Mercury Racing HP1200 SCi Dry Sump Operation, Maintenance & Warranty Manual Download Page 3

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iii

CAUTION

Indicates a hazardous situation which, if not avoided, could result

in minor or moderate injury.

NOTICE

Indicates a situation which, if not avoided, could result in engine

or major component failure.

IMPORTANT: Identifies information essential to the successful

completion of the task.

NOTE: Indicates information that helps in the understanding of a

particular step or action.
Copyright and Trademark Information

Mercury Marine, Fond du Lac, Wisconsin U.S.A.
Litho in U.S.A.
© 2006, Mercury Marine
Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser,

Mercury Racing, Mercury Precision Parts, Mercury Propellers,

Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Pro Max,

OptiMax, Sport‑Jet, K‑Planes, MerCathode, RideGuide,

SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves

logo, and SmartCraft logo are all registered trademarks of

Brunswick Corporation. Mercury Product Protection logo is a

registered service mark of Brunswick Corporation.

Summary of Contents for HP1200 SCi Dry Sump

Page 1: ...eference whenever you are on the water Again thank you for purchasing one of our Mercury Marine products We sincerely hope your boating will be pleasant Mercury Racing N7480 County Road UU Fond du Lac...

Page 2: ...tices0 accompanied by the international HAZARD symbol are used to alert the technician to special instructions concerning a particular service or operation that may be hazardous if performed incorrect...

Page 3: ...ep or action Copyright and Trademark Information Mercury Marine Fond du Lac Wisconsin U S A Litho in U S A 2006 Mercury Marine Mercury Mercury Marine MerCruiser Mercury MerCruiser Mercury Racing Mercu...

Page 4: ...iv...

Page 5: ...ng 9 Impact With Underwater Hazards 10 Trailering Boat 11 Safe Boating Suggestions 11 Stolen Power Package 14 Specifications Fuel Requirements HP1200 SCi 15 Crankcase Oil 17 Capacities 18 General Engi...

Page 6: ...e Service Responsibilities 39 Replacement Service Parts 40 Do It Yourself Maintenance Suggestions 40 Servicing High Horsepower Engines 42 Maintenance Charts 42 Checking Fluid Levels 45 Changing Fluids...

Page 7: ...rature 92 Low Engine Oil Pressure 93 Battery Will Not Come Up On Charge 93 Power Trim Does Not Operate Motor Doesn t Run 93 Power Trim Does Not Operate Motor Runs But Drive Unit Does Not Move 94 Remot...

Page 8: ...viii...

Page 9: ...WARRANTY INFORMATION 1 Warranty Coverage Mercury Racing does not offer a warranty with this power package...

Page 10: ...x WOT RPM Spark Plugs Spark Plug Gap Firing Order 1075 SCI 557 CI 9 1 Liter 5600 6000 NKG BRCECS 0 76 mm 0 03 in 1 8 4 3 6 5 7 2 Fuel Octane 92 AKI R M 2 or 98 RON Preferred Engine Oil Mercury 25W 40...

Page 11: ...er about service always specify model and serial numbers 1 The engine serial number is printed on the center of the bell housing and stamped into the front of the port cylinder head along with the cra...

Page 12: ...manufacturer following certain federal guidelines If in doubt contact your dealer or the boat manufacturer U S COAST GUARD CAPACITY MAXIMUM HORSEPOWER XXX MAXIMUM PERSON CAPACITY POUNDS XXX MAXIMUM WE...

Page 13: ...egree of any turn at shut down However the boat will not complete a full circle While the boat is coasting it can cause injury to anyone in the boat s path as seriously as the boat would when under po...

Page 14: ...ngers in the front of the boat who could be ejected over the bow and possibly struck by the gear case or propeller Loss of power and directional control in heavy seas strong current or high winds Loss...

Page 15: ...us boat accessories Carbon monoxide is a deadly gas that is odorless colorless and tasteless Early symptoms of carbon monoxide poisoning which should not be confused with seasickness or intoxication i...

Page 16: ...e b Mooring close to another boat that has its engine running While Boat is Moving 5449 a b a Running the boat with the trim angle of the bow too high b Running the boat with no forward hatches open s...

Page 17: ...occupants to be thrown out of their seats or out of the boat WARNING Avoid serious injury or death from being thrown within or out of a boat when it lands after jumping a wave or wake Avoid wave or w...

Page 18: ...go boating Consider the following Ensure that the depth finder is calibrated offset to include the distance from the waterline to the depth finder When using a depth finder that is not calibrated add...

