Mercury Racing HP1200 SCi Dry Sump Installation guide

i
Thank You
for your purchase of one of the finest marine power packages
available. It incorporates numerous design features to assure
operating ease and durability.
With proper care and maintenance, you will thoroughly enjoy
using this product for many boating seasons. To ensure
maximum performance and carefree use, we ask that you
thoroughly read this manual.
The Operation, Maintenance & Warranty Manual contains
specific instructions for using and maintaining your product.
We suggest that this manual remain with the product for ready
reference whenever you are on the water.
Again, thank you for purchasing one of our Mercury Marine
products. We sincerely hope your boating will be pleasant!
Mercury Racing,
N7480 County Road "UU"
Fond du Lac, WI 54935-9585
7406
Warranty Message
The product you have purchased comes with a limited
warranty from Mercury Marine; the terms of the warranty are
set forth in the Warranty Information section of this manual.
The warranty statement contains a description of what is
covered, what is not covered, the duration of coverage, how
to best obtain warranty coverage, important disclaimers and
limitations of damages, and other related information. Please
review this important information.
© 2006 Mercury Marine HP1200 SCi Dry Sump 90-8M8021159 1206

ii
! WARNING
The operator (driver) is responsible for the correct and safe
operation of the boat, the equipment aboard and the safety of all
occupants aboard. We strongly recommend that the operator
read this Operation, Maintenance and Warranty Manual and
thoroughly understand the operational instructions for the power
package and all related accessories before the boat is used.
! WARNING
The engine exhaust from this product contains chemicals known
to the state of California to cause cancer, birth defects or other
reproductive harm.
Safety Alerts and Notices
Throughout this publication, dangers, warnings, cautions, and
notices0., accompanied by the international HAZARD symbol
!, are used to alert the technician to special instructions
concerning a particular service or operation that may be hazardous
if performed incorrectly or carelessly. These safety alerts follow
ANSI standard Z535.6‑2006 for product safety information in
product manuals, instructions, and other collateral materials.
Observe these safety alerts carefully.
These safety alerts alone can not eliminate the hazards they
signal. Strict compliance to these special instructions when
performing the service, and common sense operation are major
accident prevention measures.
! DANGER
Indicates a hazardous situation which, if not avoided, will result
in death or serious injury.
! WARNING
Indicates a hazardous situation which, if not avoided, could result
in death or serious injury.
0.

iii
! CAUTION
Indicates a hazardous situation which, if not avoided, could result
in minor or moderate injury.
NOTICE
Indicates a situation which, if not avoided, could result in engine
or major component failure.
IMPORTANT: Identifies information essential to the successful
completion of the task.
NOTE: Indicates information that helps in the understanding of a
particular step or action.
Copyright and Trademark Information
Mercury Marine, Fond du Lac, Wisconsin U.S.A.
Litho in U.S.A.
© 2006, Mercury Marine
Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser,
Mercury Racing, Mercury Precision Parts, Mercury Propellers,
Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Pro Max,
OptiMax, Sport‑Jet, K‑Planes, MerCathode, RideGuide,
SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves
logo, and SmartCraft logo are all registered trademarks of
Brunswick Corporation. Mercury Product Protection logo is a
registered service mark of Brunswick Corporation.

iv

TABLE OF CONTENTS
v
Warranty Information
Warranty Coverage......................................................................1
General Information
Identification Record....................................................................2
Boater's Responsibilities..............................................................3
Boat Horsepower Capacity..........................................................4
High‑Speed and High‑Performance Boat Operation...................4
Lanyard Stop Switch....................................................................5
Protecting People In The Water...................................................6
Exhaust Emissions......................................................................7
Wave And Wake Jumping...........................................................9
Impact With Underwater Hazards..............................................10
Trailering Boat........................................................................... 11
Safe Boating Suggestions......................................................... 11
Stolen Power Package.............................................................. 14
Specifications
Fuel Requirements (HP1200 SCi).............................................15
Crankcase Oil............................................................................17
Capacities..................................................................................18
General Engine Specifications (HP1200 SCi)........................... 19
Engine Operating Limitations (HP1200 SCi)............................. 20
California Emissions Regulations..............................................20
Engine Break‑in.........................................................................21
After Break‑In Period.................................................................21
Operation
Instrumentation..........................................................................22
Warning System........................................................................ 22
Electrical System Overload Protection...................................... 24
Remote Controls (Console Mounted Zero Effort)......................27
Power Trim................................................................................ 28

