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Mercury Racing HP1200 SCi Dry Sump Manual

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Thank You
for your purchase of one of the finest marine power packages
available. It incorporates numerous design features to assure
operating ease and durability.
With proper care and maintenance, you will thoroughly enjoy
using this product for many boating seasons. To ensure
maximum performance and carefree use, we ask that you
thoroughly read this manual.
The Operation, Maintenance & Warranty Manual contains
specific instructions for using and maintaining your product.
We suggest that this manual remain with the product for ready
reference 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!
Warranty Message
The operator (driver) is responsible for the correct and safe
operation of the boat, the equipment aboard and the safety
of all occupants aboard. We strongly recommend that the
operator read this Operation, Maintenance and Warranty
Manual and thoroughly understand the operational
instructions for the power package and all related
accessories before the boat is used.
Mercury Racing,
N7480 County Road "UU"
Fond du Lac, WI 54935-9585
WARNING
!
i
7406

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Summary of Contents for Mercury Racing HP1200 SCi Dry Sump

  • Page 1 We suggest that this manual remain with the product for ready reference 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, WI 54935-9585 7406...
  • Page 2 The product you have purchased comes with a limited warranty from Mercury Marine; the terms of the warranty are set forth in the Warranty Information section of this manual. The warranty statement contains a description of what is covered, what is not covered, the duration of coverage, how to best obtain warranty coverage, important disclaimers and limitations of damages, and other related information.
  • Page 3 Printed in U.S.A. © 2009, Mercury Marine Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts, Mercury Propellers, Mariner, Verado, Vazer, #1 On The Water, Alpha, Bravo, Pro Max, OptiMax, Sport‑Jet, K‑Planes, MerCathode, SmartCraft, VesselView, Quicksilver, Zero Effort, M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered trademarks of Brunswick Corporation.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Warranty Information Warranty Coverage..............1 E.P.A. Emission Control Warranty..........1 California Emission Control Warranty Statement......3 General Information Identification Record..............8 Boater's Responsibilities..............9 Boat Horsepower Capacity............10 High‑Speed and High‑Performance Boat Operation....10 Lanyard Stop Switch..............11 Protecting People In The Water..........12 Exhaust Emissions..............
  • Page 6 TABLE OF CONTENTS Operation Instrumentation................31 Warning System................ 31 Electrical System Overload Protection........33 Remote Controls (Console Mounted Zero Effort)......36 Power Trim................37 Starting, Shifting, and Stopping..........40 Operation Chart.................42 Freezing Temperature Operation..........43 Drain Plug and Bilge Pump............43 Launching And Boat Operation Care.........44 Conditions Affecting Operation Weight Distribution..............45 Bottom Of Boat................45...
  • Page 7 TABLE OF CONTENTS Maintenance Service Responsibilities.............49 Replacement Service Parts............50 Do‑It‑Yourself Maintenance Suggestions........50 Servicing High Horsepower Engines.........52 Maintenance Charts..............52 Checking Fluid Levels..............55 Changing Fluids.................62 Lubrication.................71 Propellers...................72 Seawater Pump Impeller Inspection..........74 Flushing Cooling System............75 Cleaning Seawater (Raw Water) Section of Oil Cooler.....76 Cleaning the Flame Arrestors............77 Drive Belts.................77 Corrosion and Corrosion Protection..........80...
  • Page 8 TABLE OF CONTENTS Troubleshooting Engine Will Not Crank..............98 Engine Cranks But Will Not Start..........98 Engine Runs Rough, Hard to Start, Misses, and/or Backfires...99 Poor Performance..............100 Insufficient Engine Temperature..........100 Excessive Engine Temperature..........101 Low Engine Oil Pressure............101 Battery Will Not Come Up On Charge........102 Power Trim Does Not Operate (Motor Doesn't Run)....102 Power Trim Does Not Operate (Motor Runs But Drive Unit Does Not Move)................102...

  • Page 9: Warranty Information

    WARRANTY INFORMATION Warranty Coverage Mercury Racing does not offer a warranty with this power package. E.P.A. Emission Control Warranty U.S. EPA EMISSIONS LIMITED WARRANTY (MORE THAN 650 HP) Consistent with the obligations created by 40 CFR Part 1045, Subpart B, Mercury Marine provides an emission warranty of three...
  • Page 10 WARRANTY INFORMATION b. Magneto or electronic ignition system c. Spark control system d. Ignition coil or control module e. Ignition wires 4. Lubrication system a. Oil pump and internal parts b. Oil injectors c. Oil meter 5. Positive crankcase ventilation (PCV) system a.

