Volvo Penta AQ205 User manual

OPERATOR’S MANUAL
AQ205, AQ211, AQ231, AQ271, AQ311
BB231, BB261

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CONTENTS
General information ............................................... 2
Running Instructions ............................................. 4
Starting the engine ................................................... 4
Running instructions................................................. 5
Running in shallow waters ........................................ 6
Reversing................................................................. 6
Shutdown procedure................................................. 6
Checks and Service ............................................... 6
Check daily before starting....................................... 6
Check every 14 days ............................................... 7
Service every 50 hours of operation ......................... 8
Service every 100 hours of operation ....................... 8
Winter storage and Launching ............................ 12
Propellers ............................................................. 15
Fault Tracing Scheme.......................................... 16
Technical Data ...................................................... 17
Wiring Diagrams .................................................. 19
Engine component guide .................................... 23
IMPORTANT INFORMATION
Stop the engine before opening the hatch to the engine
compartment. An engine which is running has rotating
and moving parts which are dangerous to touch.
Bear in mind the risk of a fire. All engine fuel is inflam-
mable. Alcohol, methanol or ethanol is sometimes
added to fuel, especially to unleaded petrol. These ad-
ditives shorten the life of rubber and plastic compo-
nents in the fuel system. Inspect regularly.
The cooling system should be drained when there is
risk of frost. Close all drainage points when the boat is
not under constant supervision. Incorrectly performed
drainage may cause the boat to become filled with wa-
ter and sink. When working on the drive in the upper
position, lock the drive in position with the special tool
available or in some other secure way so that there is
no possibility of the drive falling down.
Instrument panel
1. Tachometer – graduated 0–6000 rev/min.
2. Temperature gauge for cooling water. Green field – normal
cooling water temperature
3. Oil pressure gauge
4. Voltmeter
5. Key-switch (Starting)
6. Operating switch for sterndrive “Up”, “Down”
7. Instrument indicating the trim angle
Operating controls
1. Operating switch for Power Trim
2. Control lever
3. Disengaging device
Push in the button when the control lever is in neutral and move
the lever forwards slightly. Release the button. The lever now
operates the throttle only. Pull back the lever when you wish to
operate the throttle and the shift mechanism simultaneously.
N = Neutral
F = Control lever in position for running “Forward”
R = Control lever in position for “reversing”
T = Engine speed

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INTRODUCTION
This instruction book contains valuable information to
assist you in the correct handling and maintenance of
your Volvo Penta engine and its equipment.
Make sure that you have the correct instruction book.
All information, all illustrations and specifications in this
instruction book are based on the latest product informa-
tion which was available when this instruction book was
printed. Volvo Penta reserves the right to introduce prod-
uct changes without previous notification and without as-
suming any obligation to carry out corresponding modifi-
cations to products which have already been
manufactured and sold. Volvo Penta also reserves the
right to discontinue production of any particular model.
All models, standard equipment and accessories are not
available in all countries. Read the instruction book care-
fully before you use the engine. Do not wait until a prob-
lem has arisen.
Every new boat has individual characteristics. Even ex-
perienced boat owners are advised to observe the boat’s
handling characteristics at different speeds for a while.
If the boat is fitted with a DP outboard drive, the fol-
lowing should be observed:
The Duoprop drive system is more effective than a con-
ventional single propeller system. It has a number of ad-
vantages, including the following:
better acceleration
higher top speed
easier planing
more stable course retention and
better reversing characteristics
The propellers have a better grip in the water which
means that the boat is able to react more quickly than
usual both in terms of steering and acceleration.
Make sure that all passengers – including children – are
prepared for sudden changes of course and speed. Rap-
id swerves at high speed can cause passengers to lose
balance and injure themselves - such manoeuvers
should therefore be avoided. Explain the workings of the
boat before anybody else is allowed to operate it.
WARRANTY
A warranty and service book, with the current warranty
conditions, and warranty card are supplied with each en-
gine.
WARRANTY REGISTRATION CARD
– WARRANTY CARD
The Warranty Registration Card (US Market) Warranty
Card (other markets) should be filled out and sent in by
the selling dealer. Warranty service can be refused if no
proof of delivery date can be provided.
VOLVO PENTA SERVICE
Volvo Penta has built up a comprehensive service or-
ganization to provide your drive system with the service
it requires. Volvo Penta dealers and service stations
have specially trained personel, they have the special
tools, test equipment and a stock of spare parts – every-
thing to provide high standards of service. When you re-
quest service or spare parts, always state the engine’s
complete model designation and its serial number. This
information is on the engine’s rating plate.
AB VOLVO PENTA
Technical Publications
WARNINGS
The following special warning signs are used in the in-
struction book and on the product.
WARNING! There is a risk of personal injury,
damage to property, or a functional fault may oc-
cur if the instruction is not followed.
Readtheinstruction book.
GENERAL INFORMATION
The following is important information for your en-
gine:
FUEL
Use gasoline with the correct octane rating (at least 91
RON, USA R+M/2 = 87). The engine can be operated on
lead-free gasoline.
Use of low octane fuel will result in severe engine dam-
age that is not covered by the factory limited warranty.
