Mercury Racing HP1200 SCi Dry Sump User manual

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
! 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.
© 2010 Mercury Marine HP1200 SCi Dry Sump 90-8M8025149 110

ii
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.
Safety Alerts and Notices
Throughout this publication, dangers, warnings, cautions, and
notices., accompanied by the international HAZARD symbol !,
are used to alert the boat operator and technician to special
instructions concerning a particular service or operation that may
be hazardous if performed incorrectly or carelessly. 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.
! 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.
.

iii
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.
! WARNING
The engine exhaust from this product contains chemicals known
to the state of California to cause cancer, birth defects or other
reproductive harm.
Copyright and Trademark Information
Mercury Marine, Fond du Lac, Wisconsin U.S.A.
Printed in U.S.A.
© 2009, Mercury Marine
Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser,
Mercury Racing, Mercury Precision Parts, Mercury Propellers,
Mariner, Verado, Vazer, #1 On The Water, Alpha, Bravo, Pro Max,
OptiMax, Sport‑Jet, K‑Planes, MerCathode, SmartCraft,
VesselView, Quicksilver, Zero Effort, M with Waves logo, Mercury
with Waves logo, and SmartCraft logo are all registered
trademarks of Brunswick Corporation. Mercury Product Protection
logo is a registered service mark of Brunswick Corporation.

iv

TABLE OF CONTENTS
v
Warranty Information
Warranty Coverage......................................................................1
E.P.A. Emission Control Warranty...............................................1
California Emission Control Warranty Statement........................3
General Information
Identification Record....................................................................8
Boater's Responsibilities..............................................................9
Boat Horsepower Capacity........................................................10
High‑Speed and High‑Performance Boat Operation................. 10
Lanyard Stop Switch..................................................................11
Protecting People In The Water.................................................12
Exhaust Emissions.................................................................... 13
Wave And Wake Jumping......................................................... 15
Impact With Underwater Hazards..............................................15
Trailering Boat........................................................................... 17
Safe Boating Suggestions......................................................... 17
Stolen Power Package.............................................................. 20
Specifications
Fuel Requirements (HP1200/1025 SCi)....................................21
Dual Fuel Option........................................................................23
Crankcase Oil............................................................................26
Capacities..................................................................................27
General Engine Specifications (HP1200 SCi)........................... 28
Engine Operating Limitations (HP1200/1025 SCi).................... 29
Engine Break‑in.........................................................................29
After Break‑In Period.................................................................30

TABLE OF CONTENTS
vi
Operation
Instrumentation..........................................................................31
Warning System........................................................................ 31
Electrical System Overload Protection...................................... 33
Remote Controls (Console Mounted Zero Effort)......................36
Power Trim................................................................................37
Starting, Shifting, and Stopping.................................................40
Operation Chart.........................................................................42
Freezing Temperature Operation..............................................43
Drain Plug and Bilge Pump........................................................43
Launching And Boat Operation Care.........................................44
Conditions Affecting Operation
Weight Distribution.....................................................................45
Bottom Of Boat..........................................................................45
Cavitation...................................................................................45
Ventilation..................................................................................46
Propeller Selection.....................................................................46
Conditions That Lower Engine Performance.............................47

TABLE OF CONTENTS
vii
Maintenance
Service Responsibilities.............................................................49
Replacement Service Parts.......................................................50
Do‑It‑Yourself Maintenance Suggestions..................................50
Servicing High Horsepower Engines.........................................52
Maintenance Charts...................................................................52
Checking Fluid Levels................................................................55
Changing Fluids.........................................................................62
Lubrication.................................................................................71
Propellers...................................................................................72
Seawater Pump Impeller Inspection..........................................74
Flushing Cooling System...........................................................75
Cleaning Seawater (Raw Water) Section of Oil Cooler.............76
Cleaning the Flame Arrestors....................................................77
Drive Belts.................................................................................77
Corrosion and Corrosion Protection..........................................80
Battery.......................................................................................85
Bottom of Boat...........................................................................86
Inspection and Maintenance......................................................86
Attention Required After Submersion........................................86
Maintenance Log.......................................................................87
Cold Weather or Extended Storage
Power Package Lay‑up..............................................................88
Draining Instructions..................................................................90
Battery Winter Storage..............................................................93
Power Package Recommissioning............................................93