  • Page 11: California Emission Control Warranty Statement

    Section 2441 (a), (13) or their equivalent. If any emission‑related part on your engine is defective under warranty, the part will be repaired or replaced by Mercury Racing. 1. Ignition System...
  • Page 12 Section 2441 (a), (13) or their equivalent. If any emission‑related part on your engine is defective under warranty, the part will be repaired or replaced by Mercury Racing. 1. Air Induction System a. Controlled hot air intake system b.
  • Page 13 WARRANTY INFORMATION 4. Exhaust Gas Recirculation (EGR) System a. EGR valve body and carburetor spacer if applicable b. EGR rate feedback and control system 5. Air Injection System a. Air pump or pulse valve b. Valves affecting distribution of flow c.
  • Page 14 As the sterndrive engine owner, you should however be aware that Mercury Racing may deny you warranty coverage if your sterndrive engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.
  • Page 15 WARRANTY INFORMATION One Star ‑ Low Emission The One Star label identifies engines that meet the Air Resources Board's 2001 exhaust emissions standards. Engines meeting these standards have 75% lower emissions than 22531 conventional carbureted two‑stroke engines. These engines are equivalent to the U.S. EPA's 2006 standards for marine engines.

  • Page 16: General Information

    GENERAL INFORMATION Identification Record Model 1075 SCI Displacement 557 CI / 9.1 Liter Fuel Octane 92 AKI [(R+M)/2] or 98 RON Mercury 25W-40 Preferred Max. WOT RPM 5600-6000 Spark Plugs Engine Oil NKG BRCECS Alternative API CI-4, CH-4, CG-4 Spark Plug Gap 0.76 mm 0.03 in.

  • Page 17: Boater's Responsibilities

    GENERAL INFORMATION Engine Model/ Propeller Number & Horsepower: Pitch: ____________________ ____________________ ____ _____ Engine Serial Number Running Rotation ____________________ ____________________ ____ _____ Transom Assembly Hull Identification Serial Numer: Number: ____________________ ____________________ ____ _____ Sterndrive Serial Boat Model & Length: ____________________ Number &...

  • Page 18: Boat Horsepower Capacity

    GENERAL INFORMATION Boat Horsepower Capacity WARNING Exceeding the boat's maximum horsepower rating can cause serious injury or death. Overpowering the boat can affect boat control and flotation characteristics or break the transom. Do not install an engine that exceeds the boat's maximum power rating. Do not overpower or overload your boat.

  • Page 19: Lanyard Stop Switch

    GENERAL INFORMATION Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves far enough away from the operator's position (as in accidental ejection from the operator's position) to activate the switch. A lanyard stop switch can be installed as an accessory ‑...

  • Page 20: Protecting People In The Water

    GENERAL INFORMATION WARNING Avoid serious injury or death from deceleration forces resulting from accidental or unintended stop switch activation. The boat operator should never leave the operator's station without first disconnecting the stop switch lanyard from the operator. Accidental or unintended activation of the switch during normal operation is also a possibility.

  • Page 21: Exhaust Emissions

    GENERAL INFORMATION WHILE BOAT IS STATIONARY WARNING A spinning propeller, a moving boat, or any solid device attached to the boat can cause serious injury or death to swimmers. Stop the engine immediately whenever anyone in the water is near your boat.
  • Page 22 GENERAL INFORMATION While Boat Is Stationary 21626 Running the engine when the boat is moored in a confined space. Mooring close to another boat that has its engine running. While Boat is Moving 5449 Running the boat with the trim angle of the bow too high. Running the boat with no forward hatches open (station wagon effect).

  • Page 23: Wave And Wake Jumping

    GENERAL INFORMATION Wave And Wake Jumping Operating recreational boats over waves and wake is a natural part of boating. However, when this activity is done with sufficient speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat re‑enters the water.
  • Page 24 GENERAL INFORMATION Reduce speed, raise the drive, and proceed with caution whenever you maneuver a boat in shallow water areas or in areas where you suspect underwater obstacles may exist. Gain as much knowledge of the area as possible from maps or local boaters before you go boating.

  • Page 25: Trailering Boat

    GENERAL INFORMATION WARNING Operating a boat or engine with impact damage can result in product damage, serious injury, or death. If the vessel experiences any form of impact, have an authorized Mercury Marine dealer inspect and repair the vessel or power package. After striking a submerged object, stop the engine as soon as possible and inspect it for any broken or loose parts.
  • Page 26 GENERAL INFORMATION Paddle or oar Signal devices: flashlight, rockets or flares, flag and whistle or horn Spare propeller, thrust hubs 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 map or chart Spare operating equipment;...
  • Page 27 GENERAL INFORMATION Make sure everyone in the boat is properly seated. Do not allow anyone to sit or ride on any part of the boat that was not intended for such use. This includes the back of seats, gunwales, transom, bow, decks, raised fishing seats, any rotating fishing seat;...