Alcohol, and primarily methanol, can accelerate the age-
ing of rubber and plastic materials. This can cause a fuel
leakage. For safety reasons, all parts made of rubber or
plastic, which are components in the fuel system, should
be checked often and at regular intervals. Examples of
such components are: fuel pump diaphragm, fuel lines,
seals and fuel tanks. Replace any part which you sus-
pect may be affected.
Gasoline mixed with alcohol can bind more water than
pure gasoline. This can result in increased corrosion on
metal parts in the fuel system. Check often and regular-
ly.
The ethanol content of the fuel being used must not ex-
ceed 10% and the prescribed octane rating must always
be maintained.
Fuel which contains methanol (methyl alcohol = wood al-
cohol) must not be used since there is a considerable
risk of damage to important parts of the system.
This type of damage is not covered by the factory
warranty.

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LUBRICATION OIL
Use only SF (SE) quality oil according to the API sys-
tem. Volvo Penta’s lubricating oil for gasoline engines
complies with these requirements and can therefore be
recommended for use. Refer to viscosity in the Techni-
cal Data if any other type of lubricating oil is used.
RUNNING IN
A new marine engine requires careful running in during
the first 20 hours of use. You should therefore avoid run-
ning the engine at maximum load during this period. A
higher consumption of oil during the running in period is
normal. Check the oil level more regularly during the run-
ning in period for this reason.
SPARE PARTS
WARNING! Components in the electrical sys-
tem, the ignition system and the fuel system on
Volvo Penta products are designed and built to
minimize the risk of explosion and fire.
The use of non-approved parts, which do not
comply with the above requirements, may result
in an explosion or fire on board.
WARRANTY INSPECTION (NOT
USA)
The warranty inspection is carried out after a running
time of between 20 and 50 hours or within 120 days after
delivery. The inspection is carried out by an authorised
Volvo Penta workshop.
FIRST INSPECTION (USA)
A first inspection should be carried out by an authorized
Volvo Penta dealer within 20 and 50 hours or 120 days
after delivery. This inspection is at the owner’s expense.
OIL CHANGES
The oil and oil filter are changed during the 20 hour in-
spection. Refer also to Checks and Servicing.

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SPEED RANGE, MAXIMUM SPEED
When selecting a propeller, it may be difficult to
find the right size to provide the recommended
maximum speed during all load and weather con-
ditions.
It may be an advantage on some boats to use a
lower maximum speed than is recommended. The
advantage of this could be lower fuel consump-
tion, lower noise and vibration levels or better pro-
peller efficiency etc. For these reasons we have
recommended a “speed range, maximum speed”.
The cruising speed should always be at least
300-500 rpm below the maximum rpm achieved.
Speed range, full speed
– AQ205A 4400–4800 rpm
– AQ211A 4000–4400 rpm
– AQ231A 4200–4600 rpm
– AQ271C 4200–4600 rpm
– AQ311B 4600–5200 rpm
– BB231A 4000–4600 rpm
– BB261A 4000–4600 rpm
SAFETY EQUIPMENT
Irrespective of whether the boat is to be used for
long trips or short day trips, it should be equipped
with the following safety equipment. This can of
course be added to depending on your own wish-
es. Make regular checks to ensure that the safety
equipment is on board and that it is serviceable.
LIFE JACKETS of an approved make and of a
sufficient quantity for all those on board.
FIRE EXTINGUISHERS of an approved make.
There should be at least one on board and it
should be easily accessible.
DISTRESS ROCKETS and matches in watertight
packing.
FIRST AID BOX
TOOLS suitable for the equipment on board.
SET OF SPARES containing an impeller, spares
for the engine etc.
ANCHOR with anchor line.
RADAR REFLECTOR with attachment device.
RADIO for listening to weather reports.
COMPASS calibrated.
BOAT HOOK AND PADDLE
TOWING LINE AND FENDERS
FOGHORN AND WHISTLE
FLASHLIGHT
EXTRA PROPELLER AND TOOLS FOR RE-
MOVING AND REFITTING.
PREPARATIONS BEFORE STARTING
Check the following before starting the engine:
make sure that there are no FUEL LEAKS
make sure that there is no WATER LEAKAGE
from the engine
there must be no OIL LEAKS
you should not be able to detect the smell of
Gasoline or LP GAS down in the boat and other
areas
make sure the OIL LEVEL in the engine is cor-
rect
up-to-date CHARTS must be kept on board
there must be sufficient FUEL on board for the
journey you have planned.
WARNING! Beforefillingwith fuel, check
that there are no open flames in nearby.
Ventilatetheboatandoperatetheengine
roomfan beforestarting the engine. Do not
overfill the tank.
If any of the crew are on board for the first time,
the person concerned shall be instructed on the
operation of the boat, where the life jackets are
located, and where to find the fire extinguisher.
Also run through everything you consider is im-
portant in terms of safety with them. If anything
unforeseen arises during the course of the trip, it
is then often too late to instruct anybody on how
safety equipment operates.
STARTING THE ENGINE
Switch on the main power switch.
WARNING!Starttheengineroomfanand
let it run for at least 2 minutes before start-
ingtheengine.
Lower the drive if it has been tilted. Check that
there are no obstacles in the way of the propeller.
