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Mercury Racing HP1200 SCi Dry Sump Operation, Maintenance & Warranty 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 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. Please
review this important information.
Mercury Racing,
N7480 County Road "UU"
Fond du Lac, WI 54935-9585
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 WARNING 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.
  • Page 3 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,...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Warranty Information Warranty Coverage..............1 General Information Identification Record..............2 Boater's Responsibilities..............3 Boat Horsepower Capacity............4 High‑Speed and High‑Performance Boat Operation....4 Lanyard Stop Switch..............5 Protecting People In The Water........... 6 Exhaust Emissions..............7 Wave And Wake Jumping............9 Impact With Underwater Hazards..........10 Trailering Boat................
  • Page 6 TABLE OF CONTENTS Starting, Shifting, and Stopping..........31 Operation Chart.................33 Freezing Temperature Operation..........34 Drain Plug and Bilge Pump............34 Launching And Boat Operation Care.........34 Conditions Affecting Operation Weight Distribution..............36 Bottom Of Boat................36 Cavitation...................36 Ventilation..................37 Propeller Selection..............37 Conditions That Lower Engine Performance......38 Maintenance Service Responsibilities.............39 Replacement Service Parts............40...
  • Page 7 TABLE OF CONTENTS Cold Weather or Extended Storage Power Package Lay‑up.............. 79 Draining Instructions..............81 Battery Winter Storage..............84 Power Package Recommissioning..........84 Troubleshooting Engine Will Not Crank..............89 Engine Cranks But Will Not Start..........90 Engine Runs Rough, Hard to Start, Misses, and/or Backfires...91 Poor Performance..............91 Insufficient Engine Temperature..........92 Excessive Engine Temperature..........92...
  • Page 8 viii...

  • Page 9: Warranty Information

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

  • Page 10: 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 11: Boater's Responsibilities

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

  • Page 12: Boat Horsepower Capacity

    GENERAL INFORMATION Boat Horsepower Capacity WARNING Avoid serious injury, death or property damage from overpowering a boat. Using a power package that exceeds the maximum horsepower limit of a boat can: • Cause loss of boat control. • Place too much weight at the transom altering the designed flotation characteristics of the boat •...

  • Page 13: 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 ‑ generally on the dashboard or side adjacent to the operator's position.

  • Page 14: 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 15: Exhaust Emissions

    GENERAL INFORMATION WHILE BOAT IS STATIONARY WARNING Stop your engine immediately whenever anyone in the water is near your boat. Serious injury to the person in the water is likely if contacted by a rotating propeller, a moving boat, a moving gearcase, or any solid device rigidly attached to a moving boat or gearcase.
  • Page 16 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 17: 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 18: Impact With Underwater Hazards

    GENERAL INFORMATION Impact With Underwater Hazards WARNING Operating the boat in shallow water can result in serious injury or death due to impact with underwater hazards. Always operate the boat at safe speeds in shallow water. 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.

  • Page 19: Trailering Boat

    GENERAL INFORMATION • Part of the sterndrive or the entire sterndrive could break loose and fly into the boat. • The boat could move suddenly in a new direction. Such a sharp change in direction can cause occupants to be thrown out of their seats or out of the boat.
  • Page 20 GENERAL INFORMATION Do not overload your boat. Most boats are rated and certified for maximum load (weight) capacities (refer to your boat capacity plate). If in doubt, contact your dealer or boat manufacturer. Perform safety checks and required maintenance. Follow a regular schedule and ensure that all repairs are properly made.
  • Page 21 GENERAL INFORMATION Direct all inquiries to the Boating Hotline, 1‑800‑368‑5647 or the Boat U.S. Foundation information number 1‑800‑336‑BOAT. We strongly recommend that all powerboat operators attend one of these courses. 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.

  • Page 22: Stolen Power Package

    GENERAL INFORMATION Report accidents. Boat operators are required by law to file a Boating Accident Report with their state boating law enforcement agency when their boat is involved in certain boating accidents. A boating accident must be reported if: 1. There is loss of life or probable loss of life. 2.