  • Page 28: Stolen Power Package

    GENERAL INFORMATION 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 list of rules and regulations. Stolen Power Package If your power package is stolen, immediately advise the local authorities and Mercury Marine of the model and serial number(s) and to whom the recovery is to be reported.

  • Page 29: Specifications

    SPECIFICATIONS Fuel Requirements (HP1200/1025 SCi) Use an Off‑road brand of leaded gasoline, preferably without alcohol. Mercury Marine recommends fuels that contain fuel injector cleaner for added internal cleanliness. WARNING Fuel leakage is a fire or explosion hazard, which can cause serious injury or death.
  • Page 30 SPECIFICATIONS USING REFORMULATED (OXYGENATED) FUELS (USA ONLY) This type of fuel is required in certain areas of the U.S. The two types of oxygenates used in these fuels are alcohol (Ethanol) or Ether (MTBE or ETBE). If Ethanol is the oxygenate that is used in the gasoline in your area, refer to the Fuel Containing Alcohol section.

  • Page 31: Dual Fuel Option

    SPECIFICATIONS IMPORTANT: Because of possible adverse effects of alcohol in gasoline, it is recommended that only alcohol‑free fuel be used where possible. If only fuel containing alcohol is available, or if the presence of alcohol is unknown, increased inspection frequency for leaks and abnormalities is required.
  • Page 32 SPECIFICATIONS 5. Install the protective caps on the lower PCM. 41160 HP1200 Configuration Engine harness Protective caps 6. Run the engine for several minutes to purge the low octane fuel from the fuel lines before applying any load to the engine. HP1025 SCI OPERATION 1.
  • Page 33 SPECIFICATIONS IMPORTANT: Inspect the pins at the PCM to ensure that they are clean and straight. Inspect the wire harness connectors. Clean, replace, or repair as necessary. Each mating cavity is different, match the connector or cap shape to the PCM mating cavity.

  • Page 34: Crankcase Oil

    SPECIFICATIONS Crankcase Oil OIL RECOMMENDATIONS Preferred Oils API Classification Mercury 4‑cycle Marine Engine Oil 25W40 SJ, SL, CF‑2, CH‑4 Other Recommendations If Preferred Oils Are Not Available Premium multi‑viscosity 20W‑50 commercial oil CG‑4, CH‑4, CI‑4 Premium multi‑viscosity 15W‑40 commercial oil CG‑4, CH‑4, CI‑4 Oil Filter Should Always Be Changed With Oil IMPORTANT OIL PRACTICES Do Not Use...

  • Page 35: Capacities

    SPECIFICATIONS TEMPERATURE/OIL VISCOSITY CHART Multi-viscosity Mercury/Quicksilver 25W 40 SJ, SL, CF-2, Premium Multi-Viscosity 20W 50 CF-4, CG-4, CH-4, CI-4 +100 7411 Capacities Model HP1200 SCi Approximately 15.2 liters (16 U.S. qt.) Oil reservoir capacity with new filter 19 liter (20 U.S. qt.) Seawater cooling system Approximately 2.84 liters (3.0 U.S.

  • Page 36: General Engine Specifications (Hp1200 Sci)

    SPECIFICATIONS General Engine Specifications (HP1200 SCi) 1200 HP (895 kW) Crankshaft Horsepower Displacement 9.1 L (557 c.i.) Cylinder arrangement V‑8 Bore 114 mm (4.47 in.) Stroke 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...

  • Page 37: Engine Operating Limitations (Hp1200/1025 Sci)

    SPECIFICATIONS Engine Operating Limitations (HP1200/1025 SCi) Maximum wide open throttle (W.O.T.) 6000‑6500 RPM (HP1200), 5600‑6000 RPM (HP1025) 6600 RPM (Warning Horn), 6700 RPM (PCM controls RPM) (HP1200), Rev limit 6150 RPM (Warning Horn), 6200 RPM (PCM controls RPM) (HP1025) Idle RPM in gear 800 RPM Idle RPM out of gear 825 RPM...

  • Page 38: After Break-In Period

    SPECIFICATIONS 5 Hr. Break‑in Procedure • Allow engine to warm‑up for 3‑5 minutes. • Do not exceed 3/4 throttle. • Avoid full throttle acceleration from idle speed. • Always vary throttle setting. • Run engine the majority of time between 2500 ‑ 4500 RPM. •...

  • Page 39: Instrumentation

    OPERATION Instrumentation Mercury Racing requires that the following critical engine functions be monitored: • Oil pressure • Engine RPM • Oil temperature • Water temperature • System voltage • Guardian fault messages The use of SmartCraft instrumentation will display all of the above critical engine functions as well as others not listed.
  • Page 40 OPERATION NOTE: The following Table lists only the possible problem areas and not specific error codes recorded by the PCM. Use a Digital Diagnostic Terminal (DDT) or Computer Diagnostic System (CDS) to extract specific problem codes from the PCM. Engine Monitor Guardian Power...