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Release the speed control from the gear function
as follows: Press the release button (1) while the
lever (2) is in neutral and then press the lever
slightly forward. Let go of the release button. The
lever will now only affect the speed control.
Turn the starter key one step to the right. Then
press it in and turn it one more step to start the
engine. Release the key as soon as the engine
starts.
Check immediately after starting that the instru-
ments for oil pressure and battery charging dis-
play normal readings. In the event of abnormal
readings, stop the engine immediately and inves-
tigate the cause.
Run the engine until it is warm at a fast idling
speed, i.e. at a speed between 900–1200 rpm.
The boat is ready for use when the needle of the
temperature gauge reaches the green area.
Reduce the engine speed to idling and check that
the engine runs smoothly. Pull back the control
level to the neutral position. The control level is
now linked to the gear function (this applies to
Volvo Penta controls).
RUNNING INSTRUCTIONS
The single control lever operates both the speed
and the power transmission.
F = Forwards
R = Reverse
N = Neutral
T = Throttle
To obtain good operating economy, the engine
should not be run at maximum speed for long pe-
riods.
While the engine is running, check that the en-
gine temperature is normal (within the green area)
and that the instruments for battery charging and
oil pressure display normal values. If the values
are abnormal, stop the engine immediately and
investigate the cause.
The outboard drive can be trimmed in and out hy-
draulically while in operation. To lower the bow of
the boat, one of the switches (1), (in the control
or on the instrument panel) shall be kept in the up
position until the required attitude is reached. To
raise the bow, switch (1) shall be kept in the low-
er position.
Caution! The two switches (1) must never be
used simultaneously.
WARNING!Exerciseextremecarewhen
running with the drive in the fully extended
position.
The Aquamatic drive can be trimmed within the
trim limit range to give the boat the best attitude.
In the case of the SP drive, the maximum trim
angle corresponds to 12 on the trim gauge and for
the DP 6.
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Running in shallow waters
If you are uncertain about the depth of water, we
recommend that you reduce the speed and tilt up
the drive. For the drive to pass the maximum trim
angle, switch (2) must be pressed in at the same
time and the overdrive (1) is held in the lower po-
sition. The drive can now be raised to a maximum
of 44. At 45 or more, the red warning lamp flash-
es on the instrument. The range above 45 is
only for use when the boat is moored in shal-
low water or when being towed on a trailer.
Reversing
The maximum position for reversing is when
the drive is raised to 44.
WARNING!Neverselectreversewhilethe
boat is planing.
SHUTDOWN PROCEDURE
After mooring, the engine should be allowed to
idle for a few minutes with the control lever in the
neutral position before the engine is switched off.
This is to prevent subsequent boiling of the en-
gine and consequent thermal loading. This is par-
ticularly important if the engine has been run at
high speed.
Stop the engine by turning the key switch to the
off position.
If the water is shallow at the mooring and there is
a risk of the drive striking the bottom, the drive
should be fully tilted. If there is sufficient depth of
water, there is no need to tilt the drive.
Switch off the main switch
WARNING! Themain switch must neverbe
switched off until the engine has stopped.
Damage to the electrical system can result.
COLD WEATHER PRECAUTIONS
Before leaving the boat, check that there are no
water leaks. If there is a risk of freezing, drain
the cooling water from the engine. The cooling
water on the port side and on the starboard side
is drained through cocks on the side of the engine
block and on the exhaust pipe.
Undo the cover on the sea water pump as well.
CAUTION! Close the cocks and tighten the cover
before you leave the boat.
If the boat is equipped with a sea cock make sure
it is also closed.
CHECK DAILY BEFORE STARTING
OIL IN THE ENGINE
Check the level daily to ensure that it is between
the maximum and minimum marks on the dip-
stick (1) and that the level is sufficient for the in-
tended trip.
Replenish with oil as required (2). Refer to “Tech-
nical Data” for the recommended oil specifica-
tions.
CHECK EVERY 14 DAYS
OIL IN THE OUTBOARD DRIVE
Check the oil when the drive is fully lowered.
Make sure that water cannot enter the hole for the
dipstick while the oil level is being checked. The
oil level shall lie between the max and min marks
on the dipstick which must not be screwed down
when checking. Replenish with oil through the dip-
stick hole as required. Refer to the Technical
Data for the choice of oil. Check that the dip-
stick’s sealing ring is in position when the dip-
stick is screwed into position again.
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OIL LEVEL IN THE MS4A REVERSE
GEAR
Check the oil using the dipstick (1). The oil level
shall be within the marks on the dipstick. CAU-
TION! The dipstick must not be screwed in when
checking the level. Replenish with oil as required
through the filler hole (2). Use the same type of
oil that is already in the reverse gear. Refer to
“Technical Data”.
OIL LEVEL IN THE HYDRAULIC
PUMP, POWER TRIM
Trim in the drive as far as possible. Remove the
level plug and check that the level reaches up to
the hole. Replenish as required through the hole.
Refer to Technical Data for the choice of oil. Ob-
serve strict cleanliness so that dirt is not drawn in
by the oil.
If the system has been drained, the system must
be trimmed in and out while replenishing.
OIL LEVEL, HYDRAULIC PUMP –
SERVO STEERING
Turn the filler cap anti-clockwise and remove it.
