HP1200 SCi Dry Sump - Brunswick Corporationdownload.brunswick-marine.com/filereader/file/pdf/... ·...

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Thank Youfor your purchase of one of the finest marine power packagesavailable. It incorporates numerous design features to assureoperating ease and durability.With proper care and maintenance, you will thoroughly enjoyusing this product for many boating seasons. To ensuremaximum performance and carefree use, we ask that youthoroughly read this manual.The Operation, Maintenance & Warranty Manual containsspecific instructions for using and maintaining your product.We suggest that this manual remain with the product for readyreference whenever you are on the water.Again, thank you for purchasing one of our Mercury Marineproducts. We sincerely hope your boating will be pleasant!

Mercury Racing, N7480 County Road "UU" Fond du Lac, WI 54935-9585

7406

Warranty MessageThe product you have purchased comes with a limitedwarranty from Mercury Marine; the terms of the warranty areset forth in the Warranty Information section of this manual.The warranty statement contains a description of what iscovered, what is not covered, the duration of coverage, howto best obtain warranty coverage, important disclaimers andlimitations of damages, and other related information. Pleasereview this important information.

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! WARNINGThe operator (driver) is responsible for the correct and safeoperation of the boat, the equipment aboard and the safety of alloccupants aboard. We strongly recommend that the operatorread this Operation, Maintenance and Warranty Manual andthoroughly understand the operational instructions for the powerpackage and all related accessories before the boat is used.

! WARNINGThe engine exhaust from this product contains chemicals knownto the state of California to cause cancer, birth defects or otherreproductive harm.

Safety Alerts and NoticesThroughout this publication, dangers, warnings, cautions, andnotices0., accompanied by the international HAZARD symbol! , are used to alert the technician to special instructions

concerning a particular service or operation that may be hazardousif performed incorrectly or carelessly. These safety alerts followANSI standard Z535.6‑2006 for product safety information inproduct manuals, instructions, and other collateral materials.Observe these safety alerts carefully.These safety alerts alone can not eliminate the hazards theysignal. Strict compliance to these special instructions whenperforming the service, and common sense operation are majoraccident prevention measures.

! DANGERIndicates a hazardous situation which, if not avoided, will resultin death or serious injury.

! WARNINGIndicates a hazardous situation which, if not avoided, could resultin death or serious injury.

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! CAUTIONIndicates a hazardous situation which, if not avoided, could resultin minor or moderate injury.

NOTICEIndicates a situation which, if not avoided, could result in engineor major component failure.

IMPORTANT: Identifies information essential to the successfulcompletion of the task.NOTE: Indicates information that helps in the understanding of aparticular step or action.

Copyright and Trademark InformationMercury Marine, Fond du Lac, Wisconsin U.S.A.Litho in U.S.A.© 2006, Mercury MarineMercury, 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 Waveslogo, and SmartCraft logo are all registered trademarks ofBrunswick Corporation. Mercury Product Protection logo is aregistered service mark of Brunswick Corporation.

TABLE OF CONTENTS

v

Warranty Information

Warranty Coverage......................................................................1

General Information

Identification Record....................................................................2Boater's Responsibilities..............................................................3Boat Horsepower Capacity..........................................................4High‑Speed and High‑Performance Boat Operation...................4Lanyard Stop Switch....................................................................5Protecting People In The Water...................................................6Exhaust Emissions......................................................................7Wave And Wake Jumping...........................................................9Impact With Underwater Hazards..............................................10Trailering Boat........................................................................... 11Safe Boating Suggestions......................................................... 11Stolen Power Package.............................................................. 14

Specifications

Fuel Requirements (HP1200 SCi).............................................15Crankcase Oil............................................................................17Capacities..................................................................................18General Engine Specifications (HP1200 SCi)........................... 19Engine Operating Limitations (HP1200 SCi)............................. 20California Emissions Regulations..............................................20Engine Break‑in.........................................................................21After Break‑In Period.................................................................21

Operation

Instrumentation..........................................................................22Warning System........................................................................ 22Electrical System Overload Protection...................................... 24Remote Controls (Console Mounted Zero Effort)......................27Power Trim................................................................................ 28

TABLE OF CONTENTS

vi

Starting, Shifting, and Stopping.................................................31Operation Chart.........................................................................33Freezing Temperature Operation..............................................34Drain Plug and Bilge Pump........................................................34Launching And Boat Operation Care.........................................34

Conditions Affecting Operation

Weight Distribution.....................................................................36Bottom Of Boat..........................................................................36Cavitation...................................................................................36Ventilation..................................................................................37Propeller Selection.....................................................................37Conditions That Lower Engine Performance.............................38

Maintenance

Service Responsibilities.............................................................39Replacement Service Parts.......................................................40Do‑It‑Yourself Maintenance Suggestions..................................40Servicing High Horsepower Engines.........................................42Maintenance Charts...................................................................42Checking Fluid Levels................................................................45Changing Fluids.........................................................................52Lubrication.................................................................................61Propellers...................................................................................63Seawater Pump Impeller Inspection..........................................65Flushing Cooling System...........................................................65Cleaning Seawater (Raw Water) Section of Oil Cooler.............66Cleaning the Flame Arrestors....................................................67Drive Belts.................................................................................67Corrosion and Corrosion Protection..........................................70Battery.......................................................................................75Bottom of Boat...........................................................................76Inspection and Maintenance......................................................77Attention Required After Submersion........................................77Maintenance Log.......................................................................77

TABLE OF CONTENTS

vii

Cold Weather or Extended Storage

Power Package Lay‑up..............................................................79Draining Instructions..................................................................81Battery Winter Storage..............................................................84Power Package Recommissioning............................................84

Troubleshooting

Engine Will Not Crank................................................................89Engine Cranks But Will Not Start...............................................90Engine Runs Rough, Hard to Start, Misses, and/or Backfires...91Poor Performance......................................................................91Insufficient Engine Temperature................................................92Excessive Engine Temperature.................................................92Low Engine Oil Pressure...........................................................93Battery Will Not Come Up On Charge.......................................93Power Trim Does Not Operate (Motor Doesn't Run).................93Power Trim Does Not Operate (Motor Runs But Drive Unit DoesNot Move)..................................................................................94Remote Control Operates Hard, Binds, Has Excessive Free‑Playor Makes Unusual Sounds.........................................................94Steering Wheel Turns Hard or Jerky.........................................94

Owner Service Assistance

Local Repair Service..................................................................95Service Away From Home.........................................................95Parts And Accessories Inquiries................................................95Service Assistance....................................................................95Mercury Mercruiser Service Offices...........................................96

Ordering Literature

United States and Canada.........................................................98Outside The United States and Canada....................................98

WARRANTY INFORMATION

1

Warranty CoverageMercury Racing does not offer a warranty with this power package.

GENERAL INFORMATION

2

Identification Record

ModelDisplacementMax. WOT RPMSpark PlugsSpark Plug GapFiring Order

1075 SCI557 CI / 9.1 Liter5600-6000NKG BRCECS0.76 mm 0.03 in. ( )1-8-4-3-6-5-7-2

Fuel Octane 92 AKI [(R+M)/2] or 98 RONPreferredEngine Oil

Mercury 25W-40

AlternativeEngine Oil

API CI-4, CH-4, CG-4

14837

ab

e

f

d

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c

g

b

GENERAL INFORMATION

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a - Engine Model/Horsepower:________________________

b - Engine SerialNumber1. :________________________

c - Transom AssemblySerial Numer:________________________

d - Sterndrive SerialNumber & GearRatio2. :________________________

e - Propeller Number &Pitch:_________________________

f - Running Rotation3. :_________________________

g - Hull IdentificationNumber:_________________________

h - Boat Model & Length:_________________________

The serial numbers are the manufacturer's keys to numerousengineering details that apply to your Mercury Marine powerpackage. When contacting your authorized Mercury Marine dealerabout 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 headalong with the crankshaft number.

2. The gear ratio is stamped on the the bolt located next to theserial number label.

3. The running rotation is stamped on the back of the strut.

Boater's ResponsibilitiesThe operator (driver) is responsible for the correct and safeoperation of the boat and safety of its occupants and generalpublic. It is strongly recommended that each operator (driver) readand understand this entire manual before operating the powerpackage.Be sure at least one additional person on board is instructed in thebasics of starting and operating the power package, and boathandling in case the driver is unable to operate the boat.

GENERAL INFORMATION

4

Boat Horsepower Capacity

! WARNINGAvoid serious injury, death or property damage fromoverpowering a boat. Using a power package that exceeds themaximum 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• Cause the boat to break apart, particularly around the transom

area.

Do not overpower or overload your boat. Most boats will carry arequired capacity plate indicating the maximum acceptable powerand load as determined by the manufacturer following certainfederal guidelines. If in doubt, contact your dealer or the boatmanufacturer.

U.S. COAST GUARD CAPACITYMAXIMUM HORSEPOWER XXXMAXIMUM PERSON CAPACITY (POUNDS) XXXMAXIMUM WEIGHT CAPACITY XXX

ob00306

High‑Speed and High‑Performance Boat OperationIf your power package is to be used on a high speed or highperformance boat with which you are unfamiliar, we recommendthat you never operate it at its high speed capability without firstrequesting an initial orientation and familiarization demonstrationride with your dealer or an operator experienced with your boat/power package combination. For additional information, obtain acopy of our Hi‑Performance Boat Operation booklet from yourdealer, distributor, or Mercury Marine.

GENERAL INFORMATION

5

Lanyard Stop SwitchThe purpose of a lanyard stop switch is to turn off the engine whenthe operator moves far enough away from the operator's position(as in accidental ejection from the operator's position) to activatethe switch. A lanyard stop switch can be installed as an accessory ‑generally on the dashboard or side adjacent to the operator'sposition.While activation of the lanyard stop switch will stop the engineimmediately, a boat will continue to coast for some distancedepending upon the velocity and degree of any turn at shut down.However, the boat will not complete a full circle. While the boat iscoasting, it can cause injury to anyone in the boat's path asseriously as the boat would when under power.

21629

a b

a - Lanyard cordb - Lanyard stop switch

We strongly recommend that other occupants be instructed onproper starting and operating procedures should they be requiredto operate the engine in an emergency (e.g. if the operator isaccidentally ejected).

! WARNINGShould the operator fall out of the boat, the possibility of seriousinjury or death from being run over by the boat can be greatlyreduced by stopping the engine immediately. Always properlyconnect both ends of the stop switch lanyard to the stop switchand the operator.

GENERAL INFORMATION

6

! WARNINGAvoid serious injury or death from deceleration forces resultingfrom accidental or unintended stop switch activation. The boatoperator should never leave the operator's station without firstdisconnecting the stop switch lanyard from the operator.

Accidental or unintended activation of the switch during normaloperation is also a possibility. This could cause any, or all, of thefollowing potentially hazardous situations:• Occupants could be thrown forward due to unexpected loss

of forward motion ‑ a particular concern for passengers in thefront of the boat who could be ejected over the bow andpossibly struck by the gear case or propeller.

• Loss of power and directional control in heavy seas, strongcurrent or high winds.

• Loss of control when docking.

Protecting People In The WaterWHILE YOU ARE CRUISINGIt is very difficult for a person in the water to take quick action toavoid a boat heading in their direction, even at slow speeds.