Page 19: ...loose parts If damage is present or suspected the sterndrive should be taken to an authorized dealer for a thorough inspection and necessary repair The boat should also be checked for any hull fractur...

Page 20: ...ubs and an appropriate wrench Tools for necessary minor repairs First aid kit and book Anchor and extra anchor line Water proof storage containers Manual bilge pump and extra drain plugs Compass and m...

Page 21: ...other boat operators Train at least one other person on board in boat operation and handling in case the driver becomes disabled or falls overboard Passenger boarding Stop the engine whenever passeng...

Page 22: ...beyond first aid 3 There is damage to boats or other property where the damage value exceeds 500 00 4 There is complete loss of the boat IMPORTANT Local law enforcement agencies will have a complete l...

Page 23: ...fuel components should be inspected for leakage softening hardening swelling or corrosion Any sign of leakage or deterioration requires replacement before further engine operation CAUTION Use of impro...

Page 24: ...are more severe with methanol Increasing the percentage of alcohol in the fuel can also worsen these adverse effects Some of these adverse effects are caused because the alcohol in the fuel can absor...

Page 25: ...fuel containing alcohol in a fuel tank for a long period of time IMPORTANT Because of possible adverse effects of alcohol in gasoline it is recommended that only alcohol free fuel be used where possi...

Page 26: ...Multi viscosity Oil 20 0 20 40 60 80 100 F C SJ SL CF 2 CF 4 CG 4 CH 4 CI 4 20 30 10 20 0 30 40 10 Mercury Quicksilver 25W 40 Premium Multi Viscosity 20W 50 7411 Capacities Model HP1200 SCi Oil reserv...

Page 27: ...troke 111 mm 4 375 in Compression ratio 7 9 1 Supercharger Dual Screw type compressors Altenator 65 amp 917 watt Battery requirements 750 CCA 950 MCA Ignition type PCM 07 Distributorless Spark plug ty...

Page 28: ...psi Minimum oil pressure idle Hot 100 kPa 15 psi Minimum oil pressure at 6000 RPM Hot 375 kPa 55 psi Maximum oil temperature at 6000 RPM Hot 140 C 284 F California Emissions Regulations An emission ce...

Page 29: ...Frequently check engine oil level at reservoir sight tube Add oil if needed It is normal for oil consumption to be high during break in period After Break In Period To help extend the life of your pow...

Page 30: ...he engine unless avoiding a hazardous situation ENGINE GUARDIAN SYSTEM The Engine Guardian System monitors the critical sensors on the engine for any early indications of problems The system responds...

Page 31: ...voked Steady Horn Yes No Low Oil Pressure Steady Horn Yes Yes 100 down to 15 Oil Temperature Overheat 5 beeps 3 Sec Long Yes Yes 100 down to 15 Engine Overspeed Steady Horn Yes No Rev limit with no po...

Page 32: ...Sensor Failure 3 Beeps 1 5 Sec Long Yes No Charge Temperature Sensor Failure 3 Beeps 1 5 Sec Long Yes Yes 70 CAN Bus Problem 3 Beeps 1 5 Sec Long Yes Yes 70 or Forced Idle Coolant Temperature Sensor 3...

Page 33: ...block B d 50 amp main power circuit breaker e 25 amp fuel pump circuit breaker f PCM Fuse Holder b Fuse Holder c 5 amp Hour Meter A RED GRN 5 amp Fuel Pump Relay A RED BLK B RED ORN B RED PNK 15 amp...

Page 34: ...sconnect all accessories connected to the engine and instrumentation wiring and reset the circuit breaker 2 If the breaker remains open electrical overload is still present Inspect the electrical syst...

Page 35: ...onsole Mounted Zero Effort 1 Control the throttle by moving the longer control lever s or to increase speed push the control lever forward Detents give the movement of the lever a notched precise feel...

Page 36: ...e should be adjusted by your dealer to engage forward reverse and neutral when the lever is at the appropriate detent a b c 4090 a Throttle control lever b Power trim switch c Shift control lever 3 Se...

Page 37: ...at a 3 to 5 angle to the water 7418 a a Boat bottom at 3 to 5 angle with water Trimming Drive Unit Up Out Can Generally increase top speed Increase clearance over submerged objects or a shallow bottom...

Page 38: ...ing if any turn is attempted or if a significant wave is encountered POWER TRIM OPERATION CAUTION Avoid twisting or binding dual engine tie bars Damage to the tie bar and sterndrives could occur Alway...

Page 39: ...installations the individual trim switches can be used to fine tune the drives by setting each drive unit to the desired trim angle The use the single trim switch in the handle to control the trim of...