Check oil level on dipstick. The level shall be up
to the mark “Full cold” if the engine is cold. For
hot engine the level should be “Full hot”. Top up if
necessary with engine oil. For cold operating con-
ditions, ATF oil may be used.
ELECTROLYTE LEVEL IN THE
BATTERY
The electrolyte level shall be 5–10 mm (0.2–0.4")
above the cell plates. Top up with distilled water
as required.
CAUTION!Somemaintenance-freebatter-
ies are supplied with special instructions.
These instructions must be complied with.
BELT TENSION
Correct belt tension is a necessity if the alternator
is to provide full power. The belt tension is proper-
ly tensioned when it is possible to depress it 10
mm (0.4") with thumb pressure applied between
the pulleys.
A badly worn or split belt must be replaced. See
“Checking the drive belt”.
CHECKING THE CORROSION
PROTECTION
Replace the zinc ring when about half has been
consumed.
WARNING:Toachievegoodgalvaniccon-
tact, it is important for the contact surface
on the drive to be cleaned before a new
zinc ring is fitted.
Replace the zinc plate under the transom cover
when about half has been consumed.
WARNING!Toachievegoodgalvaniccon-
tact, it is essential for the contact surface
on the transom cover to be cleaned before
a new zinc plate is fitted.
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SERVICE EVERY 50 HOURS
OF OPERATION
Engine oil change
Change the oil in a new or reconditioned engine
after the first 20 hours of operation and then after
every 50 hours of operation.
Run the engine until it is hot. Suck up the oil
through the tube for the dipstick.
Replenish with oil to the correct level. Refer to
Technical Data for the correct choice of oil.
N.B. The oil filter must be changed at every other
oil change.
VALVE CLEARANCE
The motor has hydraulic valve lifters and valve
adjustment is not necessary.
LUBRICATING THE PRIMARY SHAFT
AND THE STEERING SHAFT
JOURNALS
Lubricate the primary shaft (1) with about 1 cm3of
water resistant grease. Lubricate the upper steer-
ing shaft journal (2) and the lower steering shaft
journal (3) with a grease gun. Use water-resistant
grease. Continue applying grease until grease is
forced out of the journal.
SPARK PLUGS
Check the spark plug gap and adjust as required.
If the spark plugs are damaged or worn, or if the
electrodes are rounded, they must be replaced
with equivalent ones. See under Technical Data.
SERVICE EVERY 100 HOURS OF
OPERATION OR AT LEAST ONCE
PER SEASON
OIL FILTER
The oil filter is changed for the first time after 20
hours of operation and then after every 100 hours
of operation (every other oil change). Unscrew the
old filter. If the old filter is difficult to undo, there
is a special tool which can be used. Alternatively,
a screwdriver can be driven through the outer
casing of the filter and then used as a lever.
CAUTION! Be careful not to spill oil.
Coat the rubber seal on the new filter with oil.
Check the contact surface on the engine and
screw on the filter by hand until it makes contact
with the face of the engine. Then tighten the filter
a further half turn – no more.
CAUTION! Use only genuine Volvo Penta oil
filters or filters with the same capacity, connec-
tion and size.
WARNING! Filterswhichdo not comply
withthe requirements cancausethe engine
tobreakdown.
Start the engine, let it run at idling speed and
check straight away that the oil pressure gauge
shows the correct reading.
Check the oil level and also check that there is
no oil leakage around the filter.
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Oil change in the drive (every 200 hours)
Draining the oil (to be carried out on land)
Remove the dipstick. Tilt the drive up a little. Re-
move the plug on the underside of the propeller
gear housing and let the oil run out. Refit the plug
with its O-ring.
Refilling
Remove the cover and remove the oil filter plug.
Refilling with oil. Refer to Technical Data for quali-
ty and quantity. Refit the plug together with its
O-ring. Lower the drive. Check the oil level with
the aid of the dipstick. It must not be screwed in
when checking the level. Replenish to the correct
level through the hole for the dipstick. Oil must be
drained off if the level is too high. Fit the oil dip-
stick with its O-ring and tighten.
WARNING!Checkthattheoildrainplug
does not leak.
CHANGING THE OIL IN THE MS4A
REVERSE GEAR
Use the oil drain pump to suck up the oil through
the hole for the dipstick (1).
The reverse gear is refilled to the upper mark on
the dipstick through the oil filter hole (2). Then
start the engine and run it at idling speed a few
minutes to fill the reverse gear’s oil cooler with
oil. Stop the engine and check the oil level. Add
more oil as required.
CHECKING THE V BELT
The drive belt must be changed if there are signs
of wear or splits. Undo the alternator’s attachment
bolts 1 and 2 and take off the belt. Clean the
grooves on the pulleys before a new belt is fitted.
Tension the belt so that it can be depressed
about 10 mm (0.4") with thumb pressure half way
between the drive pulleys. Check the tension of
the belt again after a few hours of operation and
re-tension as necessary. The most satisfactory
tension is obtained if adjustment is carried out im-
mediately after the engine has been run and the
belt is warm and flexible. Use Volvo Penta origi-
nal V belts.
IGNITION SYSTEM
Any adjustment to the engine’s ignition system
should be carried out by an authorized workshop
that has the correct equipment for the job. The ig-
nition system is sensitive and incorrect action
may have serious consequences.