21604

Always slow down and exercise extreme caution any time you areboating in an area where there might be people in the water.Whenever a boat is moving (even coasting) and the gear shift is inneutral, there is sufficient force by the water on the propeller tocause the propeller to rotate. This neutral propeller rotation cancause serious injury.

GENERAL INFORMATION

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WHILE BOAT IS STATIONARY

! WARNINGStop your engine immediately whenever anyone in the water isnear your boat. Serious injury to the person in the water is likelyif contacted by a rotating propeller, a moving boat, a movinggearcase, or any solid device rigidly attached to a moving boator gearcase.

Shift into neutral and shut off the engine before allowing people toswim or be in the water near your boat.

Exhaust EmissionsBE ALERT TO CARBON MONOXIDE POISONINGCarbon monoxide is present in the exhaust fumes of all internalcombustion engines. This includes the outboards, sterndrives andinboard engines that propel boats, as well as the generators thatpower various boat accessories. Carbon monoxide is a deadly gasthat is odorless, colorless and tasteless.Early symptoms of carbon monoxide poisoning which should notbe confused with seasickness or intoxication, include headache,dizziness, drowsiness, and nausea.

! WARNINGAvoid the combination of a running engine and poor ventilation.Prolonged exposure to carbon monoxide in sufficientconcentration can lead to unconsciousness, brain damage, ordeath.

POOR VENTILATIONUnder certain running and/or wind conditions, permanentlyenclosed or canvas enclosed cabins or cockpits with insufficientventilation may draw in carbon monoxide. Install one or morecarbon monoxide detectors in your boat.Although the occurrence is rare, on a very calm day, swimmersand passengers in an enclosed area of a stationary boat thatcontains or is near a running engine may be exposed to ahazardous level of carbon monoxide.

GENERAL INFORMATION

8

While Boat Is Stationary

21626

ab

a - Running the engine when the boat is moored in a confinedspace.

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 (station

wagon effect).

GOOD VENTILATIONVentilate passenger area, open side curtains, or forward hatchesto remove fumes.

5448

GENERAL INFORMATION

9

Wave And Wake JumpingOperating recreational boats over waves and wake is a natural partof boating. However, when this activity is done with sufficient speedto force the boat hull partially or completely out of the water, certainhazards arise, particularly when the boat re‑enters the water.

5450

The primary concern is the boat changing direction while in themidst of the jump. In such case the landing may cause the boat toveer violently in a new direction. Such a sharp change in directioncan cause occupants to be thrown out of their seats, or out of theboat.

! WARNINGAvoid serious injury or death from being thrown within or out ofa boat when it lands after jumping a wave or wake. Avoid waveor wake jumping whenever possible. Instruct all occupants thatif a wake or wave jump occurs, get low and hang on to any boathand hold.

There is another less common hazardous result from allowing yourboat to launch off a wave or wake. If the bow of your boat pitchesdown far enough while airborne, upon water contact it maypenetrate under the water surface and submarine for an instant.This will bring the boat to a nearly instantaneous stop and can sendthe occupants flying forward. The boat may also steer sharply toone side.

GENERAL INFORMATION

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Impact With Underwater Hazards

! WARNINGOperating the boat in shallow water can result in serious injuryor death due to impact with underwater hazards. Always operatethe boat at safe speeds in shallow water.

Reduce speed, raise the drive, and proceed with caution wheneveryou maneuver a boat in shallow water areas or in areas where yoususpect underwater obstacles may exist. Gain as much knowledgeof the area as possible from maps or local boaters before you goboating. 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 (a) to (b)

= (c). Ensure that (c) is always less than (d) or (e) whenreading the water depth on the map.

• Fast acceleration will drive the sterndrive deeper into thewater.

11419

ab d e

c

f

a - Distance from depthfinder to bottom of skeg.

b - Distance from waterlineto bottom of depthfinder.

c - Distance from waterlineto bottom of skeg.

d - Distance from waterline toobstacle.

e - Distance from waterline tosea bottom.

f - Depth finder

Striking a floating or underwater object could result in the following:

GENERAL INFORMATION

11

• Part of the sterndrive or the entire sterndrive could break looseand fly into the boat.

• The boat could move suddenly in a new direction. Such asharp change in direction can cause occupants to be thrownout of their seats or out of the boat.

• A rapid reduction in speed. This will cause occupants to bethrown forward, or even out of the boat.

• Impact damage to the sterndrive and/or boat.

! WARNINGOperating a boat or engine with impact damage can result inproduct damage, serious injury, or death. If the vesselexperiences any form of impact, have an authorized MercuryMarine dealer inspect and repair the vessel or power package.

After striking a submerged object, stop the engine as soon aspossible and inspect it for any broken or loose parts. If damage ispresent or suspected, the sterndrive should be taken to anauthorized dealer for a thorough inspection and necessary repair.The boat should also be checked for any hull fractures, transomfractures, or water leaks.Operating a damaged sterndrive could cause additional damageto other parts of the sterndrive, or could affect control of the boat.If continued running is necessary, do so at greatly reduced speeds.

Trailering BoatThe boat can be trailered with the drive unit in up or down position.Adequate road clearance is required between road and gearhousing skeg when trailering with the drive unit in down position.If adequate road clearance is a problem, place drive unit in full upposition.

Safe Boating SuggestionsFamiliarize yourself with local, state and federal boatingregulations and restrictions.Use flotation devices. Have an approved personal flotation deviceof suitable size for each person aboard (it is the law).

GENERAL INFORMATION

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Do not overload your boat. Most boats are rated and certified formaximum load (weight) capacities (refer to your boat capacityplate). If in doubt, contact your dealer or boat manufacturer.Perform safety checks and required maintenance. Follow a regularschedule and ensure that all repairs are properly made.Check safety equipment on-board. Here are suggestions of thetypes of safety equipment to carry when boating:

Approved fire extinguisherPaddle or oarSignal devices: flashlight, rockets or flares, flag and whistle orhornSpare propeller, thrust hubs and an appropriate wrenchTools for necessary minor repairsFirst aid kit and bookAnchor and extra anchor lineWater‑proof storage containersManual bilge pump and extra drain plugsCompass and map or chartSpare operating equipment; batteries, bulbs, fuses, etc.VHF radio for making distress calls and receiving weatherreports, and a transistor radioDrinking water

Know signs of weather change and avoid foul weather andrough-sea boating.Tell someone where you are going and when you expect toreturn.Know and obey all nautical rules and laws of the waterways. Boatoperators should complete a boating safety course. Courses areoffered in the U.S.A. by:1. The U.S. Coast Guard Auxiliary2. The Power Squadron3. The Red Cross4. Your state boating law enforcement agency

GENERAL INFORMATION

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Direct all inquiries to the Boating Hotline, 1‑800‑368‑5647 or theBoat U.S. Foundation information number 1‑800‑336‑BOAT.We strongly recommend that all powerboat operators attend oneof these courses.Make sure everyone in the boat is properly seated. Do not allowanyone to sit or ride on any part of the boat that was not intendedfor such use. This includes the back of seats, gunwales, transom,bow, decks, raised fishing seats, any rotating fishing seat; oranywhere that an unexpected acceleration, sudden stopping,unexpected loss of boat control, or sudden boat movement couldcause a person to be injured or thrown overboard.Never be under the influence of alcohol or drugs while boating (itis the law). Alcohol or drug use impairs your judgment and greatlyreduces your ability to react quickly.Know your boating area and avoid hazards.Prepare other boat operators. Train at least one other person onboard in boat operation and handling in case the driver becomesdisabled or falls overboard.Passenger boarding. Stop the engine whenever passengers areboarding, unloading, or are near the back (stern) of the boat. Justshifting the power package into neutral is not sufficient.Be alert. The operator of the boat is responsible by law to maintaina proper lookout by sight and hearing. The operator must have anunobstructed view particularly to the front. No passengers, load,or fishing seats should block the operators view when operatingthe boat.Never follow behind a water skier. As an example, your boattraveling at 40 km/h (25 MPH) will overtake a fallen skier61 m (200 ft.) in front of you in five seconds.Watch for fallen skiers. When using your boat for water skiing orsimilar activities, always keep a fallen or downed skier on theoperator's side of the boat while returning to assist the skier. Theoperator should always have the downed skier in sight and neverback up to the skier or anyone in the water.

GENERAL INFORMATION

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Report accidents. Boat operators are required by law to file aBoating Accident Report with their state boating law enforcementagency when their boat is involved in certain boating accidents. Aboating accident must be reported if:1. There is loss of life or probable loss of life.2. There is personal injury requiring medical treatment 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 acomplete list of rules and regulations.

Stolen Power PackageIf your power package is stolen, immediately advise the localauthorities and Mercury Marine of the model and serial number(s)and to whom the recovery is to be reported. This Stolen PowerPackage information is placed into a file at Mercury Marine to aidauthorities and dealers in recovery of stolen engines.

SPECIFICATIONS

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Fuel Requirements (HP1200 SCi)Use an Off‑road brand of leaded gasoline, preferably withoutalcohol. Mercury Marine recommends fuels that contain fuelinjector cleaner for added internal cleanliness.

! WARNINGFIRE AND EXPLOSION HAZARD: Fuel leakage from any partof the fuel system can be a fire and explosion hazard which cancause serious bodily injury or death. Careful periodic inspectionof entire fuel system is mandatory, particularly after storage. Allfuel components should be inspected for leakage, softening,hardening, swelling or corrosion. Any sign of leakage ordeterioration requires replacement before further engineoperation.

! CAUTIONUse of improper fuel can seriously damage your engine. Enginedamage resulting from use of improper fuel is considered misuseof the engine and damage caused thereby will not be coveredunder the Mercury Racing limited warranty.

OCTANE REQUIREMENTS (U.S./CANADA)

FUEL TYPE MINIMUM POSTED OCTANE

Race Gas (R+M) ÷ 2 = 112 or RON = 114*

NOTE: *Research Octane NumberOCTANE REQUIREMENTS (OUTSIDE THE U.S./CANADA)

FUEL TYPE MINIMUM POSTED OCTANE

Race Gas (R+M) ÷ 2 = 112 or RON = 114*

NOTE: *Research Octane Number

SPECIFICATIONS

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USING REFORMULATED (OXYGENATED) FUELS (USAONLY)This type of fuel is required in certain areas of the U.S. The twotypes of oxygenates used in these fuels are alcohol (Ethanol) orEther (MTBE or ETBE). If Ethanol is the oxygenate that is used inthe gasoline in your area, refer to the Fuel Containing Alcoholsection.These reformulated fuels are acceptable for use in your Mercuryengine.FUEL CONTAINING ALCOHOLIf the fuel in your area contains either methanol (methyl alcohol) orethanol (ethyl alcohol), you should be aware of certain adverseeffects that can occur. These adverse effects are more severe withmethanol. Increasing the percentage of alcohol in the fuel can alsoworsen these adverse effects.Some of these adverse effects are caused because the alcohol inthe fuel can absorb moisture from the air, resulting in a separationof the water/alcohol from the gasoline in the fuel tank.The fuel system components on your Mercury engine willwithstand up to 10% alcohol content in the gasoline. We do notknow what percentage your boat’s fuel system will withstand.Contact your boat manufacturer for specific recommendations onthe boats fuel system components (fuel tanks, fuel lines, andfittings).Fuel containing alcohol may increase:• Corrosion of metal parts.• Deterioration of rubber or plastic parts.• Fuel permeation through rubber fuel lines.• Starting and operating difficulties.