  • Page 41: Electrical System Overload Protection

    OPERATION Engine Monitor Guardian Power Problem Horn Display Activated Reduced By Transmission 3 Beeps‑1.5 Overtemp Sec. Long Knock Sensor 3 Beeps‑1.5 Failure Sec. Long Oil Pressure 3 Beeps‑1.5 Sensor Failure Sec. Long Oil Temperature 3 Beeps‑1.5 Sensor Failure Sec. Long Crankshaft Sensor Steady Horn Problem...
  • Page 42 OPERATION • A circuit breaker protects the engine wiring harness and instrumentation power lead. Reset by pushing the reset button. • Four fuses are located at the upper rear of the engine containing 5 and 15 amp fuses. • Four fuses are located at the upper rear of the engine containing a 5 and three 20 amp fuses.
  • Page 43 OPERATION Fuse Holder (C24) Fuse Holder (C25) 5 amp Hour Meter A‑RED/ None B‑RED 15 amp Key switch C‑RED 20 amp Main Power C‑RED/ power Relay D‑RED/ D‑RED/ 2 amp Diagnostics E‑RED 20 amp Coil Power E‑RED/ F‑RED/ F‑RED/ 5 amp CAN G‑PPL 20 amp Fuel Injectors G‑RED/...

  • Page 44: Remote Controls (Console Mounted Zero Effort)

    OPERATION A 90 amp fuse is located on the starter. 90 amp fuse 7417 Analog gauges (if equipped) are protected with a 5 amp fuse. 7412 Helm harness connection Fuse (5 amp) Relay Ground Fused 12V (5 amp maximum) Switched 12V Remote Controls (Console Mounted Zero Effort) 1.

  • Page 45: Power Trim

    OPERATION NOTICE Shifting into gear at engine speeds above idle will damage the gearcase. Shifting into gear when the engine is not running can cause misalign the clutch, preventing proper shifting. Always shift the gearcase into gear when the engine is operating at idle. If you must shift while the engine is not operating, rotate the propeller shaft in the appropriate direction during shifting.
  • Page 46 OPERATION IMPORTANT: Each boat manufacturer has the option as to how the power trim will function on their particular boat. The boat owner/ operator must be aware of how the power trim functions before operating the boat. In most cases, best overall performance is obtained with the drive unit adjusted so the boat bottom will run at a 3°...
  • Page 47 OPERATION Trimming Drive Unit Down/In Can: 7420 • Help the boat accelerate and plane off quicker. • Generally improve the ride in choppy water. • In most cases, reduce boat speed. • If in excess, lower the bow of some boats to a point at which they begin to plow with their bow in the water while on plane.

  • Page 48: Starting, Shifting, And Stopping

    OPERATION IMPORTANT: If the power trim button is held depressed after the drive unit(s) reaches the end of upward travel, an internal circuit breaker opens and the pump stops. Should this happen, release the button and allow the trim pump motor to cool for about one minute, at which time the circuit breaker will reset and power trim operation may be resumed.
  • Page 49 OPERATION IMPORTANT: Observe the following: • Do not start the engine without supplying water to the seawater pickup pump (to prevent pump or engine damage). • Do not operate the starter motor continuously for more than 30 seconds. • Never shift the drive unit unless the engine is at idle RPM. Perform the following as appropriate: Check all items listed in Operation Chart.

  • Page 50: Operation Chart

    OPERATION 4. Check the oil pressure gauge immediately after the engine starts. If oil pressure is not within the specified range, see Specifications, stop the engine immediately, and determine cause. 5. If the engine is cold, allow the engine to run for three minutes. 6.

  • Page 51: Freezing Temperature Operation

    Engine components will be damaged if submerged. Damage caused by submersion is not covered by the Mercury Racing Limited Warranty.

  • Page 52: Launching And Boat Operation Care

    OPERATION Launching And Boat Operation Care NOTICE Some boating maneuvers can introduce water into the engine through the exhaust system, causing severe engine damage. Be careful when unloading a boat from its trailer, slowing down rapidly, backing up rapidly, and stopping suddenly. In any of the situations described in the preceding caution, water entering the engine could cause severe damage to internal parts.

  • Page 53: Conditions Affecting Operation

    CONDITIONS AFFECTING OPERATION Weight Distribution Positioning of weight (passengers and gear) inside the boat has the following effects: Shifting weight to rear (stern) may: • Increase speed and engine RPM. • Cause the boat to porpoise. • Cause the bow to bounce in choppy water. •...

  • Page 54: Ventilation

    (WOT) and operating 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 of the engine and is designed to help prevent damage from excessive engine RPM.

