive. It is the boater’s responsiblity to operate
the boat in a safe fashion and become familiar with any and all rules and laws governing
boat operation.
Warning Plates and Labels
Read and note ALL warning plates and labels from bow to stern! YOU MUST READ AND ADHERE TO
ALL CAUTIONS AND WARNINGS IN AND ON YOUR BOAT!

Rules of the Open Water
Just as there are rules that apply when driving
a vehicle on the street, there are waterway rules
that apply when you are driving a boat. These
rules are used internationally, and they are en-
forced by the United States Coast Guard and lo-
cal agencies.You should be aware of these rules
and follow them whenever you encounter another
vessel on the water.
In various geographic locations certain rules
prevail that may be unique to the locale, but all
are basically the same as the International Rules of the Road.
The rules presented in this manual are condensed and have been provided as a convenience only.
Consult your local U.S.Coast GuardAuxiliary (USCGA),Department of MotorVehicles (DMV) or Department of
Natural Resources (DNR) for a complete set of rules governing the waters in which you will be using your boat.
If you plan to travel–even for a short trip–you would be well-served to contact the regional USCGA, DMV or
DNR in the area where you will be boating.
Steering and Sailing Rules/Sound Signals
Any time two vessels on the water meet one another, one vessel has the right-of-way.It is called the stand-on
vessel. The vessel that does not have the right-of-way is called the give-way or burdened vessel.
These rules determine which vessel has the right of way, and accordingly, what each vessel should do.
The vessel with the right-of-way has the duty to continue its course and speed,except to avoid an immediate
collision.When you maintain your direction and speed, the other vessel will be able to determine how best to
avoid you.
The vessel that does not have the right-of-way has the duty to take positive and timely action to stay out of the
way of the stand-on vessel. Normally, the give-way vessel should not cross in front of the stand-on vessel. Slow
down or change directions briefly and pass behind the other vessel. You should always move in such a way that
the stand-on operator can see what you are doing.
The General Prudential Rule
This rule is called Rule 2 in the International Rules and says,
“In obeying and construing these rules due regard shall be had to all dangers of navigation and collision, and to any
special circumstances,which may render a departure from the above rules necessary in order to avoid immediate danger.”
Rules When Encountering Vessels
There are three main situations in which you may encounter other vessels and
you must avoid a collision.These are:
•Meeting (you are approaching another vessel head-on)
•Crossing (you are traveling across the other vessel’s path)
•Overtaking (you are passing or being passed by another vessel)
Using the adjacent image in which you are boat in the center, you should give
right-of-way to all vessels shown in the white area. In this instance, you are the give-
way vessel. Both you and the meeting vessel must alter course to avoid each other.
Meeting
If you are meeting another power vessel head-on, and you are close enough
to run the risk of collision, neither of you has the right-of-way. Both of you
should alter course to avoid an accident. You should keep the other vessel
on your port (left) side.This rule doesn’t apply if both of you can clear each
other by continuing your set course and speed.
RULES OF THE OPEN WATER
2-1

Crossing
When two power-driven vessels are crossing each other’s path close enough to run
the risk of collision, the vessel that views the crossing vessel to the starboard (right) side
must give-way.
If the other vessel is to the port (left) side, maintain your course and direction,
provided the other vessel gives you the right-of-way as it should.
Overtaking
If you’re passing another vessel, you are
the give-way vessel.This means that the other vessel is expected to main-
tain its course and speed.You must stay out of its way as you clear it,
altering course and speed as necessary.
Conversely, if you are being passed by another vessel, you should
maintain your speed and direction so that the vessel can steer itself
around you.
Other Special Situations
There are other rules to always remember when driving your boat around other vessels:
• When navigating in narrow channel, you should keep to the right when it is safe and practical to do so.
• If the operator of a power-driven vessel is preparing to go around a bend that may obstruct the view of other
water vessels, the operator should sound a prolonged blast on the whistle or horn for four to six seconds.
• If another vessel is around the bend, it too should sound the whistle or horn. Even if no reply is heard,
however, the vessel should still proceed around the bend with caution.
Fishing Vessel Right-of-Way
All vessels that are fishing with nets, lines or
trawls are considered under international rules
to be fishing vessels. Boats with trolling lines are
not considered fishing vessels.
Fishing vessels have the right-of-way, regard-
less of position. But these vessels cannot impede
the passage of other vessels in narrow channels.
Sailing Vessel Right-of-Way
Sailing vessels should normally be given the right-of-way.
The exceptions to this are:
• When the sailing vessel is overtaking the power-driven
vessel,the power-driven vessel has the right-of-way.
• Sailing vessels should keep clear of any fishing vessel.
• In a narrow channel, a sailing vessel should not hamper
the safe passage of a power-driven vessel that can navi-
gate only in such a channel.
Reading Buoys and Other Markers
The waters of the United States are marked for safe navigation by the lateral system of buoyage.The markers
and buoys you will encounter have an arrangement of shapes, colors, numbers and lights to show which side of
the buoy a boater should pass when navigating in a particular direction.
The markings on these buoys are oriented from the perspective of being entered from seaward while the
boater is going toward the port. This means that red buoys are passed on the starboard (right) side when
proceeding from open water into port, and the green buoys are to the port (left) side.When navigating out of
port, your position to the buoys should be reversed: red buoys to port and green buoys to starboard.
Many boating bodies of water are entirely within the boundaries of a single state.The Uniform StateWaterway
Marking Systems have been devised for these waters.This system uses buoys and signs with distinctive shapes and
colors to show regulatory or advisory information.These markers are white with black letters and orange borders.
The information signifies speed zones, restricted areas, danger areas and general information.
Remember: Markings may vary by geographic location. Always consult local boating authorities
before driving your boat in unfamiliar waters.
RULES
OF
THE
OPEN
WATER
2-2