SPECIFICATIONS

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! CAUTIONOperating a Mercury engine with fuel containing alcohol createsunique problems as a result of the long storage periods commonto a boat. In other applications, fuels containing alcohol arenormally consumed before they can absorb enough moisture tocause problems. However, boats are often idle enough for theproblem of phase separation to occur in the fuel. In addition,alcohol can wash the protective oil film from internal componentsresulting in corrosion during storage. Do not store fuel containingalcohol in a fuel tank for a long period of time.

IMPORTANT: Because of possible adverse effects of alcohol ingasoline, it is recommended that only alcohol‑free fuel be usedwhere possible.If only fuel containing alcohol is available, or if the presence ofalcohol is unknown, increased inspection frequency for leaks andabnormalities is required.

Crankcase OilOIL 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

SPECIFICATIONS

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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

• Different weights of straight weight or different weights of multi‑viscosityoils.

TEMPERATURE/OIL VISCOSITY CHART

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

CapacitiesModel HP1200 SCi

Oil reservoir capacity with new filter1. Approximately 15.2 liters (16 U.S. qt.)

Seawater cooling system2. 19 liter (20 U.S. qt.)

Transmission fluid capacity3. Approximately 2.84 liters (3.0 U.S. qt.)

1. Refer to Changing Fluids for the correct procedure to avoid overfilling.2. Seawater cooling system capacity information is for winterization use only.3. Refer to Changing Fluids for the correct procedure to avoid overfilling.

SPECIFICATIONS

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Drive Type Liter (U.S. qt.)Transom Bearing Cavity(Close Couple Models

Only)

Liter (U.S. qt.) to AddPer 2.5 cm (1 in.) of

Spacer

VI Dry Sump 4 (4.25) 0.47 liter (0.5 U.S. qt.) none

General Engine Specifications (HP1200 SCi)Crankshaft Horsepower1. 1200 HP (895 kW)

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 PCM 07 Distributorless

Spark plug type (Champion, Mercury P/N 33‑840697)

Spark plug gap 0.75 mm (0.030 in.)

Fuel system Sequential Fuel Injection

Length (transom mount to front ofengine) 84.2 cm (33.13 in.)

Width 89.5 cm (35.25 in.)

Height 92.4 cm (36.375 in.)

1. Kilowatts/horsepower rating is in compliance with the SAE J1228/ISO 3046Standard. Usable power is be reduced by gear losses.

SPECIFICATIONS

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Engine Operating Limitations (HP1200 SCi)Maximum wide open throttle (W.O.T.)RPM 6000‑6500 RPM

Rev limit 1. 6600 RPM (Warning Horn), 6700 RPM(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)

Fuel pressure at W.O.T. 498 kPa (72 psi)

Coolant thermostat is fully open attemperature 70° C (158° F)

Minimum water pressure supplied to theengine 138 kPa (20 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 RegulationsAn emission certification label, showing emission levels andengine specifications directly related to emissions, is placed on theengine at the time of manufacture.

EMISSION CONTROL INFORMATION

THIS ENGINE IS RATED AT GREATER THAN 500 HP (CRANKSHAFT) AND IS THEREFORE EXEMPT FROM CALIFORNIA EMISSIONS REGULATIONS FOR SPARK - IGNITION MARINE ENGINES.

6104

1. Engines are equipped with an ignition system that has a built‑in RPM revlimiter. Engine is performing normally if it will not exceed this RPM.

SPECIFICATIONS

21

Engine Break‑inIMPORTANT: Failure to follow the engine break‑in procedures canresult in poor performance throughout the life of the engine andcan cause engine damage. Always follow break‑in procedures.

1 Hr. Break‑in Procedure

• Do not exceed 5000 RPM

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.

• 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 PeriodTo help extend the life of your power package, Mercury Marinerecommends the following:

After 5 hr. Break‑in

• Use a propeller that allows the engine to operate at or near the top of themaximum RPM range (See Specifications section) when at full throttlewith a normal boat load.

• Do not advance the throttle until the engine runs smoothly at idle and watertemperature reaches a minimum of 54 °C (130 °F). Do not operate at fullthrottle until the engine oil temperature reaches 60 °C (140 °F).

• Follow the maintenance schedule in this manual.

OPERATION

22

InstrumentationMercury Racing requires that the following critical enginefunctions be monitored:• Oil pressure• Engine RPM• Oil temperature• Water temperature• System voltage• Guardian fault messagesThe use of SmartCraft instrumentation will display all of theabove critical engine functions as well as others not listed.SmartCraft instrumentation will also display informationabout power train sensor faults and Guardian activation.

Warning System

NOTICEA continuous horn indicates a critical fault. Operating the engineduring a critical fault can damage components. If the warninghorn emits a continuous beep, do not operate the engine unlessavoiding a hazardous situation.

ENGINE GUARDIAN SYSTEMThe Engine Guardian System monitors the critical sensors on theengine for any early indications of problems. The system respondsto a problem by emitting a continuous or intermittent horn and,under certain circumstances, reduces engine power to provideengine protection. When the key switch is turned "ON", the systemmonitors horn beeps once to verify horn operation.If the Propulsion Control Module (PCM) detects a fault signal froman engine sensor, it records a fault code.1. The horn warning can be stopped by turning the engine off. If

the horn continues to sound on restart, the system detected afault again. See your Mercury Marine dealer to correct theproblem.

2. On restart, if the beeping stops, see your authorized MercuryMarine dealer to diagnose and clear the fault.

OPERATION

23

NOTE: The following Table lists only the possible problem areasand not specific error codes recorded by the PCM. Use a DigitalDiagnostic Terminal (DDT) or Computer Diagnostic System (CDS)to extract specific problem codes from the PCM.

Problem HornMonitorDisplay

GuardianActivated

EnginePower

Reduced By

Battery range highor low

3 Beeps‑1.5Sec. Long

Yes Yes 100% downto 5%

Low SeawaterPressure Steady Horn Yes Yes 100% down

to 5%

Boost Valve Error Steady Horn Yes Yes 70%

GuardianEnvoked Steady Horn Yes No

Low Oil Pressure Steady Horn Yes Yes 100% downto 15%

Oil TemperatureOverheat.

5 beeps‑3 Sec.Long Yes Yes 100% down

to 15%

EngineOverspeed Steady Horn Yes No Rev limit with

no power loss

ReverseOverspeed

3 beeps‑1.5Sec. Long Yes No Rev limit with

no power loss

NeutralOverspeed

3 beeps‑1.5Sec. Long Yes No Rev limit with

no power loss

Coolant Overheat Steady Horn Yes Yes 100% downto 15%

PCM Error Steady Horn Yes Yes Forced Idle

Coil Pack Failure 5 Beeps‑3 Sec.Long Yes No

Fuel InjectorFailure

5 Beeps‑3 Sec.Long Yes No

Fuel Pump Failure 5 Beeps‑3 Sec.Long Yes Yes 70%

Idle Air ControlFailure

5 Beeps‑3 Sec.Long Yes No

TransmissionOvertemp

3 Beeps‑1.5Sec. Long Yes No

OPERATION

24

Problem HornMonitorDisplay

GuardianActivated

EnginePower

Reduced By

Knock SensorFailure

3 Beeps‑1.5Sec. Long Yes Yes 70%

Oil PressureSensor Failure


Oil TemperatureSensor Failure


CrankshaftSensor Problem Steady Horn Yes Yes 70%

Cam Sensor 5 Beeps‑3 Sec.Long Yes Yes 70%

MAP Sensor Error 5 Beeps‑3 Sec.Long Yes No RPM limit to

5150

Fuel PressureSensor Failure


Block PressureSensor Failure


ChargeTemperature

Sensor Failure


CAN Bus Problem 3 Beeps‑1.5Sec. Long Yes Yes 70% or

Forced Idle

CoolantTemperature

Sensor


Throttle PositionSensor


Electrical System Overload ProtectionIf an electrical overload occurs, a fuse or circuit breaker opens.Locate and correct the problem before replacing the fuse orresetting circuit breaker.• A circuit breaker protects the engine wiring harness and

instrumentation power lead. Reset by pushing the resetbutton.

• Four fuses are located at the upper rear of the enginecontaining 5 and 15 amp fuses.

OPERATION

25

• Four fuses are located at the upper rear of the enginecontaining a 5 and three 20 amp fuses. A circuit breakerprotects the fuel pump wire harness.

20

4112

ab

c d

ea

f

5 20

5

5

5

15

15

a - Fuseb - Fuse block Ac - Fuse block B

d - 50 amp main power circuitbreaker

e - 25 amp fuel pump circuitbreaker

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 CAN/MainRemote

C‑RED 20 amp IAC BoostBypass

C‑RED/GRN

D‑RED/PPL

D‑RED/BLU

15 amp Constant Power E‑RED 20 amp Coil Power E‑RED/GRN

F‑RED/BLU F‑RED/YEL

5 amp Accessories G‑PPL 20 amp Fuel Injectors G‑RED/GRN

H‑PPL/WHT

H‑RED/WHT

OPERATION

26

In an emergency, if you cannot locate and correct the cause of thehigh current draw, and you must operate the engine; perform thefollowing:1. Turn "OFF" or disconnect all accessories connected to the

engine and instrumentation wiring and reset the circuitbreaker.

2. If the breaker remains open, electrical overload is still present.Inspect the electrical system.

The power trim system is protected by a 10 amp fuse in the powertrim RED (Hot) wire.

a

7416

a - 10 amp fuse

A 90 amp fuse is located on the starter.

a

7417

a - 90 amp fuse

OPERATION

27

Analog gauges (if equipped) are protected with a 5 amp fuse.

a

b c

d

f

e

7412

a - Helm harnessconnection

b - Fuse (5 amp)c - Relay

d - Grounde - Fused 12V (5 amp

maximum)f - 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. Detents givethe movement of the lever a notched, precise feel. The detentsalso help hold the lever at the desired engine RPM to reduceoperator fatigue.

! CAUTIONAvoid possible engine damage. Never shift the unit into or outof gear unless the engine is at idle RPM.

OPERATION

28

2. Control shifting by moving the shorter control lever(s). Thiscontrol shifts the unit into gear with full lever movement. Movethe lever forward to engage the forward gear. Move leverbackward to engage reverse gear. Place the lever in thecenter position to shift to neutral. Shifting should occur onlywith the engine at idle speed. Always move to the desired gearposition with a quick, firm motion. The control handle shouldbe adjusted by your dealer to engage forward, reverse, andneutral when the lever is at the appropriate detent.

a

b

c

4090

a - Throttle control leverb - Power trim switchc - Shift control lever

3. See Power Trim section for detailed power trim operatingprocedures.

Power TrimPower Trim allows the operator to adjust the drive angle whileunderway to provide the ideal boat angle for varying load and waterconditions.IMPORTANT: Each boat manufacturer has the option as to howthe power trim will function on their particular boat. The boat owner/operator must be aware of how the power trim functions beforeoperating the boat.

OPERATION

29

In most cases, best overall performance is obtained with the driveunit adjusted so the boat bottom will run at a 3° to 5° angle to thewater.

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.• Cause the boat to accelerate and plane off slower.• In excess, cause boat porpoising (bouncing) or propeller

ventilation.