  • Page 23: Specifications

    Use of improper fuel can seriously damage your engine. Engine damage resulting from use of improper fuel is considered misuse of the engine and damage caused thereby will not be covered under the Mercury Racing limited warranty. OCTANE REQUIREMENTS (U.S./CANADA) FUEL TYPE...
  • Page 24 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 25: Crankcase Oil

    SPECIFICATIONS CAUTION Operating a Mercury engine with fuel containing alcohol creates unique problems as a result of the long storage periods common to a boat. In other applications, fuels containing alcohol are normally consumed before they can absorb enough moisture to cause problems.

  • Page 26: Capacities

    SPECIFICATIONS IMPORTANT OIL PRACTICES Do Not Use • Non‑detergent oils • Oils containing solid additives • Multi‑viscosity oils other than the ones recommended • Low quality oils Do Not Mix • Straight weight and multi‑viscosity oils • Different brands of oils, straight weight or multi‑viscosity •...

  • Page 27: General Engine Specifications (Hp1200 Sci)

    SPECIFICATIONS Transom Bearing Cavity Liter (U.S. qt.) to Add Drive Type Liter (U.S. qt.) (Close Couple Models Per 2.5 cm (1 in.) of Only) Spacer VI Dry Sump 4 (4.25) 0.47 liter (0.5 U.S. qt.) none General Engine Specifications (HP1200 SCi) 1200 HP (895 kW) Crankshaft Horsepower Displacement...

  • Page 28: Engine Operating Limitations (Hp1200 Sci)

    SPECIFICATIONS Engine Operating Limitations (HP1200 SCi) Maximum wide open throttle (W.O.T.) 6000‑6500 RPM 6600 RPM (Warning Horn), 6700 RPM Rev limit (PCM controls RPM) Idle RPM in gear 800 RPM Idle RPM out of gear 825 RPM Maximum fuel system flow rate 256 L/hr (68 gals/hr) at 5200 RPM Fuel pressure at key‑up 400 kPa (58 psi)

  • Page 29: Engine Break-In

    SPECIFICATIONS Engine Break‑in IMPORTANT: Failure to follow the engine break‑in procedures can result in poor performance throughout the life of the engine and can cause engine damage. Always follow break‑in procedures. 1 Hr. Break‑in Procedure • Do not exceed 5000 RPM 5 Hr.

  • Page 30: Operation

    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 31 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 32: Electrical System Overload Protection

    OPERATION Engine Monitor Guardian Power Problem Horn Display Activated Reduced By 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 Steady Horn Sensor Problem 5 Beeps‑3 Sec. Cam Sensor Long 5 Beeps‑3 Sec.
  • Page 33 OPERATION • Four fuses are located at the upper rear of the engine containing a 5 and three 20 amp fuses. A circuit breaker protects the fuel pump wire harness. 4112 Fuse 50 amp main power circuit breaker Fuse block A 25 amp fuel pump circuit Fuse block B breaker...
  • Page 34 OPERATION In an emergency, if you cannot locate and correct the cause of the high current draw, and you must operate the engine; perform the following: 1. Turn "OFF" or disconnect all accessories connected to the engine and instrumentation wiring and reset the circuit breaker.

  • Page 35: Remote Controls (Console Mounted Zero Effort)

    OPERATION Analog gauges (if equipped) are protected with a 5 amp fuse. 7412 Helm harness Ground connection Fused 12V (5 amp Fuse (5 amp) maximum) Relay Switched 12V Remote Controls (Console Mounted Zero Effort) 1. Control the throttle by moving the longer control lever(s) or, to increase speed, push the control lever forward.