NAUTICAL TERMINOLOGY
3-1
Nautical Terminology
Usually, boating rookies are immediately identifiable
because they don’t know the lingo. However, it’s easy to
pick up, and once you have you join the exclusive club
that is the boating world.
To help you get a jump on understanding nautical
terminology and communicating better with everyone
you meet on the water, here are some of the more
common terms:
ABROAD . . . On or within the boat.
ABREAST . . . Side by side; by the side of another boat
or object.
ADRIFT . . . Loose; not on moorings or towline.
AFT . . .Toward the back (or stern) of the boat.
AGROUND ...Touching the bottom of the lake or river
with the hull of the boat.
AHEAD . . . In a forward direction.
AIDS TO NAVIGATION ...Artificial objects to supple-
ment natural landmarks indicating safe or unsafe waters.
ALEE . . .Away from the direction of the wind. Opposite
of windward.
AMIDSHIPS . . . In or toward the center of the boat.
ANCHORAGE . . . A place suitable for anchoring in
relation to the wind, seas and bottom.
ASTERN . . . The position of the anchor as it is raised
clear of the bottom.
BATTEN DOWN ... Secure hatches and loose objects
both within the hull and on deck.
BEAM . . .The greatest width of the boat.
BEARING . . . The direction of
an object expressed either as a
true bearing as shown on the
chart, or as a bearing relative to
the boat’s heading.
BELOW . . . Beneath the deck.
BIGHT . . .The part of the rope
or line between the end and the
standing part on which a knot is
formed.
BOAT . . .An indefinite term but
generally refers to a waterborne
vehicle smaller than a ship, which
is usually thought of as being used
for ocean travel or transport of
goods.
BOAT HOOK . . .A short shaft
with a fitting at one end shaped
to facilitate use in putting a line
over a piling, recovering an ob-
ject dropped overboard or in
pushing off.
BOW . . . The forward part of the boat, usually for-
ward of the driver’s compartment.
BOW LINE . . .A docking line leading from the bow.
BUOY . . .An anchored float used for marking a
position on the water, a hazard or a shoal, and
for mooring.
CAPSIZE . . .To turn over.
CAST OFF . . .To remove mooring lines and move
away from the dock.
CHART . . .A map for use by navigators.
CHINE . . .The intersection of the bottom and sides
of a flat or v-bottomed boat.
CHOCK .. .A fitting through which anchor or moor-
ing lines are led. Usually U-shaped to reduce chafe.
CLEAT . . .A fitting to which lines are made fast.The
classic cleat to which lines are secured is roughly
anvil-shaped.
CLOVE HITCH ... A knot for temporarily fastening
a line to a spar or piling.
COIL . . .To lay a line down in circular turns to avoid
snags or unwanted knots.
COURSE ...The direction in which a boat is steered.
CURRENT . . .The horizontal movement of water.
DEAD AHEAD . . . Directly ahead.
DEAD STERN . . . Directly aft or behind.
DECK . . .A permanent covering over a hull.
DISPLACEMENT .. .The weight of water displaced
by a floating vessel.
DOCK . . . A protected water area in which vessels
are moored.The term is often used to denote a pier
or a wharf.