The distributor must be checked on a test bench.
Use a stroboscope for checking the ignition tim-
ing. Refer to Technical Data for the timing setting.
Lubricate the distributor with a few drops of oil on
the drive spindle’s felt pad under the rotor.
AQ205A, AQ271C, AQ311B
The ignition is electronically controlled and cannot
be adjusted.
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CHECKS AND SERVICE
CARBURATOR
Correct carburator adjustment is a “must” if the
engine is to operate correctly and at optimum fuel
economy. For this reason you should allow an au-
thorised workshop to check the adjustment some
time during the season.
Adjust the idling setting as follows:
1 Run the engine until it has reached its working
temperature and the choke has opened fully.
2 Adjust the idling speed (see under “Technical
Data”) with the slow running screw (1).
3 Check that there is no air leakage between the
carburetor and the induction pipe (a leakage in-
creases the engine speed).
Adjust the fuel/air mixture with the bleed screw
(2) so that the best and most regular idling is
achieved. Begin by screwing in the bleed screw
until the engine starts to run rough, then screw
out the screw until the best idling conditions are
reached. Finely adjust the engine speed with the
slow running screw if necessary.
The carburetor’s fuel filter
The carburator is fitted with a fuel filter in the fuel
line connection next to the carburator.
Check the filter at least once a season or as re-
quired
Check: Undo the fuel line and remove the nipple
in the filter housing (be careful not to spill fuel).
The filter can now be removed for checking.
(Wash in solvent.) Be careful of the spring inside
the filter. Refit in the reverse order. The filter’s
closed end must face into the carburator. Check
the seal between the nipple and the filter housing.
Start the engine and check that all connections
are tight.
Fuel filter by the fuel pump
The fuel filter must be replaced once per season
or after every 100 hours of operation. Remove the
filter, discard it and install a new one. Watch out
not to spill fuel!
CHECKING THE COOLING SYSTEM
The temperature gauge for the coolant has a
green area – this indicates the normal coolant
temperature in the engine.
Check the cooling system immediately in the
event of abnormal temperatures.
Excessive temperature may be caused by a
blocked water inlet, defective pump impeller in
the sea water pump, blockages in the cooling gal-
leries or an unserviceable thermostat or instru-
ment.
WARNING!Becarefulofwaterpenetra-
tion when working on the cooling sys-
tem.
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CHECKING AND REPLACING THE
IMPELLER IN THE SEA WATER
PUMP
The pump can be damaged by a shortage of wa-
ter. Check the pump impeller.
WARNING!Becarefulofwaterpenetrating
theboat.
Remove the cover from the water pump. Inspect
the pump impeller. The impeller must be replaced
if it is damaged. Remove the impeller with the
help of two screwdrivers. Be careful not to dam-
age the housing.
ELECTRICAL SYSTEM
WARNING!Theengineisequippedwithan
alternator.Ifthealternatorandthe regulator
are to operate satisfactorily, it is important
that the following instructions be observed.
1. The main switch must not be switched off
until the engine has stopped.
Never disconnect the battery cables or other
cables in the charging circuit when the engine
is running since this can destroy the regulator
and seriously damage the alternator.
2. The battery terminals’ polarities must
never be mixed since this can seriously
damage the electrical equipment.
The battery terminals are marked with a posi-
tive and a negative symbol. The cable from
the negative terminal is connected to the en-
gine block. The cable terminals must be prop-
erly tightened and greased.
3. The charging circuits must not be
switched while the engine is running.
Fit a Volvo Penta charge distributor (acces-
sory) to the alternator if more than one battery
is fitted.
4. An auxiliary battery shall be used as follows:
The regular battery shall remain connected.
Connect the auxiliary battery to the regular
battery with positive to positive and negative
to negative. Disconnect the auxiliary battery
when the engine has started. Do not discon-
nect the regular battery’s circuit under any cir-
cumstances.
5. Do not use a booster charger when the alter-
nator is connected to the battery. Never use a
booster charger to assist during actual start-
ing.
6. Disconnect both battery cables before any
type of work is to be carried out on the electri-
cal system or the alternator.
7. If any welding is to be carried out on the en-
gine or its equipment, the charging regulator’s
cables must be disconnected at the alternator
and insulated.
8. Check the belt tension and the cable connec-
tions regularly.
Reset button on fuse
The engine is equipped with an automatic fuse
which breaks the electrical circuit if it is overload-
ed. The fuse has a reset button (1). Always in-
vestigate the cause of the overload.
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Fuses in the electrical system (Power Trim)
The electrical circuit for the Power Trim has a
55A fuse (a spare fuse is supplied with the en-
gine) fitted by the starter motor and a 5A fuse at
the control.
Fuses in the electrical system
The engine is also fitted with two replaceable 8A
fuses in the instrument panel.
Always keep spare fuses on board.
Checking the starter motor and alternator
Let all work on the starter motor and alternator be
carried out by an authorized Volvo Penta service
workshop. An inspection and checks should be
carried out in conjunction with a general overhaul
of the engine.
BATTERY
WARNING! Thebattery mustnot be ex-
posed to a naked flame or an electric spark.