TABLE OF CONTENTS
viii
Troubleshooting
Engine Will Not Crank................................................................98
Engine Cranks But Will Not Start...............................................98
Engine Runs Rough, Hard to Start, Misses, and/or Backfires...99
Poor Performance....................................................................100
Insufficient Engine Temperature..............................................100
Excessive Engine Temperature...............................................101
Low Engine Oil Pressure......................................................... 101
Battery Will Not Come Up On Charge.....................................102
Power Trim Does Not Operate (Motor Doesn't Run)...............102
Power Trim Does Not Operate (Motor Runs But Drive Unit Does
Not Move)................................................................................102
Remote Control Operates Hard, Binds, Has Excessive Free‑Play
or Makes Unusual Sounds.......................................................103
Steering Wheel Turns Hard or Jerky.......................................103
Owner Service Assistance
Local Repair Service................................................................104
Service Away from Home........................................................104
Parts and Accessories Inquiries..............................................104
Service Assistance..................................................................104
Mercury Mercruiser Service Offices.........................................105
Ordering Literature
United States and Canada.......................................................107
Outside The United States and Canada..................................107

WARRANTY INFORMATION
1
Warranty Coverage
Mercury Racing does not offer a warranty with this power package.
E.P.A. Emission Control Warranty
U.S. EPA EMISSIONS LIMITED WARRANTY (MORE THAN
650 HP)
Consistent with the obligations created by 40 CFR Part 1045,
Subpart B, Mercury Marine provides an emission warranty of three
years or 480 hours of engine use whichever occurs first to the retail
purchaser for electrical components of the emission control
system, and one year or 50 hours of engine use whichever occurs
first to the retail purchaser for mechanical components of the
emission control system. The engine is designed, built, and
equipped so as to conform at the time of sale with applicable
regulations under section 213 of the Clean Air Act, and that the
engine is free from defects in materials and workmanship which
cause the engine to fail to conform with applicable regulations.
EMISSION CONTROL SYSTEM COMPONENTS
The emission‑related warranty covers all components whose
failure would increase an engine's emission of any regulated
component including the following list of components:
1. Fuel metering system
a. Carburetor and internal parts (or fuel pressure regulator or
fuel injection system)
b. Air/fuel ratio feedback and control system
c. Cold start enrichment system
d. Intake valves
2. Air induction system
a. Controlled hot air intake system
b. Intake manifold
c. Air filter
d. Turbo charger systems
e. Heat riser valve and assembly
3. Ignition system
a. Spark plugs

WARRANTY INFORMATION
2
b. Magneto or electronic ignition system
c. Spark control system
d. Ignition coil or control module
e. Ignition wires
4. Lubrication system
a. Oil pump and internal parts
b. Oil injectors
c. Oil meter
5. Positive crankcase ventilation (PCV) system
a. PCV valve
b. Oil filler cap
6. Exhaust system
a. Exhaust manifold
b. Exhaust elbow
c. Intermediate exhaust elbow
d. Lower exhaust pipe
e. Tailpipe
7. Catalysts or thermal reactor system
a. Catalytic converter
b. Thermal reactor
c. Exhaust manifold
d. Exhaust valves
8. Miscellaneous items used in above systems
a. Hoses, clamps, fittings, tubing, sealing gaskets or devices,
and mounting hardware
b. Pulleys, belts, and idlers
c. Vacuum, temperature, check and time sensitive valves and
switches
d. Electronic controls
NOTE: The emission‑related warranty does not cover components
whose failure would not increase an engine's emissions on any
regulated pollutant.