7419

OPERATION

30

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.This can result in an unexpected turn in either direction, calledbow steering or over steering. if any turn is attempted or if asignificant wave is encountered.

POWER TRIM OPERATION

! CAUTIONAvoid twisting or binding dual engine tie bars. Damage to the tiebar and sterndrives could occur. Always raise or lower thesterndrive units evenly.

! CAUTIONAvoid excessive wear on the U‑joint/input shaft. The VI drivedoes not have a trim limit switch. Depressing the trim or trailerbuttons allows the drive to be tilted to its full extension withoutstopping at a preset trim limit. The drive's position should bemonitored with the trim gauge(s) so that the drive is not trimmedexcessively.

OPERATION

31

IMPORTANT: If the power trim button is held depressed after thedrive unit(s) reaches the end of upward travel, an internal circuitbreaker opens and the pump stops. Should this happen, releasethe button and allow the trim pump motor to cool for about oneminute, at which time the circuit breaker will reset and power trimoperation may be resumed.Power trim switch in handle (can control up to three drives):• Raise the drive unit: Press (top) up/out button on trim switch

until the drive unit(s) reaches the desired trim position.• Lower the drive unit: Press (bottom) down/in button on trim

switch until drive unit(s) reaches the desired position.Console mounted power trim switch (one switch per drive)NOTE: On multiple engine installations, the individual trimswitches can be used to fine tune the drives by setting each driveunit to the desired trim angle. The use the single trim switch in thehandle to control the trim of all drive units simultaneously.• Raise the drive unit: Press (top) up/out button on trim switch

until the drive unit(s) reaches the desired trim position. Thisswitch can also be used to bring the drive to a traileringpositon.

• Lower the drive unit: Press (bottom) down/in button on trimswitch until drive unit(s) reaches the desired position.

Starting, Shifting, and Stopping

! WARNINGAvoid fire or explosion. Before starting the engine, operate thebilge blower for at least five minutes to remove any explosivefumes from the engine compartment. If the boat is not equippedwith a bilge blower, open the engine hatch and leave it open whilestarting the engine.

NEW ENGINES OR ENGINES COMING OUT OF STORAGESee Power Package Recommissioning.

OPERATION

32

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.Perform any other necessary checks, as indicated by yourdealer, or specified in your boat owner's manual.Place the drive unit in full the down/in position.Place the control handle in neutral.

COLD OR WARM ENGINEEFI engines require no throttle advance to start. The boat can beoperated after the engine has started and is idling smoothly.IMPORTANT: If the engine has not been operated for more than24 hours, Mercury Marine recommends priming the engine oilsystem.NOTE: Engines that have not been started for extended periodsor have had fuel filter changes may not stay running on the firstfew initial attempts to start. Do not advance the throttle to keep theengine running. Continue to restart the engine until it idlessmoothly which means the fuel system is primed. Allow the engineto warm up to 54 °C (130 °F) before advancing the throttle.1. If the engine has not been operated for more than 24 hours,

de‑activate the lanyard stop switch so that the engine will notstart and crank the engine until the oil pressure is indicated onthe oil pressure gauge.

2. Turn key switch to "ON" and wait 10 seconds to allow the fuelpump to prime the system.

3. Start the engine. Release the key when the engine starts andallow switch to return to the "ON" position.

OPERATION

33

4. Check the oil pressure gauge immediately after the enginestarts. If oil pressure is not within the specified range, seeSpecifications, stop the engine immediately, and determinecause.

5. If the engine is cold, allow the engine to run for three minutes.6. After the engine has warmed up, check the water temperature

gauge to ensure that the engine temperature is not abnormallyhigh. If it is, stop the engine immediately and determine cause.

7. Ensure that the charging system is functioning correctly.8. Observe the power package for fuel, oil, water, and exhaust

leaks.9. To shift the drive unit into gear, move the control/shift lever

with a firm, quick motion forward to shift to forward gear, orbackward 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, throttle the engine back toidle speed, then move the control/shift lever to neutral. If theengine has been operating at high speed for a long period oftime, allow the engine to cool by running at idle speed for threeto five minutes.

11.Turn key switch to "OFF."

Operation Chart1. Before Starting

Open the engine hatch.Turn battery switch "ON," if equipped.Operate bilge blowers, if equipped.Open fuel shut off valve.Open seacock, if equipped.Perform all other checks specified by your dealer and/orboat builder.

2. After StartingObserve all gauges to check condition of engine. If notnormal, stop engine.Check for fuel, oil, water, fluid and exhaust leaks, etc.

OPERATION

34

Check shift and throttle control operation.Check steering operation.

3. While UnderwayObserve all gauges to monitor engine condition.

4. After StoppingShift to neutral. Turn ignition key "OFF."Turn battery switch "OFF," if equipped.Close fuel valve.Close seacock.Flush cooling system if in saltwater area.

Freezing Temperature OperationIMPORTANT: If operating the boat during periods of freezingtemperatures, take precautions to prevent freezing damage topower package. Damage caused by freezing is not covered by theMercury Racing Limited Warranty.

Drain Plug and Bilge PumpThe engine compartment in your boat is a natural place for waterto collect. For this reason, boats are normally equipped with a drainplug and/or a bilge pump. It is very important to check these itemson a regular basis to ensure that the water level does not rise tocome in contact with your power package. Engine components willbe damaged if submerged. Damage caused by submersion is notcovered by the Mercury Racing Limited Warranty.

Launching And Boat Operation Care

NOTICESome boating maneuvers can introduce water into the enginethrough the exhaust system, causing severe engine damage. Becareful when unloading a boat from its trailer, slowing downrapidly, backing up rapidly, and stopping suddenly.

OPERATION

35

In any of the situations described in the preceding caution, waterentering the engine could cause severe damage to internal parts.Refer to Attention Required After Submersion in the GeneralInformation section of this manual.

CONDITIONS AFFECTING OPERATION

36

Weight DistributionPositioning of weight (passengers and gear) inside the boat hasthe 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.• Increase the danger of a following wave splashing into the

boat when coming off plane.Shifting weight to front (bow) may:• Improve ease of planing.• Improve rough water ride.• Cause the boat to veer back and forth (bow steer).

Bottom Of BoatTo maintain maximum speed, ensure that the bottom of the boatis:• Clean and free of 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 water inlets and causing the engine to overheat. Thisgrowth must be removed before operation.

CavitationCavitation occurs when water flow cannot follow the contour of afast‑moving, underwater object, such as a gear housing orpropeller. Cavitation permits the propeller to speed up, but the boatspeed to reduce. Cavitation can seriously erode the surface of thegear housing or propeller. Common causes of cavitation are:• Weeds or other debris snagged on propeller or gear housing.• Bent propeller blade or damaged gear housing skeg.• Raised burrs or sharp edges on propeller or gear housing.


37

VentilationVentilation occurs when surface air or exhaust gases surround thepropeller, causing propeller speed‑up (slippage) and a decreasein boat speed. Excessive ventilation is annoying and usuallycaused by:• A drive unit trimmed out too far.• A damaged propeller or gear housing, allowing exhaust gases

to escape between propeller and gear housing.• A drive unit installed too high on the transom.

Propeller SelectionIMPORTANT: Choosing the correct propeller allows the engine torun at its specified maximum wide‑open‑throttle RPM. Use anaccurate service tachometer to verify engine operating RPM.It is the boat manufacturer and/or the selling dealer's responsibilityto equip the power package with the correct propeller(s). Specifiedengine wide‑open‑throttle (WOT) and operating RPM range arelisted in Specifications.IMPORTANT: All Mercury Racing engines have a RPM rev‑limiterthat is set to an upper (or limited) RPM. This limit is slightly abovethe normal operating range of the engine and is designed to helpprevent damage from excessive engine RPM. Once the RPMdrops into the recommended operating RPM range, normal engineoperation resumes.Select a propeller that allows the engine to operate in the upperhalf of the recommended full throttle RPM range with the boatnormally loaded (refer to Specifications).If full throttle operation is below the recommended range, changethe propeller to prevent loss of performance and possible enginedamage. On the other hand, operating an engine above therecommended operating RPM range causes higher than normalwear or damage. Generally, there is a 200 ‑ 300 RPM changebetween propeller pitches.RPM loss may require changing to a lower pitch propeller dueto the following conditions:• Operating in warmer weather and greater humidity.


38

• 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 PerformanceThe following conditions lower engine performance and cannot becompensated by the engine fuel or electronic managementsystems.• Above sea level elevations• High temperature.• Low barometric pressure.• High humidity.The conditions listed above reduce air density to the enginewhich in turn reduces the following:• Boost pressure on supercharged engines• Horsepower and torque throughout the RPM range• Peak RPM• Cranking compressionEXAMPLE: An engine running at an elevation of 2,438 m (8,000ft) will have over a 30% power loss while engine power on a hotand humid day can be reduced by as much as 14%. These lossesapply to both normally aspirated and supercharged engines.Compensating for power robbing conditions:• Switch to a lower pitch propeller.• Change the gear ratio.Some boat performance can be regained by dropping to a lowerpitch propeller, but engine performance will remain lower. In somecases, a gear ratio reduction may be more beneficial. To optimizeengine performance, prop the engine to allow it to allow operationat or near the top end of the recommended maximum RPM rangeat wide open throttle with a normal boat load.Other advantages to propeller or gear ratio changes:• Reduces the possibility of detonation.• Enhances overall reliability and durability of the engine.

MAINTENANCE

39

Service ResponsibilitiesOWNER/OPERATOR RESPONSIBILITIESIt 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.• Normal maintenance service and replacement parts.Proper maintenance and care of your power package will ensureoptimum performance and dependability, and will keep youroverall operating expenses at a minimum. See your authorizedMercury Marine dealer for service aids.DEALER RESPONSIBILITIESIn general, a dealer's responsibilities to the customer includepredelivery inspection and preparation. These include:• Completing a Warranty Registration Card and mailing it to the

factory immediately upon sale of the new product.• Properly equipping the boat.• Making certain that the Mercury Marine power package and

other equipment are in proper operating condition prior todelivery.

• Making all necessary adjustments for maximum efficiency.• Familiarizing the customer with the on‑board equipment.• Explaining and demonstrating the operation of the power

package and boat.• Providing you with a copy of a Predelivery Inspection

Checklist prior to delivery.

MAINTENANCE

40

Replacement Service Parts

! WARNINGAvoid fire or explosion hazard. Electrical, ignition, and fuelsystem components on Mercury Marine products comply withU.S. Coast Guard rules to minimize risk of fire or explosion. Donot use replacement electrical or fuel system components thatdo not comply with these rules. When servicing the electrical andfuel systems, properly install and tighten all components.

Marine engines are expected to operate at or near full throttle formost of their life. They are also expected to operate in fresh andsaltwater environments. These conditions require numerousspecial parts. Care should be exercised when replacing marineengine parts, as specifications are quite different from those of thestandard automotive engine.For example, one of the most important, and probably the leastsuspected special replacement part, is the cylinder head gasket.Since saltwater is highly corrosive, the steel‑type automotive headgasket cannot be used. A marine engine head gasket uses specialmaterials to resist corrosive action.Since marine engines must be capable of running at or nearmaximum RPM much of the time, special valve springs, valvelifters, pistons, bearings, camshafts and other heavy‑duty movingparts are required for long life and peak performance.These are but a few of the many special modifications that arerequired in Mercury Marine engines to provide long life anddependable performance.