TABLE OF CONTENTS
vi
Starting, Shifting, and Stopping.................................................31
Operation Chart.........................................................................33
Freezing Temperature Operation..............................................34
Drain Plug and Bilge Pump........................................................34
Launching And Boat Operation Care.........................................34
Conditions Affecting Operation
Weight Distribution.....................................................................36
Bottom Of Boat..........................................................................36
Cavitation...................................................................................36
Ventilation..................................................................................37
Propeller Selection.....................................................................37
Conditions That Lower Engine Performance.............................38
Maintenance
Service Responsibilities.............................................................39
Replacement Service Parts.......................................................40
Do‑It‑Yourself Maintenance Suggestions..................................40
Servicing High Horsepower Engines.........................................42
Maintenance Charts...................................................................42
Checking Fluid Levels................................................................45
Changing Fluids.........................................................................52
Lubrication.................................................................................61
Propellers...................................................................................63
Seawater Pump Impeller Inspection..........................................65
Flushing Cooling System...........................................................65
Cleaning Seawater (Raw Water) Section of Oil Cooler.............66
Cleaning the Flame Arrestors....................................................67
Drive Belts.................................................................................67
Corrosion and Corrosion Protection..........................................70
Battery.......................................................................................75
Bottom of Boat...........................................................................76
Inspection and Maintenance......................................................77
Attention Required After Submersion........................................77
Maintenance Log.......................................................................77

TABLE OF CONTENTS
vii
Cold Weather or Extended Storage
Power Package Lay‑up..............................................................79
Draining Instructions..................................................................81
Battery Winter Storage..............................................................84
Power Package Recommissioning............................................84
Troubleshooting
Engine Will Not Crank................................................................89
Engine Cranks But Will Not Start...............................................90
Engine Runs Rough, Hard to Start, Misses, and/or Backfires...91
Poor Performance......................................................................91
Insufficient Engine Temperature................................................92
Excessive Engine Temperature.................................................92
Low Engine Oil Pressure...........................................................93
Battery Will Not Come Up On Charge.......................................93
Power Trim Does Not Operate (Motor Doesn't Run).................93
Power Trim Does Not Operate (Motor Runs But Drive Unit Does
Not Move)..................................................................................94
Remote Control Operates Hard, Binds, Has Excessive Free‑Play
or Makes Unusual Sounds.........................................................94
Steering Wheel Turns Hard or Jerky.........................................94
Owner Service Assistance
Local Repair Service..................................................................95
Service Away From Home.........................................................95
Parts And Accessories Inquiries................................................95
Service Assistance....................................................................95
Mercury Mercruiser Service Offices...........................................96
Ordering Literature
United States and Canada.........................................................98
Outside The United States and Canada....................................98

viii

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

GENERAL INFORMATION
2
Identification Record
Model
Displacement
Max. WOT RPM
Spark Plugs
Spark Plug Gap
Firing Order
1075 SCI
557 CI / 9.1 Liter
5600-6000
NKG BRCECS
0.76 mm 0.03 in. ( )
1-8-4-3-6-5-7-2
Fuel Octane 92 AKI [(R+M)/2] or 98 RON
Preferred
Engine Oil
Mercury 25W-40
Alternative
Engine Oil
API CI-4, CH-4, CG-4
14837
a
b
e
f
d
h
c
g
b

GENERAL INFORMATION
3
a - Engine Model/
Horsepower:
___________________
_____
b - Engine Serial
Number1. :
___________________
_____
c - Transom Assembly
Serial Numer:
___________________
_____
d - Sterndrive Serial
Number & Gear
Ratio2. :
___________________
_____
e - Propeller Number &
Pitch:
____________________
_____
f - Running Rotation3. :
____________________
_____
g - Hull Identification
Number:
____________________
_____
h - Boat Model & Length:
____________________
_____
The serial numbers are the manufacturer's keys to numerous
engineering details that apply to your Mercury Marine power
package. When contacting your authorized Mercury Marine dealer
about service, always specify model and serial numbers.
1. The engine serial number is printed on the center of the bell
housing and stamped into the front of the port cylinder head
along with the crankshaft number.
2. The gear ratio is stamped on the the bolt located next to the
serial number label.
3. The running rotation is stamped on the back of the strut.
Boater's Responsibilities
The operator (driver) is responsible for the correct and safe
operation of the boat and safety of its occupants and general
public. It is strongly recommended that each operator (driver) read
and understand this entire manual before operating the power
package.
Be sure at least one additional person on board is instructed in the
basics of starting and operating the power package, and boat
handling in case the driver is unable to operate the boat.