WARRANTY INFORMATION
3
California Emission Control Warranty Statement
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board and Mercury Racing are
pleased to explain the emission control system warranty on your
2009 sterndrive engine. In California, new sterndrive engines must
be designed, built and equipped to meet the State’s stringent
anti‑smog standards. Mercury Racing must warrant the emission
control system on your sterndrive engine for the periods of time
listed below provided there has been no abuse, neglect or
improper maintenance of your sterndrive engine.
Your emission control system may include parts such as the
carburetor or fuel injection system, the ignition system, and
catalytic converter. Also included may be hoses, belts, connectors
and other emission‑related assemblies.
Where a warrantable condition exists, Mercury Racing will repair
your sterndrive engine at no cost to you, including diagnosis, parts
and labor.
MANUFACTURER’S WARRANTY COVERAGE:
For engines with power ratings greater than 485 kW (650 H), select
emission‑related electrical parts from model year 2009 and later
sterndrive engines are warranted for 3 years or 480 hours,
whichever first occurs.
For engines with horsepower ratings greater than 485 kW (650 H),
select emission‑related mechanical parts from model year 2009
and later sterndrive engines are warranted for 1 years or 50 hours,
whichever first occurs.
ELECTRICAL COMPONENTS OF THE EMISSION CONTROL
SYSTEM
Select electrical emission‑related components are warranted for 3
years or 480 hours of operation, whichever first occurs.
Warranty coverage based on the hourly period is only permitted
for engines that are equipped with appropriate hour meters as
defined in Section 2441 (a), (13) or their equivalent. If any
emission‑related part on your engine is defective under warranty,
the part will be repaired or replaced by Mercury Racing.
1. Ignition System

WARRANTY INFORMATION
4
a. Spark plugs
b. Magneto or electronic ignition system
c. Spark advance/retard system
d. Ignition coil and/or control module
e. Ignition wires
2. Miscellaneous Items Used in Above Systems
a. Hoses, clamps, fittings, tubing, sealing gaskets or devices,
and mounting hardware
b. Vacuum, temperature, check, and time sensitive valves
and switches
c. Electronic controls
MECHANICAL COMPONENTS OF THE EMISSION
CONTROL SYSTEM
Select emission‑related mechanical components are warranted for
1 year or 50 hours of operation, whichever first occurs.
Warranty coverage based on the hourly period is only permitted
for engines that are equipped with appropriate hour meters as
defined in Section 2441 (a), (13) or their equivalent. If any
emission‑related part on your engine is defective under warranty,
the part will be repaired or replaced by Mercury Racing.
1. Air Induction System
a. Controlled hot air intake system
b. Intake manifold
c. Air filter
d. Turbocharger system
e. Heat riser valve and assembly
f. Intake valve(s)
2. Lubrication System
a. Oil pump and internal parts
b. Oil injector(s)
c. Oil meter
3. Positive Crankcase Ventilation (PCV) System
a. PCV valve
b. Oil filler cap

WARRANTY INFORMATION
5
4. Exhaust Gas Recirculation (EGR) System
a. EGR valve body and carburetor spacer if applicable
b. EGR rate feedback and control system
5. Air Injection System
a. Air pump or pulse valve
b. Valves affecting distribution of flow
c. Distribution manifold
6. Exhaust System
7. Catalyst or Thermal Reactor System
a. Catalytic converter
b. Thermal reactor
c. Exhaust manifold
d. Exhaust valve(s)
8. Miscellaneous Items Used in Covered Systems
a. Vacuum, temperature, check, and time sensitive valves
and switches
b. Pulleys, belts and idlers
FUEL SYSTEM AND EVAPORATIVE COMPONENTS OF THE
EMISSION CONTROL SYSTEM
Select mechanical emission‑related components are warranted for
1 year or 50 hours of operation, whichever first occurs.
1. Fuel Metering System
a. Carburetor and internal parts (pressure regulator or fuel
injection system)
b. Air/fuel ratio feedback and control system
c. Cold start enrichment system
2. Evaporative System
IMPORTANT: The OEM boat manufacturer is responsible for
warranty claims regarding the equipment listed below.
a. Carbon canister
b. Fuel tanks
c. Purge valve
d. Hoses, clamps, fittings, tubing, sealing gaskets or devices,
and mounting hardware