Do‑It‑Yourself Maintenance SuggestionsIf you are one of those persons who likes to do‑it‑yourself, here aresome suggestions for you.• Present‑day marine equipment, such as your Mercury Marine

power package, are highly technical pieces of machinery.Electronic ignition and special fuel delivery systems providegreater fuel economies, but are more complex for theuntrained mechanic.

MAINTENANCE

41

• Do not attempt any repairs that are not covered in this manualunless you are aware of the precautions (Cautions andWarnings) and procedures required. Your safety is of ourconcern.

• If you attempt to service the product yourself, we suggest youorder the service manual for that model. This manual outlinesthe correct procedures to follow. It is written for the trainedmechanic, so there may be procedures you don't understand.Do not attempt repairs if you do not understand theprocedures.

• Special tools and equipment may be required to perform somerepairs. Do not attempt these repairs unless you have thesespecial tools and/or equipment. You can cause damage to theproduct in excess of the cost a dealer would charge you forthe repair.

• If you partially disassemble an engine or drive assembly andare unable to repair it, the dealer's mechanic mustre‑assemble the components and test to determine theproblem. This will cost you more than taking it to the dealerimmediately upon having a problem. It may be a very simpleadjustment to correct the problem.

• Do not telephone the dealer, service office or the factory toattempt for them to diagnose a problem or request the repairprocedure. It is difficult for them to diagnose a problem overthe telephone.

• Your authorized Mercury Marine dealer is there to service yourpower package. They have qualified factory‑trainedmechanics.

Mercury Marine recommends that you have the dealer do periodicmaintenance checks on your power package. Have them winterizeit in the fall and service it before the boating season. This willreduce the possibility of any problems occurring during yourboating season when you want trouble‑free boating pleasure.

MAINTENANCE

42

IMPORTANT: Refer to Maintenance Charts (on following pages)for complete listing of all scheduled maintenance to be performed.Some listings can be done by the owner/operator, while othersshould be performed by an authorized Mercury Marine dealer.Before attempting maintenance or repair procedures not coveredin this manual, Mercury Marine recommends purchasing aMercury Marine Service Manual.

Servicing High Horsepower EnginesAll high performance engines require frequent maintenance andinspection schedules due to the extreme duty cycles and relatedstress these products endure. Failure to follow the detailedmaintenance and service schedule as written and supplied byMercury Marine could lead to catastrophic engine failure andincreased owner expense.

Maintenance ChartsENGINE AND TRANSMISSION

Interval Task

Check prior to every use and every 3hours of operation

Engine oil (reservoir), power steeringand transmission fluid ‑ Check level

Battery ‑ Check water level and inspectfor damage

Seawater pickups ‑ Check for marinegrowth or debris

After each use Flush the cooling system if used in salty,brackish, or mineral laden water

Weekly

Seawater strainer ‑ Check for debris andclean

Anodes ‑ Inspect and replace if 50percent eroded

MAINTENANCE

43

Interval Task

Every 15 hours or 90 days ofoperation

Check exhaust header mounting bolts fortightness

Flame arrestor ‑ Inspect and clean asrequired

Engine oil and filter ‑ Change

Fuel filters ‑ Change

Check and adjust valve tip clearance(lash)

Every 50 hours of operation or once ayear, whichever occurs first.

Perform 25 hour maintenance items

Change transmission fluid

Inspect condition and tension of all drivebelts

Inspect cooling system hoses andclamps

Inspect exhaust system condition andtighten clamps

Inspect electrical system for loose ordamaged wires

Replace high pressure fuel filter element

Inspect throttle and shift components forwear and proper adjustment

Every 50 hours of operationInspect all valve train components forwear, particularly the valve lifters.Replace components as needed.

Every 75 hours of operation

Inspect all engine and superchargerrotating and reciprocating componentsfor wear. Replace components asneeded.

Every 100 hours of operation or onceyearly, whichever occurs first.

Perform 25 and 50 hour maintenanceitems

Seawater pickup pump ‑ Disassembleand Inspect

Engine alignment ‑ Check

MAINTENANCE

44

DRY SUMP SIX (VI) DRIVE, TRANSOM, TRIM & STEERINGSYSTEMS MAINTENANCE SCHEDULE

Interval Task

Check prior to use and every 3 hoursof operation.

Drive, Transom, and Propeller ‑ Inspect

Lower Gear Housing Oil ‑ Check level

Power Trim Pump Oil ‑ Check level andinspect for any water contamination.Replace fluid if necessary.

Weekly Anodes ‑ Inspect for erosion

Initial break‑in at 25 hours. Lower Gear Housing Oil Filter and Oil ‑Change the oil and filter.

Every 25 hours of operation or every90 days, whichever occurs first.

Tie‑bar Mounting Bracket Nuts ‑ Inspectand tighten to specifications as needed.

Propeller Shaft ‑ Lubricate

Propeller Nut ‑ Torque to specification.

Sterndrive ‑ Inspect, clean, and spraywith rust preventative.

Every 50 hours of operation or oncea season, whichever occurs first.

Perform 25 Hour Maintenance Items.

Sterndrive Unit Input Splines (Internaland External) ‑ Lubricate with OptimolPaste White T Grease.

Drive input shaft U‑joint crosses‑Inspectand lubricate

Drive Mounting Nuts ‑ Tighten to136 Nm (100 lb. ft.)

Saltwater Use: Every 50 hours or 60days of operation, whichever occursfirst.Freshwater Use: Every 100 hours or120 days of operation, whicheveroccurs first.

Steering System ‑ Inspect for loose,damaged or missing parts. Lubricate thesteering cylinder pivot points.

MAINTENANCE

45

Interval Task

Every 100 hours of operation or oncea season, whichever occurs first.

Perform 25 and 50 Hour MaintenanceItems.

Drive Unit Bellows and Clamps ‑ Inspect

Lower Gear Housing Oil ‑ Change the oil.

Driveline Models ‑ Lubricate and inspectthe engine to transom driveshaft U‑jointcrosses and slip joint.

Steering head and remote control ‑Inspect and lubricate

Every 200 hours of operation or atre‑build.

Lower Gear Housing Oil Filter and Oil ‑Change the oil and filter.

Every 200 hours of operation or oncea year, whichever occurs first.

Perform 25, 50, and 100 HourMaintenance Items.

Transom Input Shaft Bearing Housing(Driveline Models Only) ‑ Change the oil.

Checking Fluid LevelsCHECKING ENGINE OIL (RESERVOIR)Oil consumption is greatly dependant upon engine speed, withconsumption being highest at wide‑open‑throttle and decreasingsubstantially as engine speed is reduced. It is not uncommon forbig block high performance engines to use up to one quart of oil inone to five hours if the engine is operated continuously at the upperend of the RPM range.

MAINTENANCE

46

1. With the engine at idle, observe the oil reservoir sight tube.

a

7423

a - Oil reservoir sight tube

2. Oil level in the reservoir sight tube should be approximatelyeven 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 (severaldays or longer), a certain amount of oil may drain from the reservoirback into the engine oil pan. When the engine is started this oil willbe pumped back into the reservoir.CHECKING DRIVE UNIT OIL

! CAUTIONAvoid damage to the sterndrive. The input shaft housing must befilled with lubricant on driveline models.

IMPORTANT: If more than 59 ml (2 fl oz) of gear lube is required,a seal may be leaking. Damage to drive unit may occur due to lackof lubrication. Contact your authorized Mercury Marine dealer forservice.Fill dry sump drive and transom input shaft housing withTORCO MTF Gear Oil.NOTE: Oil level will fluctuate during operation. Check the oil levelwith a cold engine before starting.

MAINTENANCE

47

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 shafthousing "b" through the top fill pipe plug hole "a" until oil flowsfrom the reservoir level plug hole "c."

a

b

c

7428

150

a - Fill pipe plug holeb - Input shaft housingc - Reservoir level pipe plug

Tube Ref No. Description Where Used Part No.

150 Torco MTF Gear OilDriveline Models

Transom AssemblyInput Shaft

92-849684-1

2. Re‑install the reservoir level pipe plug and the top fill plug.

MAINTENANCE

48

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 plugand sealing washer "b" from the gearcase and fill until oilcomes out of the top vent plug "a" opening.

7429

a

b 150

a - Drive unit vent plugb - Fill/Drain plug and sealing washer


150 Torco MTF Gear Oil VI Drive Dry SumpGearcase 92-849684-1

2. Install the drive vent plug.3. Remove the filler tube and quickly install the fill/drain plug and

sealing washer.4. Re‑check the oil level at the vent plug.

MAINTENANCE

49

CHECKING POWER TRIM PUMP FLUID1. Place the drive unit in the full down/in position.

ab

c

114

7432

a - Fill/Vent screwb - "FULL" markc - "ADD" mark


114 Power Trim andSteering Fluid Trim pump 92-858074K0

1

MAINTENANCE

50

2. Remove the fill/vent screw. Wipe clean and re‑insert back intothe pump, but do not thread it into place.

3. Remove it again and note the oil level, which must be betweenthe "ADD" and "FULL" marks on the dipstick. If necessary, addPower Trim and Steering Fluid or SAE 10W‑30 motor oilthrough the fill/vent hole to bring the oil level up to the "FULL"mark on the dipstick. Do not overfill.

4. Raise and lower the drive unit 6 to 10 times to purge air fromthe system.

5. Re‑check the oil level.IMPORTANT: Loosen the fill/vent screw 1‑1/2 turns after seatingto vent the pump reservoir. Failure to loosen the screw could resultin 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 LEVELIMPORTANT: The first time the transmission fluid is checked, theboat should be on a trailer or in a sling with the engine level. Addfluid until the dipstick reads "FULL," then put the boat in the waterand recheck the fluid level. Mark the dipstick at the new fluid leveland use this mark when checking the fluid with the boat in thewater.1. Operate the engine for at least two minutes at idle, shifting the

transmission from forward to reverse several times.NOTE: If the engine has not been run for more than two weeks,fluid can drain out of the transmission pistons and change the fluidlevel by as much as one quart.

MAINTENANCE

51

2. Shut the engine off and check the dipstick level. The fluid levelshould be up to the "FULL" mark on the dipstick or the markestablished when the boat was first run.

a

bFU

LL

c

6790

a - Dipstickb - "FULL" markc - Dipstick tube


Type F or FATransmission Fluid Transmission Obtain

Locally

3. Add Automatic Transmission Fluid Type F or FA through thedipstick tube as necessary.

4. Re‑install the dipstick and push down to tighten.

MAINTENANCE

52

5. Do not use the transmission expansion bottle as a fluidreservoir.

7434

a

a - Transmission expansion bottle

IMPORTANT: Only use the bottle for fluid expansion andoverflow.

Changing FluidsCHANGING CRANKCASE OIL (RESERVOIR) AND FILTERS1. Place a sufficiently sized container, 19 liters (20 U.S. qt.)

below the oil reservoir.2. Remove the plug from the reservoir bottom and let the oil

drain.

a7436

a - Oil drain plug

MAINTENANCE

53

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 thereservoir 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 clampb - Stop screw

a. Loosen the filter retaining clamp "a" and slide it off the filter.b. Place a container under the filter to catch oil.c. Remove the spin‑on oil filter by turning it

counter‑clockwise.