Page 40: ...ORTANT If the engine has not been operated for more than 24 hours Mercury Marine recommends priming the engine oil system NOTE Engines that have not been started for extended periods or have had fuel...

Page 41: ...firm quick motion forward to shift to forward gear or backward to shift to reverse After shifting the drive unit advance the throttle to the desired setting 10 To shift the drive unit out of gear thro...

Page 42: ...ed Warranty Drain Plug and Bilge Pump The engine compartment in your boat is a natural place for water to collect For this reason boats are normally equipped with a drain plug and or a bilge pump It i...

Page 43: ...of the situations described in the preceding caution water entering the engine could cause severe damage to internal parts Refer to Attention Required After Submersion in the General Information sect...

Page 44: ...f barnacles and marine growth Free of distortion and nearly flat where it contacts the water Straight and smooth both fore and aft Marine vegetation may accumulate when the boat is docked clogging wat...

Page 45: ...rating RPM range are listed in Specifications IMPORTANT All Mercury Racing engines have a RPM rev limiter that is set to an upper or limited RPM This limit is slightly above the normal operating range...

Page 46: ...ssion EXAMPLE An engine running at an elevation of 2 438 m 8 000 ft will have over a 30 power loss while engine power on a hot and humid day can be reduced by as much as 14 These losses apply to both...

Page 47: ...imum See your authorized Mercury Marine dealer for service aids DEALER RESPONSIBILITIES In general a dealer s responsibilities to the customer include predelivery inspection and preparation These incl...

Page 48: ...robably the least suspected special replacement part is the cylinder head gasket Since saltwater is highly corrosive the steel type automotive head gasket cannot be used A marine engine head gasket us...

Page 49: ...If you partially disassemble an engine or drive assembly and are unable to repair it the dealer s mechanic must re assemble the components and test to determine the problem This will cost you more tha...

Page 50: ...due to the extreme duty cycles and related stress these products endure Failure to follow the detailed maintenance and service schedule as written and supplied by Mercury Marine could lead to catastr...

Page 51: ...ps Inspect exhaust system condition and tighten clamps Inspect electrical system for loose or damaged wires Replace high pressure fuel filter element Inspect throttle and shift components for wear and...

Page 52: ...et Nuts Inspect and tighten to specifications as needed Propeller Shaft Lubricate Propeller Nut Torque to specification Sterndrive Inspect clean and spray with rust preventative Every 50 hours of oper...

Page 53: ...ing Oil Filter and Oil Change the oil and filter Every 200 hours of operation or once a year whichever occurs first Perform 25 50 and 100 Hour Maintenance Items Transom Input Shaft Bearing Housing Dri...

Page 54: ...e engine oil pan When the engine is started this oil will be pumped back into the reservoir CHECKING DRIVE UNIT OIL CAUTION Avoid damage to the sterndrive The input shaft housing must be filled with l...

Page 55: ...l the input shaft housing b through the top fill pipe plug hole a until oil flows from the reservoir level plug hole c a b c 7428 150 a Fill pipe plug hole b Input shaft housing c Reservoir level pipe...

Page 56: ...gearcase and fill until oil comes out of the top vent plug a opening 7429 a b 150 a Drive unit vent plug b Fill Drain plug and sealing washer Tube Ref No Description Where Used Part No 150 Torco MTF...

Page 57: ...ER TRIM PUMP FLUID 1 Place the drive unit in the full down in position a b c 114 7432 a Fill Vent screw b FULL mark c ADD mark Tube Ref No Description Where Used Part No 114 Power Trim and Steering Fl...

Page 58: ...to loosen the screw could result in damage to the pump 6 Re install the fill vent screw until it seats then loosen it 1 1 2 turns to vent the pump CHECKING TRANSMISSION FLUID LEVEL IMPORTANT The first...

Page 59: ...k established when the boat was first run a b FULL c 6790 a Dipstick b FULL mark c Dipstick tube Tube Ref No Description Where Used Part No Type F or FA Transmission Fluid Transmission Obtain Locally...

Page 60: ...nsion bottle IMPORTANT Only use the bottle for fluid expansion and overflow Changing Fluids CHANGING CRANKCASE OIL RESERVOIR AND FILTERS 1 Place a sufficiently sized container 19 liters 20 U S qt belo...

Page 61: ...into the reservoir to be drained 4 Drain the oil overflow canister into a suitable container a 7438 a Vent canister 5 To replace the spin on the oil filter b a 7439 a Retaining clamp b Stop screw a L...