Do not smoke in the vicinity of the battery.
Thebatteryproduceshydrogenwhichis
easily ignited and explosive. The battery
fluid contains sulphuric acid.
Do not allow the battery acid to come in contact
with your eyes, skin or painted surfaces. If this
should happen however, wash the area affected
with water immediately. Contact a doctor if the
eyes are affected.
Checking the battery
Check the charge state of the battery and the
electrolyte regularly. The correct level is 5–10
mm (0.4") above the cell plates. The battery con-
nections shall be clean, greased and tight.
SERVICE IN CONNECTION WITH
LAYING-UP AND LAUNCHING
THE BOAT
INHIBITING
If the boat is lying in the water unused, the engine
should be run until it is warm at least once every
14 days. If the boat is not going to be used for a
period exceeding 1 month, long-term inhibiting
should be carried out.
INHIBITING WHEN LAYING UP FOR
THE WINTER
Before the motor is long-term inhibited, an author-
ised Volvo Penta workshop should test the en-
gine and its equipment. If anything needs to be
repaired, let the workshop carry out the repair in
good time before launching the boat again.
INHIBITING PROCEDURE
Carried out while the boat is in the
water
Let the engine run at fast idle for a few minutes.
Then stop the engine.
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47 5049
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48
Pump all the oil out of the engine. Use the oil
drain pump.
Replace the oil filter. Replenish with Volvo Penta
engine oil since this also has corrosion protection
properties. The engine is now ready to be run on
this oil next season.
Use special inhibiting oil if the laying up period is
longer than a normal winter laying up period. If
this is the case, the oil filter must be changed be-
fore launching.
Inhibiting to be carried out on land
Undo the cooling water hose by the transom cov-
er and insert the free end into a bucket containing
fresh water. Make sure there is a water supply to
the bucket. Remove the thermostat.
Run the engine at fast idle for a few minutes.
CAUTION: The pump cannot withstand being run
dry. Drain the system.
Prepare a mixture of 50% fresh water and 50%
corrosion protective anti-freeze.
Insert the hose in the mixture. Arrange so that the
mixture which is pumped through is collected.
Start the engine and let it idle until the mixture is
finished. Check that nothing is lowered behind the
exhaust outlet.
WARNING!The water pump must not be
allowed to run dry.
The combined corrosion and frost protection mix-
ture need not be drained. The engine is not pro-
tected against frost if it is inhibited with emulsify-
ing oil. This must be drained. Check that the wa-
ter runs out since contamination can block the
cocks. Then close all cocks.
Remove the cover from the coolant water pump.
Remove the impeller. Check that the impeller is
serviceable. Rinse the impeller in fresh water and
store it in a sealed plastic bag until it is time to fit
it again. A worn or damaged impeller must be re-
placed. Refit the cover. Reconnect any hoses
that were undone.
Carefully undo the oil drain plug at the bottom of
the drive and let a few drops of oil run out. Check
that the oil is clean and not discoloured.
No further inhibiting of the drive lubricating sys-
tem is necessary. Remove the propeller(s) and
coat the shaft with rust inhibiting oil.
Volvo Penta strongly recommends to remove the
outdrive and carefully inspect the u-joint bellows
and hoses. Lubricate the splines and pivot pins.
Inspect and lubricate the reverse latch mecha-
nism.
Clean the exterior of the drive and the engine.
Paint over any chafed patches with original paint.
Spray the electrical system’s components and all
control parts with water-repellent spray.
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55 5857
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Remove the battery.
PROCEDURE WHEN LAUNCHING
Only the oil level need be checked if Volvo Penta
oil has been used to inhibit the engine.
Both the oil and the filter must be changed if oth-
er inhibiting oil has been used. Refer to “Service
every 50 hours”.
Check the oil in the drive. If the level is too high,
it must be lowered by draining some of it off. If
the level is too low, replenish via the dipstick
hole.
CAUTION: The dipstick must not be screwed in
when checking the level. Also check the oil in the
hydraulic pump for Power Trim and Power Steer-
ing. Replenish as required.
Check the tightness of all hose clamps. Check
that all drain cocks and drain plugs are closed.
Clean the engine and the drive externally. Check
the exhaust hose.
Carefully check the bellows for any damage and
check the tightness of the clamps. CAUTION:
The joint bellows and clamps should be changed
every third year. Let an authorized workshop
check and replace the bellows.
WARNING!Neverworkonthedrive’sbel-
lows or hydraulics before locking the drive
in the raised position in such a way that it
cannot possibly fall. A falling drive can
cause serious bodily injury.
Tool (884863-2) when carefully fitted can prevent
the drive from falling. The tool shall be used for
locking the drive in the raised position. Fit the tool
as follows:
Put your hand in from behind the cover’s zinc
plate and take hold of the retaining pawl (1).
Press the retaining pawl down at the same time
as the drive is lifted up by hand to the fully raised
position. Hold the drive steady in this position and
fit the tool (2) on the starboard side as shown in
the figure. CAUTION: Do not overload the tool by
standing on the raised drive.
Check the condition of the paintwork on the out-
board drive. Damaged paint shall be repainted
with Volvo Penta original paint. Then paint the
drive with anti-fouling paint specially formulated
for use with aluminium outdrives. Volvo Penta of-
fers such a paint for some markets (not available
in USA).