MAINTENANCE

54

d. Coat the new filter sealing ring with new oil and install ithand tight. Do not over tighten.

e. Install the filter retaining clamp "a" so that the clasp of theretaining clamp is against the stop screw "b" to secure thefilter during operation. Tighten the clamp.

6. Remove the cover of the Oberg screen‑style filter and markthe element so it can be returned to its original orientation withthe correct side up. Clean the element with solvent.

IMPORTANT: The screen‑style filter element must always bereturned to its original orientation (correct side up) to prevent theoil from flowing through it in the wrong direction.

a

7441

a - Oberg screen‑style filter

7. Re‑assemble the filter assembly, making sure that the screenis installed with the up side in the proper orientation.

NOTE: Engine to reservoir oil line lengths affect total oil capacityand will vary with each installation

MAINTENANCE

55

8. Install the bottom oil reservoir plug and tighten securely.

a7436

a - Oil drain plug

9. Begin by filling the oil reservoir with 11.4 liters (12 U.S. qt.) ofoil.

MAINTENANCE

56

10.Using an electric drill motor, manually turn the oil pump pulley(clockwise) to prime the engine oiling system until reaching anoil pressure of 276 kPa (40 psi).

a

c

b

7443

a - Oil pump pulleyb - Clockwise direction of electric drill motorc - Electric drill motor

11.Add any additional oil to the reservoir to bring the oil level toapproximately 25.4 mm (1 in.) below the bottom of thereservoir split ring.

12. Install the oil pump belt and tighten the pump mountingfasteners. Tension the oil pump belt to Specifications.

Description N lb.

Oil pump belt When the belt can be twisted with twofingers approximately 1/4 turn.

NOTE: Engine oil level in the reservoir will increase as the engineoil temperature increases.

MAINTENANCE

57

13.Start the engine and observe the engine oil level in thereservoir. The oil level should be even with the bottom of thereservoir split ring. Shut off the engine if it is necessary to addoil.

a

7423

a - Oil reservoir sight tube

14.Operate the engine at idle and monitor the oil pressure and oillevel at the reservoir sight tube.

CHANGING FUEL FILTERIMPORTANT: Fuel filter servicing requires special precedures toensure that the system operates properly and should be performedonly by an authorized Mercury MerCruiser dealer.CHANGING TRANSMISSION OIL1. Place a suitable container (approximately 3.8 liter [4 qts.])

under the transmission lower fitting.2. Remove both the upper and lower transmission‑to‑oil‑cooler

lines and drain.3. Remove the check valve assembly from the lower fitting and

drain the transmission fluid.4. Re‑install the check valve assembly and the upper and lower

oil lines.5. Fill the transmission through the dipstick tube with the

appropriate amount (see Specifications in this manual) ofType F or FA transmission fluid.

MAINTENANCE

58

6. Start the engine and let it run for at least two minutes at idle,shifting the transmission from forward to reverse severaltimes.

7. Stop the engine and check the transmission oil level with thedipstick. If addition oil is required, add it through the dipsticktube to bring the level up to the "FULL" mark.

a

b

FULL

c

6790

a - Dipstickb - "FULL" markc - Dipstick tube


Type F or FATransmission Fluid Transmission Obtain

Locally

CHANGING DRIVE UNIT OIL (DRY SUMP)IMPORTANT: Fill the dry sump drive and transom input shafthousing with TORCO MTF Gear Lube.

MAINTENANCE

59

Driveline Models Only1. Place a container below the input shaft housing and remove

the bottom pipe plug.

b

a

7445

a - Input shaft housingb - Oil drain pipe plug

! WARNINGAvoid damage to the input shaft housing. Do Not Overfill theinput shaft housing reservoir or damage to transomcomponents could occur.

MAINTENANCE

60

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 pipeplugs "a" & "b" into the input shaft housing and tightensecurely.

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 OilTransom input shaft

reservoir and drysump drive

92‑849684‑1

All Models1. Place the drive unit in a position so that the propshaft is level.

MAINTENANCE

61

2. Remove the upper oil level plug and sealing washer from thegearcase.

7429

a

b 150

a - Oil level plugb - Fill/Drain plug and sealing washer

Tube Ref.No. Description Where Used Part No.

Torco MTF Gear OilTransom input shaft

reservoir and drysump drive

92‑849684‑1

IMPORTANT: If water drains from the gearcase, or if gear lubeappears milky; the drive unit is leaking. Have the unit checkedimmediately by your authorized Mercury Marine dealer.3. Remove the lower fill/drain plug and sealing washer from the

gearcase and allow the oil to drain into a suitable container.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.

LubricationLubricate the following grease fittings with Optimal PD‑2:

MAINTENANCE

62

• 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

79 79

145145


145Optimal Longtime PD2Extreme PressureGrease

Engine drive shaft andtransmission shift lever 92-848767


79 MerCruiser 4-cycle25W40 Engine Oil

Shift cable and throttlelinkage 92-802837A1

MAINTENANCE

63

Propellers

! WARNINGAvoid serious injury or death. Place the remote control in neutraland remove the ignition key from the switch before removing and/or installing the propeller. Place a block of wood between theanti‑ventilation plate and the propeller to protect hands frompropeller blades and to prevent the propeller from rotating whenremoving the propeller nut.

! CAUTIONAvoid propeller/sterndrive damage or injury. Periodically checkpropeller nut for tightness during boating season. A minimum of136 Nm (100 lb‑ft) torque is required.

REMOVAL1. Place a wood block between the propeller blade and the

anti‑ventilation plate to prevent rotation. Straighten bent tabson tab washer.

a

b

7448

a - Wood blockb - Propeller nut

2. Turn the propeller shaft nut counter‑clockwise to remove thenut.

MAINTENANCE

64

3. Slide washer, continuity washer, and propeller off propellershaft.

NOTE: Some damaged propellers can be repaired. See yourdealer.INSTALLATION1. Apply a liberal coat of Optimal Longtime PD2 Extreme

Pressure Grease to propeller shaft.2. Align splines and install propeller, washer and propeller nut.

a

b c

d

5915

94

a - Propshaftb - Cleaver propeller

c - Flat washerd - Propeller nut


145Optimal LongtimePD2 ExtremePressure Grease

Propeller shaftsplines 92-848767

3. Place wood block between the propeller blade andanti‑ventilation plate to prevent rotation and tighten thepropeller nut. After first use, re‑tighten propeller nut. Checkpropeller at least every 20 hours of operation. Do not operatewith a loose propeller.

Description Nm lb. in. lb. ft.

Propeller nut 136 100

MAINTENANCE

65

Seawater Pump Impeller InspectionSeawater Pump Impeller service should be performed by anauthorized Mercury Marine dealer.The seawater pump impellers (three in one pump assembly)should be inspected whenever insufficient seawater flow issuspected. The two rear impellers supply the engine with waterand the front impeller supplies the charge air cooler (CAC). Theimpellers supplying the engine should be inspected if the engineoperating temperature exceeds the normal range. The charge aircooler impeller should be inspected if the discharge stream for thecharge air cooler is less than normal. Consult your boat ownersmanual for the location of the charge air cooler discharge location.

7451

Flushing Cooling System

! WARNINGAvoid possible death or serious injury. Always remove thepropeller before flushing the cooling system.

! CAUTIONAvoid engine damage from overheating. If the engine is operatedabove 1500 RPM during flushing, suction created by theseawater pickup pump may collapse the flushing water hosecausing the engine to overheat.

MAINTENANCE

66

To prevent silt and salt buildup in the cooling system, flush withfreshwater.1. Install a flushing hose from a water tap to the flushing

connector. Consult your boat owners manual for the locationof the flushing connector.

2. Completely open the water tap. Place the remote control inneutral position and start the engine. Operate the engine atidle speed, in neutral, for about 10 minutes or until dischargewater is clear. Stop the engine, shut off the water, and removethe flushing hose.

Cleaning Seawater (Raw Water) Section of OilCoolerENGINE COOLERSIMPORTANT: Cleaning of the engine oil coolers should beperformed by an authorized Mercury Marine dealer.

3712

a

dd a

bb

c

Transmission/Power Steering Cooler ‑ (Starboard Side)a - Water hose clampsb - End plate/gaskets

c - Coolerd - Retaining clamps

1. Loosen the inlet and outlet water hose clamps "a" and removethe hoses from the cooler "c."

2. Remove the two clamps "d" that retain the cooler and lift thecooler away from the engine to gain access to the end platefasteners.

MAINTENANCE

67

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. Re‑install the cooler on its bracket and tighten clamps

securely.8. Re‑install the inlet and outlet water hoses onto the cooler and

tighten clamps securely.9. Start the engine and check all hoses for leaks.

Cleaning the Flame ArrestorsExternal contamination on the outside of the filter such asfiberglass particals or insects can be removed with a lint free clothor a vacuum cleaner. If the filter appears to be clogged from heavycontamination, contact your Mercury Marine MerCruiser dealer forcleaning of the filters.

Drive Belts

! WARNINGAvoid possible serious injury. Make sure that the engine is turnedoff and the ignition key is removed before inspecting belts.

Periodically inspect all of the following drive belts for condition andtension.See your authorized Mercury Marine dealer for replacement ortension adjustments.

MAINTENANCE

68

1. Seawater Pump/Alternator Drive Belt

ab

c

d

ef

rmc22

a - Sea pump pulleyb - Seawater pump/

alternator drive beltc - Crankshaft pulley

d - Idler pulleye - Alternator pulley (adjust

belt tension here)f - Tensioner gauge

Description N lb.

Seawater pump/alternator belt 360‑440 80‑100

MAINTENANCE

69

2. Power Steering Pump Drive Belt

b c

a

25978

a - Tensioner gaugeb - Jam nutc - 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

ab

c

a - Crankshaft pulleyb - Oil pump drive beltc - Oil pump (adjust belt tension here)

MAINTENANCE

70

4. Supercharger Belt ‑ Self‑tensioning

a a

b

c

e

rmc23

d

a - Supercharger pulleyb - Supercharger drive

beltc - Crankshaft pulley

d - Idler pulleyse - Belt tensioner

Corrosion and Corrosion ProtectionAdd info about replacing anodes in the flywheel coolersWhenever two or more dissimilar metals (like those found on thesterndrive) are submerged in a conductive solution, such assaltwater, polluted water, or water with a high mineral content, achemical reaction takes place causing electrical current to flowbetween metals. The electrical current flow causes the metal thatis most chemically active, or anodic, to erode. This is known asgalvanic corrosion and, if not controlled, it will in time cause theneed for replacement of power package components exposed towater.Refer to the Quicksilver booklet, Everything You Need to KnowAbout Marine Corrosion for more corrosion information.

MAINTENANCE

71

! CAUTIONAvoid corrosion damage. Do not use magnesium anodes in saltwater. They will provide overprotection, resulting in a differentelectrochemical reaction that will create hydrogen on the metalsurface of the drive, under the paint. This causes the paint toblister and peel completely from the surface of the overprotecteddrive.

MAINTENANCE

72

IMPORTANT: Mercury Marine recommends installing anAnti‑Corrosion Kit. If the boat is equipped with stainless steel afterplanes, a large anode should be installed on each to handle theincreased galvanic corrosion potential.Replace sacrificial anodes if eroded 50% or more.Mercury Marine recommends using anodes sold through MercuryPrecision Parts only. Some other manufacturers of aluminumanodes use alloys that are insufficiently pure to adequately protectcritical drive components for the duration of the anodes' expectedlife.

a b7454

a - VI SSM - An anode ismounted to theunderside of theanti‑ventilation plate andis retained by two nuts.

b - VI SSM - There areadditional anodes on thetrim cylinder pins.