  • Page 36: Power Trim

    OPERATION 2. Control shifting by moving the shorter control lever(s). This control shifts the unit into gear with full lever movement. Move the lever forward to engage the forward gear. Move lever backward to engage reverse gear. Place the lever in the center position to shift to neutral.
  • Page 37 OPERATION In most cases, best overall performance is obtained with the drive unit adjusted so the boat bottom will run at a 3° to 5° angle to the water. 7418 Boat bottom at 3° to 5° angle with water Trimming Drive Unit Up/Out Can: •...
  • Page 38 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 39: 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 40 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 41: 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 42: Freezing Temperature Operation

    Engine components will be damaged if submerged. Damage caused by submersion is not covered by the Mercury Racing Limited Warranty. Launching And Boat Operation Care NOTICE Some boating maneuvers can introduce water into the engine through the exhaust system, causing severe engine damage.
  • Page 43 OPERATION In any 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 section of this manual.

  • Page 44: 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 45: 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 46: 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 47: Maintenance

    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 48: 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 U.S. Coast Guard rules to minimize risk of fire or explosion. Do not use replacement electrical or fuel system components that do not comply with these rules.
  • Page 49 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 50: 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 51 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 52 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 and of operation.

  • Page 53: 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 oil. Every 100 hours of operation or once Driveline Models ‑ Lubricate and inspect a season, whichever occurs first. the engine to transom driveshaft U‑joint crosses and slip joint.
  • Page 54 MAINTENANCE 1. With the engine at idle, observe the oil reservoir sight tube. 7423 Oil reservoir sight tube 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 55 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 56 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 57 MAINTENANCE CHECKING POWER TRIM PUMP FLUID 1. Place the drive unit in the full down/in position. 7432 Fill/Vent screw "FULL" mark "ADD" mark Tube Ref No. Description Where Used Part No. Power Trim and 92-858074K0 Trim pump Steering Fluid...
  • Page 58 MAINTENANCE 2. Remove the fill/vent screw. Wipe clean and re‑insert back into the pump, but do not thread it into place. 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"...
  • Page 59 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 Ref No.

  • Page 60: Changing Fluids

    MAINTENANCE 5. Do not use the transmission expansion bottle as a fluid reservoir. 7434 Transmission expansion 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.) below the oil reservoir.
  • Page 61 MAINTENANCE 3. Loosen the oil pump mounting bolts and remove the belt. Using an electric drill, manually turn the oil pump pulley (clockwise) to discharge any remaining engine oil into the reservoir to be drained. 4. Drain the oil overflow canister into a suitable container. 7438 Vent canister 5.
  • Page 62 MAINTENANCE d. Coat the new filter sealing ring with new oil and install it hand tight. Do not over tighten. e. Install the filter retaining clamp "a" so that the clasp of the retaining clamp is against the stop screw "b" to secure the filter during operation.
  • Page 63 MAINTENANCE 8. Install the bottom oil reservoir plug and tighten securely. 7436 Oil drain plug 9. Begin by filling the oil reservoir with 11.4 liters (12 U.S. qt.) of oil.
  • Page 64 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 65 MAINTENANCE 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. Shut off the engine if it is necessary to add oil. 7423 Oil reservoir sight tube 14.
  • Page 66 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 67 MAINTENANCE Driveline Models Only 1. Place a container below the input shaft housing and remove the bottom pipe plug. 7445 Input shaft housing Oil drain pipe plug WARNING Avoid damage to the input shaft housing. Do Not Overfill the input shaft housing reservoir or damage to transom components could occur.
  • Page 68 MAINTENANCE 2. Fill the input shaft housing through the top pipe plug hole "a" until oil flows from oil level pipe plug hole "b." Install the pipe plugs "a" & "b" into the input shaft housing and tighten securely. 7447 Fill pipe plug hole (fill through here) Oil level pipe plug hole Tube Ref.