Paint the bottom of the boat with growth inhibiting
paint. CAUTION! Growth inhibiting paint which
contains copper must not be used since this can
cause corrosion damage to the drive. Launch the
boat when the paint has dried.
Check that the batteries are fully charged. Smear
the cable terminals with terminal grease. Connect
the battery cables. CAUTION! Do not mix the
polarities. Tighten the battery connection proper-
ly.
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60
Start the engine. Run the engine with the drive en-
gaged if possible. Check that there are no fuel,
water or exhaust leaks in the boat. Also check
that the controls operate correctly.
Contact an authorized Volvo Penta workshop as
required.
Let the workshop carry out a service on the motor
and the drive according to the instructions in the
servicing schedule.
PROPELLERS, DP
The propellers are matched sets. Propellers with
different colour marking must not be fitted to the
same drive. A damaged propeller must be
changed without delay. Operate with extreme cau-
tion if a propeller is damaged. Do not drive with a
single propeller since this can damage the propel-
ler shafts.
The forward propeller is locked with a nut (1) and
tab washer (2). One of the tabs on the washer
must be bent into one of the recesses in the nut.
The rear propeller is locked with a cone (3). The
cone is locked with a screw (4), spanner jaw width
24 mm. (Tightening torque 22 Nm, 16 lb.ft.) Lubri-
cate the shaft with grease. Use Volvo Penta
grease (part number 828250-1).
WARNING! Handlethefishline cutter with
care since the edge is sharp and can cause
injuryanddamage.
PROPELLERS, SP
The propeller is locked to the shaft with a screw
and a propeller cone. Undo the screw and remove
the boss. Remove the propeller. CAUTION: In-
side the propeller there is a spacer sleeve and a
deflector ring. A damaged propeller must be re-
placed.
1. Apply a thin film of grease on the propeller
shaft.
2. Fit the deflector ring (1).
3. Fit the propeller.
4. Fit the plastic washer (3).
5. Fit and tighten the propeller cone (4).
6. Fit and tighten the center screw.
ADJUSTING THE RETAINING PAWL
Check once a season and if necessary adjust the
location of the retaining pawl rod in relation to the
retaining paw] (A). Adjust as follows:
1. Remove the protective cover (1). Move the
control lever to neutral.
2. Disengage the shift cable swivel (2) and the
fork (3).
3. Release the locknut for the fork (3). Adjust
the fork so that when it is connected to the
lever it causes the retaining pawl rod (4) to
take up such a position that it reaches the re-
taining pawl bracket at “A” without pressing
against it. Lock the fork (3) with the locknut.
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4. Adjust the swivel (2) so that it easily enters
the hole in the shift yoke. Move the control
lever to the “Forward” position and check that
the corner “C” does not foul the housing. Refit
the cover (1).
ADJUSTING COURSE DEVIATION
Check for any course deviation by cautiously re-
leasing the wheel while the boat is planing. If the
boat veers to port, undo the trim tab under the
cavitation plate. Then turn the trim tab (1) to port
and lock it in this position. Test run the boat.
Continue adjustment if the boat still tends to veer
to port. Reverse the adjustment for starboard
course deviation.
PROPELLERS – Aquamatic DP model
WARNING!Thereare2differentpropeller
series for the Aquamatic model DP. Series
“A” is intended for diesel engines and series
“B”is intended onlyfor petrol (gasoline)en-
gines. The series type is shown on a decal
attached to the front edge of the hub on the
rearpropellerandalso by thenumberof
bladesontherearpropeller.Series “A” have
a green decal and 4 blades, series “B” have
a red decal and 3 blades.
Series “B” must only be used together with
V6 and V8 Aquamatic engines.
Series “A” must under no circumstances be
used together with V6 and V8 Aquamatic
engines, as this combination can make the
boatunstable andresultin“unexpected”
turns at high speeds.
NOTE! Earlier versions of series “A” Duoprop pro-
pellers were painted black, for series “B” white.
They were not provided with decals, but the se-
ries type can be established by the number of
blades of the rear propeller.
Troubleshooting chart
Troubleshooting
The troubleshooting chart given below lists only
the more common types of faults which could oc-
cur. With the help of the instructions given in the
handbook, the owner can usually rectify most of
the faults listed below. When in doubt, always
contact the nearest Volvo Penta workshop.
Follow the instructions in the troubleshooting
chart – it helps to provide trouble-free run-
ning.
Engine
will not
start
Engine
stops Engine does
not attain top
speed at full
throttle
Runs une-
venly or vi-
brates ab-
normally
Engine
overheats CAUSE
Main switch not switched on, flat battery, break in
electric circuit or main fuse.
Empty fuel tank, fuel cock closed, blocked fuel filter.
Water or contamination in the fuel.
Worn or oily spark plug.
Burned points (Not AQ205, AQ271, AQ311), mois-
ture in the distributor and ignition cables.
Idling speed not properly adjusted.
Incorrect rev counter.
Boat abnormally loaded.
Growth on the bottom of the boat and on the out-
board drive.
Damaged or incorrect propeller.
Blocked coolant inlet, oil cooler, cooling galleries,
heat exchanger, damaged impeller or thermostat.