MAINTENANCE

73

a

b

c cd18998

a - Anodesb - Fittings

c - Oil cooler drain fittingsd - Flywheel housing drain

fitting

In addition to the corrosion protection devices, follow these stepsto inhibit corrosion:1. Painting Boat Hull or Boat Transom

MAINTENANCE

74

a. If anti‑fouling protection is required for boat hull or boattransom, copper or tin base paints can be used unlessotherwise prohibited by law.

b. If using copper or tin based anti‑fouling paints, avoid anyelectrical interconnection between the Mercury MarineProduct, anodic blocks, and the paint by allowing aminimum of 40 mm (1.5 in.) unpainted area on the transomof the boat around these items.

a b6118

a - Anti‑fouling paintb - Unpainted area

IMPORTANT: Corrosion damage that results from the improperapplication of anti‑fouling paint will not be covered by the limitedwarranty.

MAINTENANCE

75

NOTE: Do not paint anodes or the MerCathode System referenceelectrode and anode, as this will render them ineffective asgalvanic corrosion inhibitors.2. Painting Drive Unit or Transom Assembly

• Paint the drive unit and transom assembly with a goodquality marine paint or an anti‑fouling paint that does notcontain copper, tin, or any other material that could conductelectrical current. Do not paint drain holes, anodes, or itemsspecified by the boat manufacturer.

3. Additional Corrosion Prevention Tips• Spray the power package components on the inside of the

boat every two to three weeks with Corrosion Guard toprotect the finish from dulling and corrosion. Externalpower package components may also be sprayed.


120 Corrosion Guard Power package 92-802878-55

• All lubrication points, especially the steering system andshift and throttle linkages, should be kept well lubricated.

• Flush the cooling system after each use.

BatteryAll lead acid batteries discharge when not in use. Recharge every30 to 45 days, or when specific gravity drops below batterymanufacturer's specifications.Refer to specific instructions and warnings accompanying yourbattery. If this information is not available, observe the following:

MAINTENANCE

76

! WARNINGObserve the following when jump starting, charging or handlinga 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.• Do not recharge a weak battery in the boat.• Remove battery and recharge in a ventilated area away from

fuel vapors, sparks or flames.• Hydrogen gases that escape from the battery during charging

are explosive.• Batteries contain acid that can cause severe burns ‑ Avoid

contact with skin, eyes 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 hoursafter it has been charged.

• Sparks or flames can ignite the gas and cause an explosionwhich may shatter the battery and could cause blindness orother serious injury.

Bottom of BoatTo maintain maximum speed, ensure that the boat bottom is:• Clean, free of barnacles and marine growth.• Free of distortion, nearly flat where it contacts water.• Straight and smooth, fore and aft.ANTI-FOULING PAINTSSee anti‑fouling paint recommendations and related informationon previous pages.IMPORTANT: Refer to Corrosion and Corrosion Protection foradditional information.

MAINTENANCE

77

Inspection and MaintenanceInspect the power package often and at regular intervals to helpmaintain its top operating performance, and correct potentialproblems before they occur. The entire power package should bechecked carefully, including all accessible engine parts.1. Check for loose, damaged or missing parts, hoses and

clamps; tighten or replace as required.2. Check plug leads and electrical leads for damage.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 paints ‑ see yourauthorized Mercury Marine dealer.

Attention Required After Submersion• Before recovery, contact an authorized Mercury Marine

dealer.• After recovery, immediate service by an authorized Mercury

Marine dealer is required to prevent serious damage to powerpackage.

Maintenance LogRecord all maintenance performed on your outboard here. Be sureto save all work orders and receipts.

Date Maintenance Performed Engine Hours

MAINTENANCE

78

Date Maintenance Performed Engine Hours

COLD WEATHER OR EXTENDED STORAGE

79

Power Package Lay‑upIMPORTANT: This service should be performed by an authorizedMercury Marine dealer.

! CAUTIONAvoid engine or sterndrive damage; Do not operate the enginewithout water flowing through the seawater pickup pump. Thepump impeller can be damaged and damage to the engine orsterndrive unit may result.

IMPORTANT: Before starting the engine, attach a water source tothe seawater pickup pump. Follow all warnings and flushingattachment procedures stated in the Flushing Cooling Systemsection of this manual.Refer to Flushing Cooling System to prepare the engine forflushing. Cooling system flushing and the fuel system storageprocedures are performed together.

! WARNINGAvoid Fire or Explosion. Ensure that the engine compartment iswell ventilated and no gasoline vapors are present during thefollowing operation.

Prepare the fuel system for extended storage by:1. Mixing the following in a 23 liter (6 U.S. gal) remote outboard

fuel tank:• 19 liter (5 U.S. gal) premium unleaded 92 octane (R+M)/2

(98 RON) gasoline.• 1.89 liter (64 fl oz) Premium Plus 2‑cycle TC‑W3 outboard

oil.• 150 ml (5 fl oz) Fuel System Treatment and Stabilizer or

30 ml (1 fl oz) Fuel System Treatment and StabilizerConcentrate.

2. Close the fuel shutoff valve located between the fuel tank andthe water separating fuel filter.

3. Disconnect and plug the boat's fuel line from the waterseparating fuel filter inlet.


80

4. Connect the remote outboard fuel tank to the inlet of the waterseparating fuel filter.

5. Have the engine ready for flushing as explained in theFlushing Cooling System section of this manual (coolingsystem flushing and the fuel system storage procedures areperformed together). Start and run the engine at 1000 RPMfor a minimum of five minutes or longer (if required) tocomplete the fuel system preperation and the cooling systemflushing.

6. After the specified running time is complete, slowly return thethrottle to idle RPM and shut off the engine.

IMPORTANT: Maintain an adequate supply of the fuel/foggingmixture in the remote 23 liter (6 U.S. gal) tank to complete the fuelsystem treatment and flushing procedure. Do not let the remotetank or fuel system run dry.7. If fuel in the main tank(s) contains alcohol, (if fuel without

alcohol is not available) drain the fuel tank(s) completely andadd Gasoline Stabilizer and Conditioner to any fuel remainingin the tank(s) before storage.

8. Close the fuel shut off valve, if equipped.9. Change the engine oil and oil filter.

NOTICEThe universal joint bellows may develop a set when stored in araised or up position, causing the bellows to fail when returnedto service and allowing water to enter the boat. Store thesterndrive in the full down position.

10.Place the drive unit in the full down position.


81

Draining Instructions

NOTICEAvoid cooling system and engine damage. Water trapped in theseawater section of the cooling system can cause corrosiondamage, freeze damage, or both. Ensure the seawater sectionof the cooling system is drained immediately after operation, orbefore any length of storage in cold weather, if the possibility offreezing temperatures exists. If the boat is in the water, keep theseacock closed until restarting the engine to prevent water fromflowing back into the cooling system. If the boat is not fitted witha seacock, leave the water inlet hose disconnected and plugged.

NOTE: As a precautionary measure, attach a tag to the key switchor steering wheel of the boat reminding the operator to open theseacock or unplug and reconnect the water inlet hose beforestarting the engine.IMPORTANT: The boat must be as level as possible to ensurecomplete draining of cooling system.


82

1. Drain the cooling system at the following locations:

3713

a

b

e

cd

a - Cylinder block (portand starboard). Use astiff wire to clean outdrain holes until entiresystem is drained.

b - Transmission/powersteering cooler

c - Recirculating pump

d - Seawater pumpe - Center/bottom of bell

housing (drains theengine oil coolers).


83

hose

NOTE: It may be necessary to lift or bend hoses to allow water todrain 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 drain plugs (port and starboard)

3. Charge Air Cooler Draining:


84

a. Disconnect the charge air cooler's exhaust hose "a" andinlet hose "c." The exhaust hose location varies, dependingon engine location.

a

c

3720

b

a - Charge air cooler (CAC) exhaust hoseb - Plugc - Charge air cooler inlet hose

b. Back flush the charge air cooler through the inlet port "c"with 138 kPa (20 psi) of air pressure (maximum) to removethe water from the charge air cooler.

4. Reconnect all hoses and drain plugs.

Battery Winter StorageFollow the battery manufacturer's instructions for storage.

Power Package RecommissioningThe power package may be started in two ways, with or withoutpriming the fuel system. If the water separating fuel filter wasdrained of fuel or replaced, Mercury Marine recommends primingthe fuel system prior to starting.Read and follow the complete recommissioning procedure beforestarting the engine.


85

BEFORE STARTING

! WARNINGTo prevent possible injury or damage to equipment, do not installthe battery until all engine maintenance has been performed.

! CAUTIONAvoid severe engine damage. Prime the engine oiling systembefore starting the engine.

1. Manually prime the engine oiling system until oil pressure isseen at the oil gauge. Refer to the oil changing procedure inthis manual.

2. Ensure all cooling hoses are connected and clamps are tight.

! CAUTIONReversing the battery cables or connection order will damagethe electrical system. When installing the battery, be sure toconnect the positive (+) battery cable to the positive (+) batteryterminal first, and the negative (–) battery cable to the negative(–) battery terminal second.

3. Install a fully charged battery. Clean battery cable clamps andterminals and reconnect cables. Tighten each cable clampsecurely when connecting.

4. Perform all checks detailed in Operation Chart, BeforeStarting.

IMPORTANT: Refer to Cooling System Flush before starting theengine.5. Supply water to the engine cooling system.STARTING WITHOUT PRIMING THE FUEL SYSTEMIMPORTANT: Do not advance the throttle until the engine idlesand runs smoothly and the water temperature reaches a minimumof 54 °C (130 °F).1. Perform all Before Starting steps.2. Connect the main permanent fuel line to the engine if it was

disconnected during storage.


86

3. Open the fuel shut off valve located between the tank and thewater separating fuel filter.

4. Turn the key switch to "RUN" and wait three seconds to allowthe fuel pump to prime the system.

5. Start the engine.6. If the engine does not stay running, repeat the starting

procedure until the engine starts and runs smoothly.7. Check the oil pressure gauge immediately after the engine

starts. If the oil pressure is not within the specified range, seeSpecifications, stop the engine immediately, and determinecause.

8. Do not advance the throttle until the engine idles and runssmoothly and the water temperature reaches a minimum of 54°C (130 °F).

9. Observe instrumentation to ensure that all systems arefunctioning properly.

10.After the engine has warmed up, check the water temperaturegauge to ensure that the engine temperature is not abnormallyhigh. If it is, stop the engine immediately and determine cause.

11. Inspect the engine for fuel, oil, fluid, water and exhaust leaks.12.Check the steering system and shift and throttle control for

proper operation.PRIMING THE FUEL SYSTEM PRIOR TO STARTING

! WARNINGAvoid fire or explosion. Gasoline is extremely flammable andhighly explosive. Ensure key switch is "OFF." Do not smoke orallow a spark or open flame in area when removing or installingfuel components. Wipe up any spilled fuel immediately.

1. Perform all Before Starting steps.2. Close the fuel shut off valve located between the fuel tank and

the water separating fuel filter.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.


87

NOTE: Do not turn the key switch to the "START" position duringthe 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 thewater separating fuel filter but not to the point of having thesystem completely full and the primer bulb hard and underpressure.