  • Page 69: Lubrication

    MAINTENANCE 2. Remove the upper oil level plug and sealing washer from the gearcase. 7429 Oil level plug Fill/Drain plug and sealing washer Tube Ref. Description Where Used Part No. Transom input shaft Torco MTF Gear Oil reservoir and dry 92‑849684‑1 sump drive IMPORTANT: If water drains from the gearcase, or if gear lube...
  • Page 70 MAINTENANCE • Engine driveshaft. • Transmission shift lever ‑ Lubricate poppet ball. Lubricate pivot points with SAE 25W40 motor oil: • Shift cable. • Throttle linkage and cable ‑ Lubricate cable and swivels. F - N - R 7446 Tube Ref No. Description Where Used Part No.

  • Page 71: Propellers

    MAINTENANCE Propellers WARNING Avoid serious injury or death. Place the remote control in neutral and remove the ignition key from the switch before removing and/ or installing the propeller. Place a block of wood between the anti‑ventilation plate and the propeller to protect hands from propeller blades and to prevent the propeller from rotating when removing the propeller nut.
  • Page 72 MAINTENANCE 3. Slide washer, continuity washer, and propeller off propeller shaft. NOTE: Some damaged propellers can be repaired. See your dealer. INSTALLATION 1. Apply a liberal coat of Optimal Longtime PD2 Extreme Pressure Grease to propeller shaft. 2. Align splines and install propeller, washer and propeller nut. 5915 Propshaft Flat washer...

  • Page 73: Seawater Pump Impeller Inspection

    MAINTENANCE Seawater Pump Impeller Inspection Seawater Pump Impeller service should be performed by an authorized Mercury Marine dealer. 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).

  • Page 74: 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 75: Cleaning The Flame Arrestors

    MAINTENANCE 3. Remove the end plates and gaskets "b." 4. Clean the cooler with a suitable brush and flush passages with fresh water. 5. Inspect the end plate gaskets and replace if necessary. 6. Install the gaskets and end plates. Tighten screws securely. 7.
  • Page 76 MAINTENANCE 1. Seawater Pump/Alternator Drive Belt rmc22 Sea pump pulley Idler pulley Seawater pump/ Alternator pulley (adjust alternator drive belt belt tension here) Crankshaft pulley Tensioner gauge Description Seawater pump/alternator belt 360‑440 80‑100...
  • Page 77 MAINTENANCE 2. Power Steering Pump Drive Belt 25978 Tensioner gauge Jam nut Tensioning lug Description Power steering pump drive belt 360‑440 80‑100 3. Oil Pump Belt ‑ Belt Should Twist 1/4 Turn rmc21 Crankshaft pulley Oil pump drive belt Oil pump (adjust belt tension here)

  • Page 78: Corrosion And Corrosion Protection

    MAINTENANCE 4. Supercharger Belt ‑ Self‑tensioning rmc23 Supercharger pulley Idler pulleys Supercharger drive Belt tensioner belt Crankshaft pulley Corrosion and Corrosion Protection Add info about replacing anodes in the flywheel coolers 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...
  • Page 79 MAINTENANCE CAUTION Avoid corrosion damage. Do not use magnesium anodes 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 blister and peel completely from the surface of the overprotected drive.
  • Page 80 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 81 MAINTENANCE 18998 Anodes Oil cooler drain fittings 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 82 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 83: 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 84: Bottom Of Boat

    MAINTENANCE WARNING Observe the following when jump starting, charging or handling a battery: • Do not use jumper cables and a booster battery to start engine. • When charging batteries, ensure battery compartment or area where batteries are located, is well‑vented. •...

  • Page 85: Inspection And Maintenance

    MAINTENANCE Inspection and Maintenance Inspect the power package often and at regular intervals to help maintain its top operating performance, and correct potential problems before they occur. The entire power package should be checked carefully, including all accessible engine parts. 1.
  • Page 86 MAINTENANCE Date Maintenance Performed Engine Hours...