DOLPHIN . . .A group of piles driven close together
and bound with wire cables into a single structure.
DRAFT . . .The depth a boat floats in the water.
EBB . . . A receding current.
FATHOM . . . Six feet down in the water.
FENDER . . .A cushion, placed between boats or be-
tween a boat and a pier to prevent damage.
FIGURE EIGHT KNOT . . .A knot in the form of a
figure eight, placed in the end of a line to prevent the
line from passing through a grommet or a block.
FLOOD . . .An incoming current.
FLOORBOARDS . . .The surface of the deck; usually
removable sections placed for access to storage areas
or the drive train.
FORE-AND-AFT . . . In a line parallel to the keel.
FORWARD . . .Toward the bow of the boat.
FOULED . . . Any piece of equipment that is jammed
or entangled.
GEAR ...A general term for ropes,blocks, skis,boards,
and other equipment brought aboard.
GIVE-WAY VESSEL ...A term used to describe the
vessel that must yield in meeting, crossing or overtak-
ing situations (see Rules of the OpenWater section).
GRAB RAILS . . . Hand-hold fittings mounted for per-
sonal safety when moving around the boat.
GUNWALE . . . (also gunnel) The upper edge of a boat’s
sides.
HARD CHINE . . .An abrupt intersection between the
hull side and the hull bottom created to affect a boat’s
wake and handling.
HEADING . . . The direction in which a vessel’s bow
points at any given time.
HEADWAY . . .The forward motion of a boat.
HULL . . .The main body of a vessel.
INBOARD . . . A type of boat in which the motor is
inside the hull.
INTRACOASTALWATERWAY (ICW) . . . Bays , riv-
ers and canals along the coasts, such as the Gulf of Mexico
and Atlantic coasts, connected so that vessels may travel
without going into the sea.
JETTY . . . A structure, usually masonry, projecting out
from the shore. A jetty may protect a harbor entrance.
KEEL ...The center line of a boat;the backbone of a vessel.
KNOT . . .The measure of speed equal to one nautical
mile (6076 feet) per hour.
3-2
NAUTICAL
TERMINOLOGY

NATUICAL TERMINOLOGY
LEE . . .The side sheltered from the wind.
LEEWARD . . .The direction away from the wind.
LEEWAY ...The sideways movement of the boat caused
by wind or current.
LINE . . . Rope and cordage used aboard a vessel.
LOT . . .A record of courses or operation.
LUBBER’S LINE . . .A mark or permanent line on a
compass indicating the direction forward parallel to
the keep.
MIDSHIP . . .Approximately in a location equal distance
from bow to stern.
MOORING . . .An arrangement for securing a boat to a
mooring buoy or a pier.
NAUTICAL MILE . . . One minute of latitude; approxi-
mately 6076 feet or about 1/8 longer than the statute
mile of 5280 feet.
NAVIGATION . . .The art and science of conducting a
boat safely from one point to another.
NAVIGATION RULES . . . The regulations governing
the movement of vessels in relation to each other.
OUTBOARD . . . A detachable engine mounted
on a boat’s stern.
OVERBOARD . . . Over the side or out of the boat.
PIER . . . A loading platform extending at an angle
from the shore.
PILE . . .A wood, metal or concrete pole driven into the
bottom.
PILOTING . . . Navigation by use of visible refer-
ences, the depth of the water, etc.
PLANING . . .A boat is said to be planing when it is
essentially moving over the top of the water rather
than through the water.
PORT . . . The left side of the boat when looking
forward.Also used to refer to a harbor.
RUDDER ... A vertical plate of board for steer-
ing a boat.
RUN . . .To allow a line to feed freely.
RUNNING LIGHTS . . . Lights required to be shown
on boats underway between sundown and sun up.
SCREW . . . A boat’s propeller.
SEA ROOM . . . A safe distance from the shore or
other hazards.
SEAWORTHY . . . A boat or boat’s gear able to
meet the usual conditions.
SECURE . . .To make fast.
SLACK . . . Not fastened; loose.
SOUNDING . . . A measurement of the depth of
water.
SQUALL . . .A sudden violent wind often accompa-
nied by rain.
SQUARE KNOT . . .A knot used to join two lines of
similar size.Also called a “reef knot.”
STARBOARD .. .The right side of a boat when look-
ing forward.
STEM . . .The most forward part of the bow.
STERN . . .The back-most part of the boat.
STERN LINE ...A docking line leading from the stern.
STOW . . . To put an item away in its proper place.
SWAMP ...To fill with water, but not settle to the
bottom.
TRANSOM . . .The stern cross-section of a square-
sterned boat.
TRIM . . . Fore and aft balance of a boat.
UNDERWAY . . .Vessel in motion.
V-BOTTOM . . .A hull with the bottom section in the
shape of a “V.”
WAKE . . . Moving waves, track or path that a boat
leaves behind it when moving across the water.
WAY . . . Movement of the vessel through the water
such as a headway, sternway or leeway.
WINDWARD . . .Toward the direction from which
the wind is coming.
YAW . . .To swing or steer off course.
NAUTICAL TERMINOLOGY
3-3