GENERAL INFORMATION
4
Boat Horsepower Capacity
! WARNING
Avoid serious injury, death or property damage from
overpowering a boat. Using a power package that exceeds the
maximum horsepower limit of a boat can:
• Cause loss of boat control.
• Place too much weight at the transom altering the designed
flotation characteristics of the boat
• Cause the boat to break apart, particularly around the transom
area.
Do not overpower or overload your boat. Most boats will carry a
required capacity plate indicating the maximum acceptable power
and load as determined by the manufacturer following certain
federal guidelines. If in doubt, contact your dealer or the boat
manufacturer.
U.S. COAST GUARD CAPACITY
MAXIMUM HORSEPOWER XXX
MAXIMUM PERSON
CAPACITY (POUNDS) XXX
MAXIMUM WEIGHT
CAPACITY XXX
ob00306
High‑Speed and High‑Performance Boat Operation
If your power package is to be used on a high speed or high
performance boat with which you are unfamiliar, we recommend
that you never operate it at its high speed capability without first
requesting an initial orientation and familiarization demonstration
ride with your dealer or an operator experienced with your boat/
power package combination. For additional information, obtain a
copy of our Hi‑Performance Boat Operation booklet from your
dealer, distributor, or Mercury Marine.

GENERAL INFORMATION
5
Lanyard Stop Switch
The purpose of a lanyard stop switch is to turn off the engine when
the operator moves far enough away from the operator's position
(as in accidental ejection from the operator's position) to activate
the switch. A lanyard stop switch can be installed as an accessory ‑
generally on the dashboard or side adjacent to the operator's
position.
While activation of the lanyard stop switch will stop the engine
immediately, a boat will continue to coast for some distance
depending upon the velocity and degree of any turn at shut down.
However, the boat will not complete a full circle. While the boat is
coasting, it can cause injury to anyone in the boat's path as
seriously as the boat would when under power.
21629
ab
a - Lanyard cord
b - Lanyard stop switch
We strongly recommend that other occupants be instructed on
proper starting and operating procedures should they be required
to operate the engine in an emergency (e.g. if the operator is
accidentally ejected).
! WARNING
Should the operator fall out of the boat, the possibility of serious
injury or death from being run over by the boat can be greatly
reduced by stopping the engine immediately. Always properly
connect both ends of the stop switch lanyard to the stop switch
and the operator.

GENERAL INFORMATION
6
! WARNING
Avoid serious injury or death from deceleration forces resulting
from accidental or unintended stop switch activation. The boat
operator should never leave the operator's station without first
disconnecting the stop switch lanyard from the operator.
Accidental or unintended activation of the switch during normal
operation is also a possibility. This could cause any, or all, of the
following potentially hazardous situations:
• Occupants could be thrown forward due to unexpected loss
of forward motion ‑ a particular concern for passengers in the
front of the boat who could be ejected over the bow and
possibly struck by the gear case or propeller.
• Loss of power and directional control in heavy seas, strong
current or high winds.
• Loss of control when docking.
Protecting People In The Water
WHILE YOU ARE CRUISING
It is very difficult for a person in the water to take quick action to
avoid a boat heading in their direction, even at slow speeds.
21604
Always slow down and exercise extreme caution any time you are
boating in an area where there might be people in the water.
Whenever a boat is moving (even coasting) and the gear shift is in
neutral, there is sufficient force by the water on the propeller to
cause the propeller to rotate. This neutral propeller rotation can
cause serious injury.

GENERAL INFORMATION
7
WHILE BOAT IS STATIONARY
! WARNING
Stop your engine immediately whenever anyone in the water is
near your boat. Serious injury to the person in the water is likely
if contacted by a rotating propeller, a moving boat, a moving
gearcase, or any solid device rigidly attached to a moving boat
or gearcase.
Shift into neutral and shut off the engine before allowing people to
swim or be in the water near your boat.
Exhaust Emissions
BE ALERT TO CARBON MONOXIDE POISONING
Carbon monoxide is present in the exhaust fumes of all internal
combustion engines. This includes the outboards, sterndrives and
inboard engines that propel boats, as well as the generators that
power various boat accessories. Carbon monoxide is a deadly gas
that is odorless, colorless and tasteless.
Early symptoms of carbon monoxide poisoning which should not
be confused with seasickness or intoxication, include headache,
dizziness, drowsiness, and nausea.
! WARNING
Avoid the combination of a running engine and poor ventilation.
Prolonged exposure to carbon monoxide in sufficient
concentration can lead to unconsciousness, brain damage, or
death.
POOR VENTILATION
Under certain running and/or wind conditions, permanently
enclosed or canvas enclosed cabins or cockpits with insufficient
ventilation may draw in carbon monoxide. Install one or more
carbon monoxide detectors in your boat.
Although the occurrence is rare, on a very calm day, swimmers
and passengers in an enclosed area of a stationary boat that
contains or is near a running engine may be exposed to a
hazardous level of carbon monoxide.