Page 62: ...nt so it can be returned to its original orientation with the correct side up Clean the element with solvent IMPORTANT The screen style filter element must always be returned to its original orientati...

Page 63: ...MAINTENANCE 55 8 Install the bottom oil reservoir plug and tighten securely a 7436 a Oil drain plug 9 Begin by filling the oil reservoir with 11 4 liters 12 U S qt of oil...

Page 64: ...drill motor 11 Add any additional oil to the reservoir to bring the oil level to approximately 25 4 mm 1 in below the bottom of the reservoir split ring 12 Install the oil pump belt and tighten the p...

Page 65: ...to ensure that the system operates properly and should be performed only by an authorized Mercury MerCruiser dealer CHANGING TRANSMISSION OIL 1 Place a suitable container approximately 3 8 liter 4 qts...

Page 66: ...with the dipstick If addition oil is required add it through the dipstick tube to bring the level up to the FULL mark a b FULL c 6790 a Dipstick b FULL mark c Dipstick tube Tube Ref No Description Wh...

Page 67: ...below the input shaft housing and remove the bottom pipe plug b a 7445 a Input shaft housing b Oil drain pipe plug WARNING Avoid damage to the input shaft housing Do Not Overfill the input shaft housi...

Page 68: ...plugs a b into the input shaft housing and tighten securely 7447 b a 150 a Fill pipe plug hole fill through here b Oil level pipe plug hole Tube Ref No Description Where Used Part No Torco MTF Gear O...

Page 69: ...y the drive unit is leaking Have the unit checked immediately by your authorized Mercury Marine dealer 3 Remove the lower fill drain plug and sealing washer from the gearcase and allow the oil to drai...

Page 70: ...linkage and cable Lubricate cable and swivels F N R 7446 79 79 145 145 Tube Ref No Description Where Used Part No 145 Optimal Longtime PD2 Extreme Pressure Grease Engine drive shaft and transmission...

Page 71: ...blades and to prevent the propeller from rotating when removing the propeller nut CAUTION Avoid propeller sterndrive damage or injury Periodically check propeller nut for tightness during boating seas...

Page 72: ...a b c d 5915 94 a Propshaft b Cleaver propeller c Flat washer d Propeller nut Tube Ref No Description Where Used Part No 145 Optimal Longtime PD2 Extreme Pressure Grease Propeller shaft splines 92 848...

Page 73: ...if the engine operating temperature exceeds the normal range The charge air cooler impeller should be inspected if the discharge stream for the charge air cooler is less than normal Consult your boat...

Page 74: ...harge water is clear Stop the engine shut off the water and remove the flushing hose Cleaning Seawater Raw Water Section of Oil Cooler ENGINE COOLERS IMPORTANT Cleaning of the engine oil coolers shoul...

Page 75: ...hoses for leaks Cleaning the Flame Arrestors External contamination on the outside of the filter such as fiberglass particals or insects can be removed with a lint free cloth or a vacuum cleaner If t...

Page 76: ...rive Belt a b c d e f rmc22 a Sea pump pulley b Seawater pump alternator drive belt c Crankshaft pulley d Idler pulley e Alternator pulley adjust belt tension here f Tensioner gauge Description N lb S...

Page 77: ...c a 25978 a Tensioner gauge b Jam nut c Tensioning lug Description N lb Power steering pump drive belt 360 440 80 100 3 Oil Pump Belt Belt Should Twist 1 4 Turn rmc21 a b c a Crankshaft pulley b Oil p...

Page 78: ...erged in a conductive solution such as saltwater polluted water or water with a high mineral content a chemical reaction takes place causing electrical current to flow between metals The electrical cu...

Page 79: ...s in salt water They will provide overprotection resulting in a different electrochemical reaction that will create hydrogen on the metal surface of the drive under the paint This causes the paint to...

Page 80: ...odes if eroded 50 or more Mercury Marine recommends using anodes sold through Mercury Precision Parts only Some other manufacturers of aluminum anodes use alloys that are insufficiently pure to adequa...

Page 81: ...c c d 18998 a Anodes b Fittings c Oil cooler drain fittings d Flywheel housing drain fitting In addition to the corrosion protection devices follow these steps to inhibit corrosion 1 Painting Boat Hu...

Page 82: ...ouling paints avoid any electrical interconnection between the Mercury Marine Product anodic blocks and the paint by allowing a minimum of 40 mm 1 5 in unpainted area on the transom of the boat around...

Page 83: ...ackage components on the inside of the boat every two to three weeks with Corrosion Guard to protect the finish from dulling and corrosion External power package components may also be sprayed Tube Re...