! WARNINGAvoid fuel spillage and fire hazard. When removing the remotefuel tank line from the engine connection, ensure that the primerbulb is soft. If the primer bulb is hard, pressurized fuel will besprayed in the engine compartment.

7. With the primer bulb soft, remove the remote fuel line andfitting from the water separating fuel filter.

8. Re‑install the fuel line to the water separating fuel filter.IMPORTANT: The throttle must not be advanced until the engineidles and runs smoothly and the water temperature has reacheda minimum of 54 °C (130 °F).9. Attempt to start the engine by turning the key switch to the

"START" position for a maximum of 15 seconds or until theengine starts and runs smoothly. Do not advance the throttleuntil the water temperature has reached a minimum of 54 °C(130 °F).

10.Check the oil pressure gauge immediately after the enginestarts. If the oil pressure is not within the specified range, seeSpecifications, stop the engine immediately, and determinecause.

11.Observe instrumentation to ensure that all systems arefunctioning.

12.After the engine has warmed up, check the water temperaturegauge to ensure that the engine temperature is not abnormallyhigh. If it is, stop the engine immediately and determine cause.

13. Inspect engine for fuel, oil, fluid, water and exhaust leaks.


88

14.Check steering system and shift/throttle control for properoperation.

TROUBLESHOOTING

89

Engine Will Not CrankPossible Causes Remedy

Battery switch turned "OFF." Turn switch "ON."

Gearshift not in neutral position. Position control lever to neutral.

Open circuit breaker or fuse. Check and reset circuit breaker orreplace fuse.

Loose or dirty electrical connections ordamaged wiring.

Check all electrical connections andwires (especially battery cables). Cleanand tighten faulty connection.

Defective battery. Test and replace if defective.

Defective starter. Test and replace if defective.

Flywheel ring gear is damaged. Confirm diagnosis and replaceflywheel.

Engine is seized.Check to see if engine can be rotatedby hand with the spark plugs removed.If not, then determine cause.

Faulty ignition switch.Test ignition wiring and see if the startermotor can be activated with a remotestarter switch.

Faulty PCM ground circuit or faultyPCM Repair or replace as necessary.

TROUBLESHOOTING

90

Engine Cranks But Will Not StartPossible Cause Remedy

Improper starting procedure Read starting procedure

Low battery voltage Charge the battery

Empty fuel tank or fuel shut off valveclosed Fill tank or open valve

Faulty fuel pump, wiring, fuel pumpfuse, 50 amp circuit breaker or a fuelpump relay

Replace faulty component

Faulty 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 withfresh fuel

Fuel line or tank vent line kinked orrestricted

Replace kinked lines or blow out lineswith compressed air to removeobstruction

Crankshaft position sensor faulty Test and replace if faulty

Faulty fuel pressure regulatordiaphragm

Test and replace if faulty. Do notattempt to start the engine if the fuelpressure regulator diaphragm isruptured.

TROUBLESHOOTING

91

Engine Runs Rough, Hard to Start, Misses, and/orBackfires

Possible Cause Remedy

Faulty ignition system component. Service ignition system.

Clogged fuel filter. Replace filters.

Stale or contaminated fuel. If contaminated, drain tank. Fill withfresh fuel.

Kinked or clogged fuel line or fuel tankvent line.

Replace kinked lines or blow outlines with compressed air to removeobstruction.

Flame arrestor plugged. Clean or replace the flame arrestor.

Rev limiter engaging atwide‑open‑throttle. Change to propeller with more pitch.

Manifold Air Pressure (MAP) sensorfailure.

Test MAP sensor and replace iffaulty.

Poor PerformancePossible Cause Remedy

Throttle not fully open. Inspect throttle cable and linkages forproper operation.

Damaged or wrong propeller. Replace propeller.

Excessive bilge water. Drain and check for cause of entry.

Boat overloaded or load improperlydistributed.

Reduce load or redistribute load moreevenly.

Boat bottom fouled or damaged. Clean or repair as necessary.

Flame arrestor dirty. Change or clean flame arrestor.

Supercharger not creating boost. Check supercharger belt, determinecause for low boost.

Manifold Air Pressure (MAP) sensorfailure. Test MAP sensor and replace if faulty.

TROUBLESHOOTING

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Insufficient Engine TemperaturePossible Cause Remedy

Faulty water thermostat. Replace water thermostat.

Faulty gauge or sender. Test with shop gauge; test sender.

Faulty oil thermostat. Replace.

Excessive Engine TemperaturePossible Cause Remedy

Seacock closed. Open.

Charge Air Cooler plugged with foreignmaterial. Clean Charge Air Cooler.

Seawater pump drive belt loose or inpoor condition. Replace or adjust belt.

Seawater pickups obstructed. Inspect.

Faulty thermostat. Replace.

Oil cooler cores plugged with foreignmaterial. Clean cooler cores.

Faulty seawater pickup pump. Repair.

Seawater discharge restricted orplugged. Clean exhaust elbows.

Faulty gauges or senders. Test with shop gauges; test senders.

Aerated water supply to water pick‑up. Place water pick‑up in a non‑aeratedwater supply.

TROUBLESHOOTING

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Low Engine Oil PressurePossible Cause Remedy

Insufficient oil in system. Check and add oil.

Excessive oil in system (causing it tobecome aerated).

Check and bring oil to required level.Check for cause of excessive oil(improper filling, defective fuel pump,etc.).

Diluted or improper viscosity oil.

Change oil and oil filter, using correctgrade and viscosity oil. Determinecause for dilution (excessive idling,faulty fuel pump, etc.).

Faulty gauge or sender. Test with mechanical shop gauge; testsender.

Excessive oil temperature. Faulty oil thermostat.

Engine mechanical: oil pump, excessivebearing clearance, etc. Repair as necessary.

Battery Will Not Come Up On ChargePossible Cause Remedy

Excessive current draw from battery. Turn off non‑essential accessories.


Check all associated electricalconnections and wires (especiallybattery cables). Clean and tighten faultyconnections. Repair or replacedamaged wiring.

Alternator drive belt loose or in poorcondition. Replace and/or adjust.

Defective battery. Test battery.

Power Trim Does Not Operate (Motor Doesn't Run)Possible Cause Remedy

Open fuse. Replace fuse.


Check all associated electricalconnections and wires (especiallybattery cables). Clean and tighten faultyconnections. Repair or replacedamaged wiring.

TROUBLESHOOTING

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Power Trim Does Not Operate (Motor Runs ButDrive Unit Does Not Move)


Trim pump oil level low. Fill pump with oil.

Drive binding in gimbal ring. Check for obstruction.

Remote Control Operates Hard, Binds, HasExcessive Free‑Play or Makes Unusual Sounds


Insufficient lubrication on shift andthrottle linkage fasteners. Lubricate.

Loose or missing shift and throttlelinkage fasteners.

Check all linkages. If any are loose ormissing, see authorized Mercury Marinedealer immediately.

Shift or throttle cable kinked. Replace cable.

Friction adjustment excessive. Adjust friction.

Steering Wheel Turns Hard or JerkyPossible Cause Remedy

Low power steering pump fluid level. Refill system with fluid and check forleaks.

Drive belt loose or damaged. Replace and/or adjust.

Insufficient lubrication on steeringsystem components. Lubricate.

Loose or missing steering fasteners orparts.

Check all parts and fasteners. If anyare loose or missing, see authorizedMercury Marine dealer immediately.

Contaminated power steering fluid. Drain and replace.

OWNER SERVICE ASSISTANCE

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Local Repair ServiceAlways return your outboard to your local authorized dealer shouldthe need for service arise. Only he has the factory trainedmechanics, knowledge, special tools, equipment, and genuineparts and accessories to properly service your engine should theneed occur. He knows your engine best.

Service Away From HomeIf you are away from your local dealer and the need arises forservice, contact the nearest authorized dealer. Refer to the YellowPages of the telephone directory. If, for any reason, you cannotobtain service, contact the nearest Mercury Marine Service Office.

Parts And Accessories InquiriesAll inquiries concerning genuine replacement parts andaccessories should be directed to your local authorized dealer. Thedealer has the necessary information to order parts andaccessories for you. When inquiring on parts and accessories, thedealer requires the model and serial number to order the correctparts.

Service AssistanceSatisfaction with your Sterndrive or Inboard product is veryimportant to your dealer and to us. If you ever have a problem,question or concern about your Sterndrive or Inboard product,contact your dealer or any authorized Mercury Marine dealer. Ifadditional assistance is required, take these steps.1. Talk with the dealership's sales manager or service manager.

If this has already been done, then contact the owner of thedealership.

2. Should you have a question, concern, or problem that cannotbe resolved by your dealership, please contact MercuryMarine Service Office for assistance. Mercury Marine will workwith you and your dealership to resolve all problems.

The following information will be needed by the service office:• Your name and address• Daytime telephone number


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• Model and serial number of your outboard• The name and address of your dealership• Nature of problem

Mercury Mercruiser Service OfficesFor assistance, call, fax, or write. Please include your daytimetelephone number with mail and fax correspondence.

United States

Telephone Fax Mercury MerCruiser3003 N. Perkins RoadStillwater, OK 74075(405) 743‑6566 (405) 743‑6570

United States (Mercury Racing)

Telephone Fax Mercury RacingN7480 County Rd. UUFond du Lac, WI 54935-9585(920) 924‑2088 (920) 924‑2096

Canada

Telephone Fax Mercury Marine Ltd.2395 Meadowpine Blvd.Mississauga, Ontario L5N 7W6Canada

(905) 567‑6372 (905) 567‑8515

Australia, Pacific

Telephone Fax Mercury Marine Australia132-140 Frankston RoadDandenong, Victoria 3164Australia

(61) (3) 9791‑5822 (61) (3) 9793‑5880


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Europe, Middle East, Africa

Telephone Fax Marine Power - Europe, Inc.Parc Industriel de Petit-RechainB-4800Verviers,Belgium

(32) (87) 32 • 32 • 11 (32) (87) 31 • 19 • 65

Mexico, Central America, South America, Caribbean

Telephone Fax Mercury Marine11650 Interchange Circle NorthMiramar, FL 33025U.S.A.

(954) 744‑3500 (954) 744‑3535

Japan

Telephone Fax Mercury Marine - Japan283-1 Anshin-cho HamamatsuShizuoka, 435-0005Japan

81‑53‑423‑2500 81‑53‑423‑2510

Asia, Singapore

Telephone Fax Mercury Marine- Singapore72 Loyang WaySingapore, 5087625466160 5467789

ORDERING LITERATURE

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United States and CanadaBefore ordering literature, please have the following informationabout your power package available:

EngineModel: Horsepower:

SerialNumber: Model year:

For information on additional literature that is available for yourparticular Mercury/MerCruiser power package and how to orderthat literature contact your nearest dealer or contact:

MERCURY MARINE

Telephone Fax Mail

(920) 929‑5110 (920) 929‑4894

Mercury MarineAttn: Publications Department

P.O. Box 1939Fond du Lac, WI 54936-1939

Outside The United States and CanadaBefore ordering literature, please have the following informationabout your power package available:

EngineModel: Horsepower:

SerialNumber: Model year:

Contact your nearest dealer or Marine Power Service Center forinformation on additional literature that is available for yourparticular Mercury/MerCruiser power package and how to orderthat literature.

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