MerCruiser Vazer 100 Owner's Manual
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MerCruiser Vazer 100 Owner's Manual

MerCruiser Vazer 100 Owner's Manual

With emissions control
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NOTE: The following applies to CE marked products only.
Declaration of Conformance – Mercury MerCruiser
This sterndrive or inboard engine when installed in accordance to Mercury
MerCruisers' instructions complies with the requirements of the following directives
by meeting the associated standards, as amended:
Recreational Craft Directive 94/25/EC; 2003/44/EC
Owner's manual (A.2.5)
Openings in Hull, Deck and superstructure (A.3.4) ISO 9093‑1; ISO 9093‑2
Handling characteristics (A.4)
Inboard Engine (A.5.1.1)
Fuel System (A.5.2)
Electrical System (A.5.3)
Steering system (A.5.4)
Exhaust emission requirements (B.2)
Owner's manual (B.4)
Noise emission levels (C.1)
Ignition‑protected equipment (Annex II)
Mercury MerCruiser declares that our sterndrive or inboard engines without integral
exhaust, when installed in a recreational craft, in accordance with the manufacturers
supplied instructions, will meet the exhaust emissions requirements of the directive
mentioned above. This engine must not be put into service until the recreational craft
in which it is to be installed has been declared in conformity, if so required, with the
relevant provision of the directive.
Electromagnetic Compatibility Directive 89/336/EC, 92/31/EEC and 93/68/EEC
Generic emission standard
Generic immunity standard
Vehicles, boats and internal combustion engine
driven devices ‑ Radio disturbance characteristics
Electrostatic discharge testing
The notified body responsible for surveillance of the quality system under Full Quality Assurance
Module H of Directive 2003/44/EC is:
Det Norske Veritas
Norway
Notified Body Number: 0575
This declaration is issued under the sole responsibility of Mercury Marine and Mercury MerCruiser.
President ‑ Mercury Marine, Fond du Lac, WI USA
Applicable Requirement
Patrick C. Mackey
Standards Applied
ISO 10240
ISO 8665
ISO 15584; ISO 10088; ISO 7840; ISO 10133
ISO 10088; ISO 7840; ISO 8469
ISO 10133; ISO 8846
Applicable portions of: ISO 10592, ISO 8848 and
ABYC P‑17
ISO 8178
ISO 8665
ISO 14509
ISO 8846; SAE J1171; SAE J1191; SAE J 2031
EN 50081‑1
EN 50082‑1
SAE J551 (CISPR 12)
EN 61000‑6‑2; EN 61000‑4‑2; EN61000‑4‑3

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  • Page 1 Module H of Directive 2003/44/EC is: Det Norske Veritas Norway Notified Body Number: 0575 This declaration is issued under the sole responsibility of Mercury Marine and Mercury MerCruiser. Patrick C. Mackey President ‑ Mercury Marine, Fond du Lac, WI USA...
  • Page 2 Exhaust Gas Emissions Certification Number The serial numbers are the manufacturer’s keys to numerous engineering details that apply to your Mercury MerCruiser® power package. When contacting your Authorized Mercury MerCruiser Dealer about service, always specify model and serial numbers. The description and specifications contained herein were in effect at the time this guide was approved for printing.

  • Page 3: Read This Manual Thoroughly

    We suggest that this manual remain with the product for ready reference whenever you are on the water. Thank you for purchasing one of our Mercury MerCruiser products. We sincerely hope your boating will be pleasant!
  • Page 4 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. 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.

  • Page 5: Table Of Contents

    Mercury Product Protection Plan: United States and What Is Not Covered........12 Canada..............3 Components Of The Emission Control System 13 Mercury MerCruiser Limited Warranty Disclaimers And Limitations......14 (Gasoline‑Fueled Products Only) ......4 California Emission Control Warranty Statement. .14 3‑Year Limited Warranty Against Corrosion....6 Your Warranty Rights and Obligations.....14...
  • Page 6 Weight Distribution (Passengers and Gear) Propeller Selection........44 Inside the Boat..........42 Getting Started............. 44 Bottom Of Boat..........43 20‑Hour Break‑In Period....... 44 Cavitation............43 After the Break‑In Period....... 44 Ventilation............. 43 End of First Season Checkup....... 45 Elevation and Climate........43 Section 4 - Specifications Fuel Requirements..........48 Engine............50...
  • Page 7 Section 6 - Storage Cold Weather (Freezing Temperature) and Extended Engine and Fuel System Preparation....99 Storage..............98 Battery Storage............100 Draining the Vazer 100 Seawater System..98 Power Package Recommissioning......100 Preparing the Power Package for Extended Storage............98 Section 7 - Troubleshooting Diagnosing EFI Problems........102 Low Engine Oil Pressure......104...
  • Page 8 Page iv 90-899883182 NOVEMBER 2007...