MASTERCRAFT DESIGN PROCESS
4-1
The MasterCraft
Design Process:
The Perfect Blending
of Art and Science
Our engineers and designers have never been able
to leave well enough alone. Armed with true 3-D
computer-aided design technology, they have a design
approach that allows them to visualize and create every
part of the boat on the computer—the same way it’s done
in the automotive industry. No other ski boat company
even comes close to our technology—or to our talent.
It’s the most advanced team in the business,and the fruits
of its labor are evident in every 2004 MasterCraft model.
But at MasterCraft, we’re not just designing better boats.
We’re designing better ways to build them. Today’s
MasterCrafts are built better, smarter and lighter.Which
means you have the most durable, most carefree and
most reliable boat on the planet.
Even with the most advanced technology available, however, MasterCraft will never replace an important
step in the design: Hands-on involvement. Our artisans use clay modeling, inspired by the automotive industry, to
touch and feel every surface of the boat before it ever sees a mold. Changes are made overnight.And re-made
over and over again until every aspect of the ergonomics, styling and design is just right.When everything is
flawless, we build the part, carefully crafting each piece by hand.This careful blending of technology, experience
and intuition allows us to reduce the time it takes to introduce innovations into our boats.
We’re proud of the balance we’ve achieved and of the results we’re getting. For example, parametric
modeling and finite element analysis allow us to create computerized images of each part long before we build
it. We zero in to test stress levels and to perfect tolerances to the last thousandth of an inch.The result is a
boat that has minimum weight and maximum strength–a boat that is powerful, durable and seamless from
bow to stern.
The MasterCraft LifeMasterTM
Construction Process
We use an exclusive process that we call
LifeMasterTM, an eight-step production method that
gives every MasterCraft strength and reliability that
ordinary boats cannot equal. We believe in this
process so much that we offer a limited lifetime
warranty on every new MasterCraft. The warranty
is even transferable to a second owner for up to
five years.
Step 1: Superior Molds
The first step in the LifeMasterTM Process is our
boat molds. Our molds are built to tighter tolerances
than most boats, with steel reinforcement to prevent
flexing and to maintain precision. After every fourth

MASTERCRAFT DESIGN PROCESS
4-2
use, molds are hand-waxed with an
industrial quality paste wax.This ensures
a mirror-like gel coat finish and easy mold
release.After 50 uses, every mold is sent
back to the mold maintenance shop for a
complete overhaul, allowing us to produce
a boat with a superior finish. Also note
that our molds are green in color. Our
molds used to be orange, but we
discovered that the green pigment was
more environmentally friendly (no lead),
so we switched.
Step 2: Gel Coat
Boats are built from the outside in.The
first layer to be applied to the model is our special Ultimate 8000TM neopentyl glycol/isophthalic 20-mil gel coat.
Our skilled production team can control our gel coat to tolerances within .005" for optimum strength, gloss and
resistance to cracking, fading, blistering and water and chemical damage. Most manufacturers do not even have
standards for gel coat thickness.
Some graphics are applied right in the gel coat, and this extra care pays off. New MasterCrafts come out of
the mold with a gloss that looks like they were just waxed and buffed.
Step 3: Hand-Laid Fiberglass
There are many ways of building boats, but the best way we have found is to do it by hand. MasterCraft uses
multiple layers of hand-laid fiberglass for the hull and structural components.Three types of fiberglass are used:
matting, woven roving and coremat. There are even two types of woven roving—biaxial stitched and triaxial
stitched cloth.
Why so many? Because the different types of fiberglass provide strength in different directions.The result
is a hull that resists the tremendous forces generated by running across the water at high speed and taking
tight turns.
Our hand-laid method is superior to chopper-gun fiberglass application because it ensures uniform strength
and consistency throughout the boat. Chopper guns can create thin spots in the hull that are weak.
Step 4: Integral MonocoqueTM Stringer System
MasterCraft uses no wood for structural components. Over
time, wood weakens and rots. MasterCraft pioneered the use of
fiberglass stringers (or hull bracing system) in ski boat construction.
All the way back in 1983, we developed an entirely new stringer
system. The exclusive MonocoqueTM stringers, constructed of bi-
directional fiberglass and closed-cell foam, are precision built to
aerospace tolerances, then fiberglassed into the hull so that they
become an integral part of the structure. It is as if the hull and stringers
are one single piece.
That means extra strength, more stability, and a great feel for the
driver.
Step 5: Floor Liner
The fiberglass floor liner, another hull component that adds
strength, is chemically bonded with GlassLock to the hull and
stringers,under tons of pressure. The result is a bond that is stronger
than the fiberglass itself, proven far superior to mechanical bonds
that other companies use.