WARRANTY INFORMATION
6
OWNER’S WARRANTY RESPONSIBILITIES:
As the sterndrive engine owner, you are responsible for the
performance of the required maintenance listed in your owner’s
manual. Mercury Racing recommends that you retain all receipts
covering maintenance on your sterndrive engine, but Mercury
Racing cannot deny warranty solely for the lack of receipts or your
failure to ensure the performance of all scheduled maintenance.
As the sterndrive engine owner, you should however be aware that
Mercury Racing may deny you warranty coverage if your sterndrive
engine or a part has failed due to abuse, neglect, improper
maintenance or unapproved modifications.
You are responsible for presenting your sterndrive engine to a
Mercury Marine distribution center as soon as a problem exists.
The warranty repairs will be completed in a reasonable amount of
time, not to exceed 30 days.
If you have any questions regarding your warranty rights and
responsibilities, you should contact Mercury Racing at
1‑920‑924‑2088.
STAR LABEL
Engines are labeled with one of the following star labels.
The Symbol for Cleaner Marine Engines Means:
Cleaner Air and Water ‑ for a healthier lifestyle and environment.
Better Fuel Economy ‑ burns up to 30‑40 percent less gas and oil
than conventional carbureted two‑stroke engines, saving money
and resources.
Longer Emission Warranty ‑ Protects consumer for worry free
operation.
IMPORTANT: Although labeled as Two or Three Star, the
engine(s) in this boat meet the requirements of the Air Resources
Board's 2009 and later exhaust emission standards for High
Performance Sterndrive and Inboard Marine Engines with power
> 373 kW.

WARRANTY INFORMATION
7
22531
One Star ‑ Low Emission
The One Star label identifies engines that meet
the Air Resources Board's 2001 exhaust
emissions standards. Engines meeting these
standards have 75% lower emissions than
conventional carbureted two‑stroke engines.
These engines are equivalent to the U.S. EPA's
2006 standards for marine engines.
FO
IDA
22532
Two Stars ‑ Very Low Emission
The Two Star label identifies engines that meet
the Air Resources Board's Personal Watercraft
and Outboard marine engine 2004 exhaust
emissions standards. Engines meeting these
standards have 20% lower emissions than One
Star ‑ Low Emission engines.
A
SS
D
22533
Three Stars ‑ Ultra Low Emission
The Three Star label identifies engines that meet
the Air Resources Board's Personal Watercraft
and Outboard marine engine 2008 exhaust
emissions standards or the Sterndrive and
Inboard marine engine 2003‑2008 exhaust
emission standards. Engines meeting these
standards have 65% lower emissions than One
Star ‑ Low Emission engines.
RN
F
T
22534
Four Stars ‑ Super Ultra Low Emission
The Four Star label identifies engines that meet
the Air Resources Board's Sterndrive and Inboard
marine engine 2009 exhaust emission standards.
Personal Watercraft and Outboard marine
engines may also comply with these standards.
Engines meeting these standards have 90%
lower emissions than One Star ‑ Low Emission
engines.

GENERAL INFORMATION
8
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
9
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
10
Boat Horsepower Capacity
! WARNING
Exceeding the boat's maximum horsepower rating can cause
serious injury or death. Overpowering the boat can affect boat
control and flotation characteristics or break the transom. Do not
install an engine that exceeds the boat's maximum power rating.
Do not overpower or overload your boat. 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 CAP ACITY
MAXIMUM HORSEPOWER XXX
MAXIMUM PERSON
CAPACITY (POUNDS) XXX
MAXIMUM WEIGHT
CAPACITY XXX
26777
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
11
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.
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
If the operator falls out of the boat, stop the engine immediately
to reduce the possibility of serious injury or death from being
struck by the boat. Always properly connect the operator to the
stop switch using a lanyard.
21629
ab

GENERAL INFORMATION
12
! 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.