  • Page 55: Conditions That Lower Engine Performance

    CONDITIONS AFFECTING OPERATION • Operating in a higher elevation. • Operating with a damaged propeller or dirty boat bottom. • Operating with increased load (additional passengers, pulling skiers, etc.). Conditions That Lower Engine Performance The following conditions lower engine performance and cannot be compensated by the engine fuel or electronic management systems.
  • Page 56 CONDITIONS AFFECTING OPERATION • Enhances overall reliability and durability of the engine.

  • Page 57: Service Responsibilities

    MAINTENANCE Service Responsibilities OWNER/OPERATOR RESPONSIBILITIES It is the owner/operator's responsibility to perform the following: • Perform all safety checks. • Make sure lubrication and maintenance instructions are complied with for safe operation. • Return the unit to an authorized Mercury Marine dealer for a periodic checkup.

  • Page 58: Replacement Service Parts

    MAINTENANCE Replacement Service Parts WARNING Avoid fire or explosion hazard. Electrical, ignition, and fuel system components on Mercury Marine products comply with federal and international standards to minimize risk of fire or explosion. Do not use replacement electrical or fuel system components that do not comply with these standards.
  • Page 59 MAINTENANCE • Do not attempt any repairs that are not covered in this manual unless you are aware of the precautions (Cautions and Warnings) and procedures required. Your safety is of our concern. • If you attempt to service the product yourself, we suggest you order the service manual for that model.

  • Page 60: Servicing High Horsepower Engines

    MAINTENANCE Maintenance Charts (on following pages) IMPORTANT: Refer to for complete listing of all scheduled maintenance to be performed. Some listings can be done by the owner/operator, while others should be performed by an authorized Mercury Marine dealer. Before attempting maintenance or repair procedures not covered in this manual, Mercury Marine recommends purchasing a Mercury Marine Service Manual.
  • Page 61 MAINTENANCE Interval Task Check exhaust header mounting bolts for tightness Flame arrestor ‑ Inspect and clean as required Every 15 hours or 90 days of operation Engine oil and filter ‑ Change Fuel filters ‑ Change Check and adjust valve tip clearance (lash) Perform 25 hour maintenance items Change transmission fluid...
  • Page 62 MAINTENANCE DRY SUMP SIX (VI) DRIVE, TRANSOM, TRIM & STEERING SYSTEMS MAINTENANCE SCHEDULE Interval Task Drive, Transom, and Propeller ‑ Inspect Lower Gear Housing Oil ‑ Check level Check prior to use and every 3 hours Power Trim Pump Oil ‑ Check level of operation.

  • Page 63: Checking Fluid Levels

    MAINTENANCE Interval Task Perform 25 and 50 Hour Maintenance Items. Drive Unit Bellows and Clamps ‑ Inspect Lower Gear Housing Oil ‑ Change the Every 100 hours of operation or once oil. a season, whichever occurs first. Driveline Models ‑ Lubricate and inspect the engine to transom driveshaft U‑joint crosses and slip joint.
  • Page 64 MAINTENANCE 1. With the engine at idle, observe the oil reservoir sight tube. Oil reservoir sight tube 7423 2. Oil level in the reservoir sight tube should be approximately even with the bottom of the reservoir split ring. IMPORTANT: Do not overfill engine oil. NOTE: If the engine is not operated for a period of time (several days or longer), a certain amount of oil may drain from the reservoir back into the engine oil pan.
  • Page 65 MAINTENANCE Check The Input Shaft Housing Oil Level On Driveline Models As Follows: 1. Remove the reservoir level pipe plug "c." The oil level should be even with the bottom of the hole. If low, fill the input shaft housing "b" through the top fill pipe plug hole "a" until oil flows from the reservoir level plug hole "c."...
  • Page 66 MAINTENANCE Check Drive Unit Oil Level As Follows: 1. Remove the drive vent plug "a." The oil level should be even with the bottom of the hole. If low, remove the drain/fill plug and sealing washer "b" from the gearcase and fill until oil comes out of the top vent plug "a"...
  • Page 67 MAINTENANCE CHECKING POWER TRIM PUMP FLUID 1. Place the drive unit in the full down/in position. Fill/Vent screw "FULL" mark "ADD" mark 7432 Tube Description Where Used Part No. Ref No. Power Trim and Steering Trim pump 92-858074K01 Fluid 2. Remove the fill/vent screw. Wipe clean and re‑insert back into the pump, but do not thread it into place.
  • Page 68 MAINTENANCE 3. Remove it again and note the oil level, which must be between the "ADD" and "FULL" marks on the dipstick. If necessary, add Power Trim and Steering Fluid or SAE 10W‑30 motor oil through the fill/vent hole to bring the oil level up to the "FULL" mark on the dipstick.
  • Page 69 MAINTENANCE 2. Shut the engine off and check the dipstick level. The fluid level should be up to the "FULL" mark on the dipstick or the mark established when the boat was first run. 6790 Dipstick "FULL" mark Dipstick tube Tube Description Where Used...