Page 84: ...and clothing Batteries produce hydrogen and oxygen gases when being charged This explosive gas escapes fill vent cell caps and may form an explosive atmosphere around the battery for several hours aft...

Page 85: ...3 Remove and inspect the propeller If nicked bent or cracked see your authorized Mercury Marine dealer 4 Repair nicks and corrosion damage on the power package s exterior finish Use Quicksilver spray...

Page 86: ...MAINTENANCE 78 Date Maintenance Performed Engine Hours...

Page 87: ...ne for flushing Cooling system flushing and the fuel system storage procedures are performed together WARNING Avoid Fire or Explosion Ensure that the engine compartment is well ventilated and no gasol...

Page 88: ...ORTANT Maintain an adequate supply of the fuel fogging mixture in the remote 23 liter 6 U S gal tank to complete the fuel system treatment and flushing procedure Do not let the remote tank or fuel sys...

Page 89: ...y of freezing temperatures exists If the boat is in the water keep the seacock closed until restarting the engine to prevent water from flowing back into the cooling system If the boat is not fitted w...

Page 90: ...wing locations 3713 a b e c d a Cylinder block port and starboard Use a stiff wire to clean out drain holes until entire system is drained b Transmission power steering cooler c Recirculating pump d S...

Page 91: ...necessary to lift or bend hoses to allow water to drain completely 2 Remove the drain plugs a from the water distribution tubes at the headers port and starboard Location may vary a 3721 a Header drai...

Page 92: ...psi of air pressure maximum to remove the water from the charge air cooler 4 Reconnect all hoses and drain plugs Battery Winter Storage Follow the battery manufacturer s instructions for storage Powe...

Page 93: ...attery be sure to connect the positive battery cable to the positive battery terminal first and the negative battery cable to the negative battery terminal second 3 Install a fully charged battery Cle...

Page 94: ...perly 10 After the engine has warmed up check the water temperature gauge to ensure that the engine temperature is not abnormally high If it is stop the engine immediately and determine cause 11 Inspe...

Page 95: ...separating fuel filter 8 Re install the fuel line to the water separating fuel filter IMPORTANT The throttle must not be advanced until the engine idles and runs smoothly and the water temperature ha...

Page 96: ...COLD WEATHER OR EXTENDED STORAGE 88 14 Check steering system and shift throttle control for proper operation...

Page 97: ...wires especially battery cables Clean and tighten faulty connection Defective battery Test and replace if defective Defective starter Test and replace if defective Flywheel ring gear is damaged Confir...

Page 98: ...ty ignition system component Service ignition system Lanyard Stop Activated Reset Obstructed fuel filter Replace filters Stale or contaminated fuel If contaminated drain tank and fill with fresh fuel...

Page 99: ...nge to propeller with more pitch Manifold Air Pressure MAP sensor failure Test MAP sensor and replace if faulty Poor Performance Possible Cause Remedy Throttle not fully open Inspect throttle cable an...

Page 100: ...ugged with foreign material Clean Charge Air Cooler Seawater pump drive belt loose or in poor condition Replace or adjust belt Seawater pickups obstructed Inspect Faulty thermostat Replace Oil cooler...

Page 101: ...xcessive bearing clearance etc Repair as necessary Battery Will Not Come Up On Charge Possible Cause Remedy Excessive current draw from battery Turn off non essential accessories Loose or dirty electr...

Page 102: ...ck all linkages If any are loose or missing see authorized Mercury Marine dealer immediately Shift or throttle cable kinked Replace cable Friction adjustment excessive Adjust friction Steering Wheel T...

Page 103: ...has the necessary information to order parts and accessories for you When inquiring on parts and accessories the dealer requires the model and serial number to order the correct parts Service Assistan...

Page 104: ...ephone Fax Mercury MerCruiser 3003 N Perkins Road Stillwater OK 74075 405 743 6566 405 743 6570 United States Mercury Racing Telephone Fax Mercury Racing N7480 County Rd UU Fond du Lac WI 54935 9585 9...

Page 105: ...Mexico Central America South America Caribbean Telephone Fax Mercury Marine 11650 Interchange Circle North Miramar FL 33025 U S A 954 744 3500 954 744 3535 Japan Telephone Fax Mercury Marine Japan 283...

Page 106: ...arest dealer or contact MERCURY MARINE Telephone Fax Mail 920 929 5110 920 929 4894 Mercury Marine Attn Publications Department P O Box 1939 Fond du Lac WI 54936 1939 Outside The United States and Can...

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