  • Page 9: Section 1 - Warranty

    Mercury Product Protection Plan: United States and Components Of The Emission Control Canada..............3 System ............13 Mercury MerCruiser Limited Warranty (Gasoline- Disclaimers And Limitations ......14 Fueled Products Only) ......... 4 California Emission Control Warranty Statement 3-Year Limited Warranty Against Corrosion..6 ................

  • Page 10: Warranty Registration: United States And Canada

    A temporary Owner Warranty Registration Card will be presented to you when you purchase the product. Upon receipt of the Warranty Registration Card at the factory, Mercury MerCruiser will send you an owner resource guide that includes your warranty registration confirmation. If you do not receive your owner resource guide within 60 days from date of new product sale, please contact your selling dealer.

  • Page 11: Transfer Of Warranty

    Section 1 - Warranty The warranty registration card identifies your name and address, product model and serial numbers, date of sale, type of use, and the selling distributor’s and dealer’s code number, name, and address. The distributor or dealer also certifies that you are the original purchaser and user of the product.

  • Page 12: Mercury Mercruiser Limited Warranty (Gasoline-Fueled Products Only)

    Coverage for Sterndrive Models with Closed Cooling, Inboard Models, Scorpion 377 Models, and Vazer 100 Models The Limited Warranty for Sterndrive Models with Closed Cooling, Inboard Models, Scorpion 377 Models, and Vazer 100 Models is four (4) years when installed by an Installation Quality Certified Installer or three (3) years for noncertified installations.
  • Page 13 Section 1 - Warranty Conditions That Must Be Met in Order to Obtain Warranty Coverage Warranty coverage is available only to retail customers that purchase from a dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the pre‑delivery inspection process specified by Mercury Marine is completed and documented.

  • Page 14: 3-Year Limited Warranty Against Corrosion

    Mercury Marine warrants that each new Mercury, Mariner, Mercury Racing, Sport Jet, M Jet Drive, Tracker by Mercury Marine Outboard, MerCruiser Inboard or Sterndrive engine (Product) will not be rendered inoperative as a direct result of corrosion for the period of time described below.

  • Page 15: Global Warranty Charts

    Section 1 - Warranty This limited warranty does not cover electrical system corrosion; corrosion resulting from damage, corrosion which causes purely cosmetic damage, abuse or improper service; corrosion to accessories, instruments, steering systems; corrosion to factory installed jet drive unit; damage due to marine growth; product sold with less than a one year limited Product warranty;...

  • Page 16: Commercial Application Warranty Chart

    Section 1 - Warranty Commercial Application Warranty Chart Limited Corrosion Commercial Application: Standard Factory Limited Warranty by Region & Boat Brand Warranty Non-Certified Boat Brand Certified Boat Brand All Boat Brands Vazer, Standard Vazer and Vazer and Models, Models Models Scorpion Scorpion and and...

  • Page 17: Government Application Warranty Chart

    Section 1 - Warranty Government Application Warranty Chart Limited Corrosion Government Application: Standard Factory Limited Warranty by Region & Boat Brand Warranty Non-Certified Boat Brand Certified Boat Brand All Boat Brands Vazer, Standard Vazer and Vazer and Models, Models Models Scorpion Scorpion and and...

  • Page 18: California Emissions Limited Warranty

    California Emissions Limited Warranty NOTE: Mercury Marine does not establish model years for the Mercury MerCruiser product line. In order to comply with CARB warranty regulations, and for that limited purpose only, model year shall have the same meaning as calendar year. As an example, 2003 model year products refers to products manufactured during calendar year 2003.

  • Page 19: Duration Of Coverage

    Duration Of Coverage NOTE: Mercury Marine does not establish model years for the Mercury MerCruiser product line. In order to comply with CARB warranty regulations, and for that limited purpose only, model year shall have the same meaning as calendar year. As an example, 2003 model...

  • Page 20: How To Obtain Warranty Coverage

    Section 1 - Warranty How To Obtain Warranty Coverage The customer must provide Mercury with a reasonable opportunity to repair and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, please notify Mercury Marine and Mercury will then arrange for the inspection and any covered repair.

  • Page 21: Components Of The Emission Control System

    Section 1 - Warranty Components Of The Emission Control System 1. Fuel Metering System Carburetor and internal parts (and/or pressure regulator or fuel injection system) Air/fuel ratio feedback and control system Cold start enrichment system Intake valve(s) 2. Air Induction System Controlled hot air intake system Intake manifold Air filter...

  • Page 22: Components Of The Emission Control System 13 Disclaimers And Limitations

    1. Mercury Marine does not establish model years for the Mercury MerCruiser product line. In order to comply with CARB warranty regulations, and for that limited purpose only, model year shall have the same meaning as calendar year. As an example, 2003 model year products refers to products manufactured during calendar year 2003.