  • Page 70: Changing Fluids

    MAINTENANCE 5. Do not use the transmission expansion bottle as a fluid reservoir. Transmission expansion bottle 7434 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.) below the oil reservoir.
  • Page 71 MAINTENANCE 4. Drain the oil overflow canister into a suitable container. Vent canister 7438 5. To replace the spin‑on the oil filter: 7439 Retaining clamp Stop screw a. Loosen the filter retaining clamp "a" and slide it off the filter. b.
  • Page 72 MAINTENANCE 6. Remove the cover of the Oberg screen‑style filter and mark the element 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 orientation (correct side up) to prevent the oil from flowing through it in the wrong direction.
  • Page 73 MAINTENANCE 8. Install the bottom oil reservoir plug and tighten securely. Oil drain plug 7436 9. Begin by filling the oil reservoir with 11.4 liters (12 U.S. qt.) of oil.
  • Page 74 MAINTENANCE 10. Using an electric drill motor, manually turn the oil pump pulley (clockwise) to prime the engine oiling system until reaching an oil pressure of 276 kPa (40 psi). 7443 Oil pump pulley Clockwise direction of electric drill motor Electric drill motor 11.
  • Page 75 MAINTENANCE NOTE: Engine oil level in the reservoir will increase as the engine oil temperature increases. 13. Start the engine and observe the engine oil level in the reservoir. The oil level should be even with the bottom of the reservoir split ring.
  • Page 76 MAINTENANCE 6. Start the engine and let it run for at least two minutes at idle, shifting the transmission from forward to reverse several times. 7. Stop the engine and check the transmission oil level with the dipstick. If addition oil is required, add it through the dipstick tube to bring the level up to the "FULL"...
  • Page 77 MAINTENANCE Driveline Models Only 1. Place a container below the input shaft housing and remove the bottom pipe plug. Input shaft housing Oil drain pipe plug 7445 IMPORTANT: Do not overfill the input shaft housing reservoir or damage to the transom components could occur. 2.
  • Page 78 MAINTENANCE Tube Ref. Description Where Used Part No. Transom input shaft Torco MTF Gear Oil reservoir and dry 92‑849684‑1 sump drive All Models 1. Place the drive unit in a position so that the propshaft is level. 2. Remove the upper oil level plug and sealing washer from the gearcase.

  • Page 79: Lubrication

    MAINTENANCE 4. Fill the drive unit through the lower fill/drain hole until oil comes out of the top oil level plug opening. 5. Install the upper oil level plug and sealing washer. 6. Remove filler tube and quickly install the lower fill/drain plug and sealing washer.

  • Page 80: Propellers

    MAINTENANCE Tube Ref Description Where Used Part No. Optimal Longtime PD2 Engine drive shaft and Extreme 92-848767 transmission shift lever Pressure Grease MerCruiser 4- cycle 25W40 Shift cable and throttle linkage 92-858048K01 Engine Oil Propellers WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed.
  • Page 81 MAINTENANCE REMOVAL 1. Place a wood block between the propeller blade and the anti‑ventilation plate to prevent rotation. Straighten bent tabs on tab washer. Wood block Propeller nut 7448 2. Turn the propeller shaft nut counter‑clockwise to remove the nut. 3.

  • Page 82: Seawater Pump Impeller Inspection

    MAINTENANCE 2. Align splines and install propeller, washer and propeller nut. 5915 Propshaft Cleaver propeller Flat washer Propeller nut Tube Description Where Used Part No. Ref No. Optimal Longtime PD2 Extreme Propeller shaft splines 92-848767 Pressure Grease 3. Place wood block between the propeller blade and anti‑ventilation plate to prevent rotation and tighten the propeller nut.

  • Page 83: Flushing Cooling System

    MAINTENANCE The seawater pump impellers (three in one pump assembly) should be inspected whenever insufficient seawater flow is suspected. The two rear impellers supply the engine with water and the front impeller supplies the charge air cooler (CAC). The impellers supplying the engine should be inspected if the engine operating temperature exceeds the normal range.

  • Page 84: Cleaning Seawater (Raw Water) Section Of Oil Cooler

    MAINTENANCE To prevent silt and salt buildup in the cooling system, flush with freshwater. 1. Install a flushing hose from a water tap to the flushing connector. Consult your boat owners manual for the location of the flushing connector. 2. Completely open the water tap. Place the remote control in neutral position and start the engine.