  • Page 87: 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. CAUTION Avoid engine or sterndrive damage; Do not operate the engine without water flowing through the seawater pickup pump. The pump impeller can be damaged and damage to the engine or sterndrive unit may result.
  • Page 88 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 89: Draining Instructions

    COLD WEATHER OR EXTENDED STORAGE Draining Instructions NOTICE Avoid cooling system and engine damage. Water trapped in the seawater section of the cooling system can cause corrosion damage, freeze damage, or both. Ensure the seawater section of the cooling system is drained immediately after operation, or before any length of storage in cold weather, if the possibility of freezing temperatures exists.
  • Page 90 COLD WEATHER OR EXTENDED STORAGE 1. Drain the cooling system at the following locations: 3713 Cylinder block (port Seawater pump and starboard). Use a Center/bottom of bell stiff wire to clean out housing (drains the drain holes until entire engine oil coolers). system is drained.
  • Page 91 COLD WEATHER OR EXTENDED STORAGE hose NOTE: It may be 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. 3721 Header drain plugs (port and starboard) 3.

  • Page 92: 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 93 COLD WEATHER OR EXTENDED STORAGE BEFORE STARTING WARNING To prevent possible injury or damage to equipment, do not install the battery until all engine maintenance has been performed. CAUTION Avoid severe engine damage. Prime the engine oiling system before starting the engine. 1.
  • Page 94 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 95 COLD WEATHER OR EXTENDED STORAGE NOTE: Do not turn the key switch to the "START" position during the following priming procedure. 5. Cycle the ignition key switch to the "RUN" position for three seconds and then "OFF". 6. Repeat the previous two steps one to two more times. The object of this procedure is to prime the fuel system and fill the water separating fuel filter but not to the point of having the system completely full and the primer bulb hard and under...
  • Page 96 COLD WEATHER OR EXTENDED STORAGE 14. Check steering system and shift/throttle control for proper operation.

  • Page 97: Troubleshooting

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

  • Page 98: Engine Cranks But Will Not Start

    TROUBLESHOOTING Engine Cranks But Will Not Start Possible Cause Remedy Improper starting procedure Read starting procedure Low battery voltage Charge the battery Empty fuel tank or fuel shut off valve Fill tank or open valve closed Faulty fuel pump, wiring, fuel pump fuse, 50 amp circuit breaker or a fuel Replace faulty component pump relay...

  • Page 99: Engine Runs Rough, Hard To Start, Misses, And/Or Backfires

    TROUBLESHOOTING Engine Runs Rough, Hard to Start, Misses, and/or Backfires Possible Cause Remedy Faulty ignition system component. Service ignition system. Clogged fuel filter. Replace filters. If contaminated, drain tank. Fill with Stale or contaminated fuel. fresh fuel. Replace kinked lines or blow out Kinked or clogged fuel line or fuel tank lines with compressed air to remove vent line.

  • Page 100: Insufficient Engine Temperature

    TROUBLESHOOTING Insufficient Engine Temperature Possible Cause Remedy Faulty water thermostat. Replace water thermostat. Faulty gauge or sender. Test with shop gauge; test sender. Faulty oil thermostat. Replace. Excessive Engine Temperature Possible Cause Remedy Seacock closed. Open. Charge Air Cooler plugged with foreign Clean Charge Air Cooler.

  • Page 101: Low Engine Oil Pressure

    TROUBLESHOOTING Low Engine Oil Pressure Possible Cause Remedy Insufficient oil in system. Check and add oil. Check and bring oil to required level. Excessive oil in system (causing it to Check for cause of excessive oil become aerated). (improper filling, defective fuel pump, etc.).

  • Page 102: Power Trim Does Not Operate (Motor Runs But Drive Unit Does Not Move)

    TROUBLESHOOTING Power Trim Does Not Operate (Motor Runs But Drive Unit Does Not Move) Possible Cause Remedy Trim pump oil level low. Fill pump with oil. Drive binding in gimbal ring. Check for obstruction. Remote Control Operates Hard, Binds, Has Excessive Free‑Play or Makes Unusual Sounds Possible Cause Remedy...

  • Page 103: 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 104: 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 105 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 106: 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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