GENERAL INFORMATION
8
While Boat Is Stationary
21626
a
b
a - Running the engine when the boat is moored in a confined
space.
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 VENTILATION
Ventilate passenger area, open side curtains, or forward hatches
to remove fumes.
5448

GENERAL INFORMATION
9
Wave And Wake Jumping
Operating recreational boats over waves and wake is a natural part
of boating. However, when this activity is done with sufficient speed
to force the boat hull partially or completely out of the water, certain
hazards arise, particularly when the boat re‑enters the water.
5450
The primary concern is the boat changing direction while in the
midst of the jump. In such case the landing may cause the boat to
veer violently in a new direction. Such a sharp change in direction
can cause occupants to be thrown out of their seats, or out of the
boat.
! WARNING
Avoid serious injury or death from being thrown within or out of
a boat when it lands after jumping a wave or wake. Avoid wave
or wake jumping whenever possible. Instruct all occupants that
if a wake or wave jump occurs, get low and hang on to any boat
hand hold.
There is another less common hazardous result from allowing your
boat to launch off a wave or wake. If the bow of your boat pitches
down far enough while airborne, upon water contact it may
penetrate under the water surface and submarine for an instant.
This will bring the boat to a nearly instantaneous stop and can send
the occupants flying forward. The boat may also steer sharply to
one side.

GENERAL INFORMATION
10
Impact With Underwater Hazards
! WARNING
Operating the boat in shallow water can result in serious injury
or death due to impact with underwater hazards. Always operate
the boat at safe speeds in shallow water.
Reduce speed, raise the drive, and proceed with caution whenever
you maneuver a boat in shallow water areas or in areas where you
suspect underwater obstacles may exist. Gain as much knowledge
of the area as possible from maps or local boaters before you go
boating. Consider the following:
• Ensure that the depth finder is calibrated (offset) to include the
distance from the waterline to the depth finder.
• When using a depth finder that is not calibrated; add (a) to (b)
= (c). Ensure that (c) is always less than (d) or (e) when
reading the water depth on the map.
• Fast acceleration will drive the sterndrive deeper into the
water.
11419
a
bde
c
f
a - Distance from depth
finder to bottom of skeg.
b - Distance from waterline
to bottom of depth
finder.
c - Distance from waterline
to bottom of skeg.
d - Distance from waterline to
obstacle.
e - Distance from waterline to
sea 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 loose
and fly into the boat.
• The boat could move suddenly in a new direction. Such a
sharp change in direction can cause occupants to be thrown
out of their seats or out of the boat.
• A rapid reduction in speed. This will cause occupants to be
thrown forward, or even out of the boat.
• Impact damage to the sterndrive and/or boat.
! WARNING
Operating a boat or engine with impact damage can result in
product damage, serious injury, or death. If the vessel
experiences any form of impact, have an authorized Mercury
Marine dealer inspect and repair the vessel or power package.
After striking a submerged object, stop the engine as soon as
possible and inspect it for any broken or loose parts. If damage is
present or suspected, the sterndrive should be taken to an
authorized dealer for a thorough inspection and necessary repair.
The boat should also be checked for any hull fractures, transom
fractures, or water leaks.
Operating a damaged sterndrive could cause additional damage
to other parts of the sterndrive, or could affect control of the boat.
If continued running is necessary, do so at greatly reduced speeds.
Trailering Boat
The boat can be trailered with the drive unit in up or down position.
Adequate road clearance is required between road and gear
housing skeg when trailering with the drive unit in down position.
If adequate road clearance is a problem, place drive unit in full up
position.
Safe Boating Suggestions
Familiarize yourself with local, state and federal boating
regulations and restrictions.
Use flotation devices. Have an approved personal flotation device
of suitable size for each person aboard (it is the law).

GENERAL INFORMATION
12
Do not overload your boat. Most boats are rated and certified for
maximum load (weight) capacities (refer to your boat capacity
plate). If in doubt, contact your dealer or boat manufacturer.
Perform safety checks and required maintenance. Follow a regular
schedule and ensure that all repairs are properly made.
Check safety equipment on-board. Here are suggestions of the
types of safety equipment to carry when boating:
Approved fire extinguisher
Paddle or oar
Signal devices: flashlight, rockets or flares, flag and whistle or
horn
Spare propeller, thrust hubs and an appropriate wrench
Tools for necessary minor repairs
First aid kit and book
Anchor and extra anchor line
Water‑proof storage containers
Manual bilge pump and extra drain plugs
Compass and map or chart
Spare operating equipment; batteries, bulbs, fuses, etc.
VHF radio for making distress calls and receiving weather
reports, and a transistor radio
Drinking water
Know signs of weather change and avoid foul weather and
rough-sea boating.
Tell someone where you are going and when you expect to
return.
Know and obey all nautical rules and laws of the waterways. Boat
operators should complete a boating safety course. Courses are
offered in the U.S.A. by:
1. The U.S. Coast Guard Auxiliary
2. The Power Squadron
3. The Red Cross
4. Your state boating law enforcement agency