  • Page 85: Cleaning The Flame Arrestors

    MAINTENANCE 2. Remove the two clamps "d" that retain the cooler and lift the cooler away from the engine to gain access to the end plate fasteners. 3. Remove the end plates and gaskets "b." 4. Clean the cooler with a suitable brush and flush passages with fresh water.
  • Page 86 MAINTENANCE 1. Seawater Pump/Alternator Drive Belt rmc22 Sea pump pulley Seawater pump/alternator drive belt Crankshaft pulley Idler pulley Alternator pulley (adjust belt tension here) Tensioner gauge Description Seawater pump/alternator belt 360‑440 80‑100...
  • Page 87 MAINTENANCE 2. Power Steering Pump Drive Belt Tensioner gauge Jam nut Tensioning lug 25978 Description Power steering pump drive belt 360‑440 80‑100 3. Oil Pump Belt ‑ Belt Should Twist 1/4 Turn Crankshaft pulley Oil pump drive belt Oil pump (adjust belt tension here) rmc21...

  • Page 88: Corrosion And Corrosion Protection

    MAINTENANCE 4. Supercharger Belt ‑ Self‑tensioning 34390 Supercharger pulley Supercharger drive belt Crankshaft pulley Idler pulleys Belt tensioner Corrosion and Corrosion Protection Add info about replacing anodes in the flywheel coolers...
  • Page 89 MAINTENANCE Whenever two or more dissimilar metals (like those found on the sterndrive) are submerged 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.
  • Page 90 MAINTENANCE IMPORTANT: Mercury Marine recommends installing an Anti‑Corrosion Kit. If the boat is equipped with stainless steel after planes, a large anode should be installed on each to handle the increased galvanic corrosion potential. Replace sacrificial anodes if eroded 50% or more. Mercury Marine recommends using anodes sold through Mercury Precision Parts only.
  • Page 91 MAINTENANCE 18998 Anodes Fittings Oil cooler drain fittings Flywheel housing drain fitting In addition to the corrosion protection devices, follow these steps to inhibit corrosion: 1. Painting Boat Hull or Boat Transom...
  • Page 92 MAINTENANCE a. If anti‑fouling protection is required for boat hull or boat transom, copper or tin base paints can be used unless otherwise prohibited by law. b. If using copper or tin based anti‑fouling 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 these items.

  • Page 93: Battery

    MAINTENANCE NOTE: Do not paint anodes or the MerCathode System reference electrode and anode, as this will render them ineffective as galvanic corrosion inhibitors. 2. Painting Drive Unit or Transom Assembly • Paint the drive unit and transom assembly with a good quality marine paint or an anti‑fouling paint that does not contain copper, tin, or any other material that could conduct electrical current.

  • Page 94: Bottom Of Boat

    MAINTENANCE WARNING Recharging a weak battery in the boat, or using jumper cables and a booster battery to start the engine, can cause serious injury or product damage from fire or explosion. Remove the battery from the boat and recharge in a ventilated area away from sparks or flames.

  • Page 95: Maintenance Log

    MAINTENANCE • After recovery, immediate service by an authorized Mercury Marine dealer is required to prevent serious damage to power package. Maintenance Log Record all maintenance performed on your outboard here. Be sure to save all work orders and receipts. Date Maintenance Performed Engine Hours...

  • Page 96: Cold Weather Or Extended Storage

    COLD WEATHER OR EXTENDED STORAGE Power Package Lay‑up IMPORTANT: This service should be performed by an authorized Mercury Marine dealer. NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation.
  • Page 97 COLD WEATHER OR EXTENDED STORAGE 4. Connect the remote outboard fuel tank to the inlet of the water separating fuel filter. 5. Have the engine ready for flushing as explained in the Flushing Cooling System section of this manual (cooling system flushing and the fuel system storage procedures are performed together).

  • Page 98: Draining Instructions

    COLD WEATHER OR EXTENDED STORAGE Draining Instructions NOTICE Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage. Drain the seawater section of the cooling system immediately after operation or before any length of storage in freezing temperatures. 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.
  • Page 99 COLD WEATHER OR EXTENDED STORAGE 1. Drain the cooling system at the following locations: 3713 Cylinder block (port and starboard). Use a stiff wire to clean out drain holes until entire system is drained. Transmission/power steering cooler Recirculating pump hose Seawater pump Center/bottom of bell housing (drains the engine oil coolers).
  • Page 100 COLD WEATHER OR EXTENDED STORAGE 2. Remove the drain plugs "a" from the water distribution tubes at the headers (port and starboard). Location may vary. 3721 Header drain plugs (port and starboard) 3. Charge Air Cooler Draining:...