  • Page 23: Emission Control Information Label

    A tamper‑resistant Emission Control Information label is affixed in a visible location to the engine at time of manufacture by Mercury MerCruiser. In addition to the required emissions statement, the label lists the engine serial number, family, STD (emission standard/level), date of manufacture (month, year), and the engine displacement.

  • Page 24: Owner Responsibility

    Beginning January 1, 2003, one Three‑Star or Four‑Star label will be included with each factory‑certified Mercury MerCruiser engine. All Mercury MerCruiser engines (500 hp and below) will have a Three‑Star Ultra Low Emission rating or Four‑Star Super Ultra Low Emission rating. The Star label identifies that these engines meet the California Air Resources Board's Sterndrive and Inboard marine engine 2007 and later exhaust emission standards.
  • Page 25 Section 1 - Warranty One Star - Low emission The one‑star label identifies personal watercraft, outboard, sterndrive and inboard engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2001 exhaust emission standards. Engines meeting these standards have 75% lower emissions than conventional carbureted two‑stroke engines.
  • Page 26 Section 1 - Warranty Notes: Page 18 90-899883182 NOVEMBER 2007...

  • Page 27: Section 2 - Getting To Know Your Power Package

    Section 2 - Getting to Know Your Power Package Section 2 - Getting to Know Your Power Package Table of Contents Identification............20 Panel Mount Features........24 Engine Serial Number........20 Console Mount Features.......25 Vazer Sterndrive Identification......20 Power Trim............25 Vazer Transom Serial Number......21 Single Engine Trim and Trailer......27 Lanyard Stop Switch...........

  • Page 28: Identification

    Section 2 - Getting to Know Your Power Package Identification The serial numbers are the manufacturer's keys to numerous engineering details that apply to your Mercury MerCruiser power package. When contacting Mercury Marine about service, always specify model and serial numbers. Engine Serial Number The engine serial number is located on a metal tag just below the alternator on the engine block.

  • Page 29: Vazer Transom Serial Number

    Section 2 - Getting to Know Your Power Package The drive ratio is located on the starboard side decal. 26204 Drive ratio Vazer Transom Serial Number The Vazer transom serial number is located on the decal at the top of the transom assembly.
  • Page 30 Section 2 - Getting to Know Your Power Package • bass boats • high performance boats Accidental ejections can also occur from: • poor operating practices • sitting on the seat or gunwale at planing speeds • standing at planing speeds •...

  • Page 31: Instrumentation

    Section 2 - Getting to Know Your Power Package Instrumentation Digital Gauges A Mercury SmartCraft System instrument package can be purchased for this product. A few of the functions the instrument package will display are engine RPM, coolant temperature, oil pressure (requires a SmartCraft oil pressure sender kit), battery voltage, fuel consumption, and engine operating hours.

  • Page 32: Remote Controls

    Section 2 - Getting to Know Your Power Package Reference Gauge Function Speedometer Indicates boat speed. Tachometer Indicates engine RPM. Oil pressure gauge Indicates engine oil pressure. Voltmeter Indicates battery voltage. Coolant temperature gauge Indicates engine operating temperature. Fuel gauge Indicates quantity of fuel in tank.

  • Page 33: Console Mount Features

    Section 2 - Getting to Know Your Power Package Control handle. Operation of the shift and throttle are controlled by the movement of the control handle. Push the control handle forward from neutral with a quick, firm motion to the first detent for forward gear. Continue pushing forward to increase speed. Pull the control handle back from neutral with a quick, firm motion to the first detent for reverse gear and continue pushing back to increase speed.
  • Page 34 Section 2 - Getting to Know Your Power Package WARNING Excessive trim can cause serious injury or death at high speeds. Use caution when trimming the sterndrive, and never trim out beyond the gimbal ring support flanges while the boat is underway or at engine speeds above 1200 RPM. For best performance trim the sterndrive so that the boat bottom is at a 3–5°...

  • Page 35: Single Engine Trim And Trailer

    Reset the circuit breaker. If the breaker remains open, you must make more checks on the electrical system. Contact your authorized Mercury MerCruiser dealer. A circuit breaker provides protection for the engine wiring harness and the instrumentation power lead.
  • Page 36 Section 2 - Getting to Know Your Power Package A 100 amp fuse protects the main power circuits. A fuse block contains four separate fuses, which protect the engine wiring harness from electrical overload. All of these fuses are located on the remote oil filter bracket. e e e 26206 100 amp main fuse...
  • Page 37 Section 2 - Getting to Know Your Power Package A 15 amp accessory fuse protects the accessory circuits. This fuse is located on the rear of the engine. 7524 In the ignition switch "I" terminal lead, there may be a 20 amp fuse that protects the electrical system.