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Technical data
General
Engine designation................................................... AQ205A AQ211A AQ271C
AQ231A AQ311B
BB231A BB261A
Type ........................................................................... 4-stroke 4-stroke 4-stroke
Number of cylinders (90°V) ...................................... 6 8 8
Output (see ‘Sales Literature’)
Bore mm (in).............................................................. 101.6 (4.0) 95 (3.75) 101.6 (4.0)
Stroke mm (in) ........................................................... 88.4 (3.48) 88.4 (3.48) 88.4 (3.48)
Swept volume dm3(cu.in) ......................................... 4.29 (262) 5 (305) 5.74 (350)
Compression ratio .................................................... 9.3:1 9.3:1 9.3:1
Compression pressure (starter motor) ..................... 10.0–11.0 10.0–11.0 10.0–11.0
kp/cm2kp/cm2kp/cm2
(142–156 p.s.i.) (142–156 p.s.i.)
Recommended cruising speed ................................ 300–500 rpm lower than the
obtained max. speed
Idling speed............................................................... 750 rpm
Direction of rotation (seen from front of engine) ... Clockwise
Maximum propeller diameter.................................... 16"
Gross weight (engine, risers and sterndrive) kg (lbs) DP355 (782) SP351 (773) DP402 (885) SP398 (876)
Ratio, sterndrive model SP ...................................... 1.61:1 1.61:1 1.61:1
sterndrive model DP...................................... 2.30:1 1.95:1 1.95:1*
reverse gear MS4A........................................ – 1,5:1 or 1,9:1
* NOTE! Sterndrive model DP not available for AQ311B.
Valves
Valve system ............................................................. Overhead valves Hydraulic
lifters (non-adjustable)
Cooling system
Thermostat, limit values °C (°F)................................ 62–72 (153–160)
Fuel System
AQ205, AQ211, AQ231, BB231, BB261 –
Carburettors model ................................................... ‘Rochester’
AQ271, AQ231 – Carburettors model ...................... ‘Holley’
Fuel Quality
Gasoline with an octane value of min. 91 (RON)
(USA 87 R+M/2). The engines can be run on
unleaded fuel.
Lubricating System
Engine:
Oil Quality............................................................... Service SF (SE)
Viscosity ................................................................. SAE 10W/30
Capacity, excl oil filter litres/US qts. ...................... 3.8/4.0 5.0/5.3 5.0/5.3
Capacity incl. oil filter litres/US qts. ....................... 4.2/4.4 5.4/5.7 5.4/5.7
Capacity incl. oil filter litres/US qts. and oil cooler 5.6/5.9
AQ311B only

18
Capacity between min and max marks on the
dipstick litres/US qts .............................................. 1.0/1.0 1.0/1.0 1.0/1.0
Sterndrive, model SP:
Oil quality/viscosity ................................................ Same as engine
Capacity litres/US qts................................................ 2.6/2.7
Capacity between min and max marks on the
dipstick litres/US qts. ............................................. 0.15
Sterndrive, model DP:
Oil quality/viscosity ................................................ API-GL5 (SAE90 or 80W90)
Capacity litres/US qts. ........................................... 2.7/2.8
Capacity, Power Trim hydraulic system litres/US qts. 0.52/0.54
Quality, Power Trim hydraulic system .................... Same as engine or ATF
Power steering
Oil quality ............................................................... Same as engine or ATF
Reverse gear MS4A
Oil volume litres/US qts ......................................... 1.7 (1.8)
Oil quality ............................................................... API-GL5 (SAE90 or 80W90)
Ignition System
Firing order ................................................................ 1-6-5-4-3-2 (V6), 1-8-4-3-6-5-7-2 (V8)
Stroboscope setting
AQ205A, 2500 rpm ................................................ 16° BTDC
AQ211A, AQ231A, BB231A, 2500 rpm................. 14° BTDC
BB261A, AQ271C, 3000 rpm ................................ 23° BTDC
AQ311B, 3000 rpm ................................................ 25° BTDC
Basic setting (idling speed)................................... 6° BTDC
(AQ205A, AQ311B, 8° BTDC)
Distributor, contact gap mm (in)
(AQ211A, AQ231A, BB231A, BB261A).................... 0.36–0.48 (.014–.019")*
Dwell angle – AQ211A, AQ231A, BB231A, BB261A 28°–34°
Spark Plugs – Volvo Penta p/n 875816-1 gap mm (in) 0.9 (.035")
Electrical system
Voltage ...................................................................... 12 V (negative ground)
Battery capacity ......................................................... 60 Ah
Battery electrolyte spec. gravity ................................ 1.275–1.285
to be recharged at ........................................ 1.230
Alternator, max output Amp (W)................................ 50 (50x14)
Starter motor output kW (hp)..................................... 0.96 (1.3)
Tightening torques
Cylinder head bolts................................................... 90 Nm 9.0 kpm 66 lb.ft
Spark plugs ............................................................... 21 Nm 2.1 kpm 16 lb.ft
Steering helmet bolts (Aquamatic) ........................... 35 Nm 3.5 kpm 26 lb.ft
* AQ205A, AQ271, 311 Air gap 0.2 (0.008").