  • Page 101: Battery Winter Storage

    COLD WEATHER OR EXTENDED STORAGE a. Disconnect the charge air cooler's exhaust hose "a" and inlet hose "c." The exhaust hose location varies, depending on engine location. 3720 Charge air cooler (CAC) exhaust hose Plug Charge air cooler inlet hose b.
  • Page 102 COLD WEATHER OR EXTENDED STORAGE BEFORE STARTING IMPORTANT: Do not install the battery until all engine maintenance is completed. NOTICE Lack of oil pressure in the system can cause severe internal engine damage during start‑up. Prime the oil injection pump on new or rebuilt engines or after performing maintenance on the oiling system.
  • Page 103 COLD WEATHER OR EXTENDED STORAGE 3. Open the fuel shut off valve located between the tank and the water separating fuel filter. 4. Turn the key switch to "RUN" and wait three seconds to allow the fuel pump to prime the system. 5.
  • Page 104 COLD WEATHER OR EXTENDED STORAGE 3. Attach an outboard type portable fuel tank with primer bulb to the water separating fuel filter inlet fitting with a hose clamp. 4. Squeeze the primer bulb until the bulb becomes firm. NOTE: Do not turn the key switch to the "START" position during the following priming procedure.
  • Page 105 COLD WEATHER OR EXTENDED STORAGE 12. 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. 13. Inspect engine for fuel, oil, fluid, water and exhaust leaks. 14.

  • Page 106: Troubleshooting

    TROUBLESHOOTING Engine Will Not Crank Possible Causes Remedy Battery switch turned "OFF." Turn switch "ON." Gearshift not in neutral Position control lever to neutral. position. Check and reset circuit breaker or replace Open circuit breaker or fuse. fuse. Loose or dirty electrical Check all electrical connections and wires connections or damaged (especially battery cables).

  • Page 107: Engine Runs Rough, Hard To Start, Misses, And/Or Backfires

    TROUBLESHOOTING Possible Cause Remedy Replace kinked lines or blow out lines Fuel line or tank vent line kinked or with compressed air to remove restricted obstruction Crankshaft position sensor faulty Test and replace if faulty Test and replace if faulty. Do not Faulty fuel pressure regulator attempt to start the engine if the fuel diaphragm...

  • Page 108: Poor Performance

    TROUBLESHOOTING Poor Performance Possible Cause Remedy Inspect throttle cable and linkages for Throttle not fully open. proper operation. Damaged or wrong propeller. Replace propeller. Excessive bilge water. Drain and check for cause of entry. Boat overloaded or load improperly Reduce load or redistribute load more distributed.

  • Page 109: Excessive Engine Temperature

    TROUBLESHOOTING Excessive Engine Temperature Possible Cause Remedy Seacock closed. Open. Charge Air Cooler plugged with foreign Clean Charge Air Cooler. material. Seawater pump drive belt loose or in poor Replace or adjust belt. condition. Seawater pickups obstructed. Inspect. Faulty thermostat. Replace.

  • Page 110: Battery Will Not Come Up On Charge

    TROUBLESHOOTING Battery Will Not Come Up On Charge Possible Cause Remedy Excessive current draw from Turn off non‑essential accessories. battery. Check all associated electrical connections and wires (especially battery Loose or dirty electrical cables). Clean and tighten faulty connections or damaged wiring. connections.

  • Page 111: Remote Control Operates Hard, Binds, Has Excessive Free-Play Or Makes Unusual Sounds

    TROUBLESHOOTING Remote Control Operates Hard, Binds, Has Excessive Free‑Play or Makes Unusual Sounds Possible Cause Remedy Insufficient lubrication on shift and Lubricate. throttle linkage fasteners. Check all linkages. If any are loose Loose or missing shift and throttle or missing, see authorized Mercury linkage fasteners.

  • Page 112: Owner Service Assistance

    OWNER SERVICE ASSISTANCE Local Repair Service Always return your outboard to your local authorized dealer should the need for service arise. Only he has the factory trained mechanics, knowledge, special tools, equipment, and genuine parts and accessories to properly service your engine should the need occur.

  • Page 113: Mercury Mercruiser Service Offices

    United States Telephone Mercury MerCruiser 3003 N. Perkins Road (405) 743‑6566 (405) 743‑6570 Stillwater, OK 74075 United States (Mercury Racing) Telephone Mercury Racing N7480 County Rd. UU (920) 924‑2088 (920) 924‑2096 Fond du Lac, WI 54935-9585 Canada Telephone Mercury Marine Ltd.
  • Page 114 OWNER SERVICE ASSISTANCE Europe, Middle East, Africa Telephone Marine Power - Europe, Inc. Parc Industriel de Petit-Rechain B-4800 (32) (87) 32 • 32 • 11 (32) (87) 31 • 19 • 65 Verviers, Belgium Mexico, Central America, South America, Caribbean Telephone Mercury Marine 11650 Interchange Circle North...

  • Page 115: Ordering Literature

    ORDERING LITERATURE United States and Canada Before ordering literature, please have the following information about your power package available: Engine Horsepower: Model: Serial Model year: Number: For information on additional literature that is available for your particular Mercury/MerCruiser power package and how to order that literature contact your nearest dealer or contact: MERCURY MARINE Telephone...

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