  • Page 38: Audio Warning System

    Audio Warning System Your Mercury MerCruiser power package may be equipped with an Audio Warning System. The Audio Warning System will not protect the engine from damage. It is designed to warn the operator that a problem has occurred.

  • Page 39: Testing The Audio Warning System

    To avoid a possible recurrence of the problem you should contact an authorized Mercury MerCruiser dealer. The ECM stores the fault and with this information the technician will be able to more rapidly diagnose problems.
  • Page 40 Section 2 - Getting to Know Your Power Package Notes: Page 32 90-899883182 NOVEMBER 2007...

  • Page 41: Section 3 - On The Water

    Section 3 - On The Water Section 3 - On The Water Table of Contents Safe Boating Suggestions........34 Passenger Safety in Pontoon Boats and Deck Be Alert To Carbon Monoxide Poisoning... 35 Boats.............40 Good Ventilation ........... 36 Boats Having An Open Front Deck ..40 Poor Ventilation ...........

  • Page 42: Safe Boating Suggestions

    Most boats are rated and certified for maximum load (weight) capacities (refer to your boat capacity plate). Know your boat's operating and loading limitations. Know if your boat will float if full of water. When in doubt, contact your authorized Mercury MerCruiser dealer or the boat manufacturer.

  • Page 43: Be Alert To Carbon Monoxide Poisoning

    Section 3 - On The Water • Do not allow anyone to sit or ride on any part of the boat that was not intended for such use. This includes the backs of seats, gunwales, transom, bow, decks, raised fishing seats and any rotating fishing seat;...

  • Page 44: Good Ventilation

    Section 3 - On The Water Good Ventilation Ventilate the passenger area, open the side curtains or forward hatches to remove fumes. 1. Example of desired air flow through the boat. mc79553-1 Poor Ventilation Under certain conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide.

  • Page 45: Operation Chart

    Section 3 - On The Water OPERATION CHART Operation Chart WHILE STOPPING and SHUT BEFORE STARTING AFTER STARTING UNDERWAY DOWN Frequently observe Observe all gauges to all gauges to check check the condition of Shift the remote control the condition of the Install the bilge drain plug.

  • Page 46: Stopping The Engine

    Section 3 - On The Water 3. Turn the ignition key to the "START" position. Release the key when the engine starts and allow the switch to return to the "ON" position. Allow the engine to warm up 6–10 minutes on first start of the day. NOTE: The engine will only start if the control handle is in neutral or is being operated using the throttle-only button.

  • Page 47: Trailering The Boat

    IMPORTANT: The seawater section of the Vazer 100 is self draining and will drain when the boat is removed from the water. If there is a chance of ice forming on the water, remove the boat from the water and allow the seawater section to drain completely of water.

  • Page 48: While Boat Is Stationary

    Section 3 - On The Water 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.

  • Page 49: Wave And Wake Jumping

    Section 3 - On The Water Any unexpected, sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat. mc79557-1 Wave And Wake Jumping WARNING Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat.

  • Page 50: Sterndrive Impact Protection

    After striking a submerged object, stop the engine as soon as possible and inspect the drive system for any broken or loose parts. If damage is present or suspected, the power package should be taken to an authorized Mercury MerCruiser dealer for a thorough inspection and any necessary repair.

  • Page 51: Bottom Of Boat

    Section 3 - On The Water • At extremes, can cause the boat to porpoise Shifting weight to front (bow): • Improves ease of planing • Improves rough water ride • At extremes, can cause the boat to veer back and forth (bow steer) Bottom Of Boat To maintain maximum speed, the boat bottom should be: •...

  • Page 52: Propeller Selection

    Frequently check engine oil level. Add oil as needed. It is normal for oil consumption to be high during the break‑in period. After the Break‑In Period To help extend the life of your Mercury MerCruiser power package, the following recommendations should be considered; •...

  • Page 53: End Of First Season Checkup

    Change the engine oil and oil filter. Refer to Engine Oil in the Maintenance section. End of First Season Checkup At the end of the first season of operation, contact an authorized Mercury MerCruiser dealer to discuss or perform scheduled maintenance items. If you are in an area where the product is operated continuously, year‑round, you should contact your dealer at the end of the first...
  • Page 54 Section 3 - On The Water Notes: Page 46 90-899883182 NOVEMBER 2007...

  • Page 55: Section 4 - Specifications

    Section 4 - Specifications Section 4 - Specifications Table of Contents Fuel Requirements..........48 Engine............50 Fuel Ratings ..........48 Sterndrives............50 Using Reformulated (Oxygenated) Gasoline Power-Assisted Steering and Power Trim Fluids (USA Only) ........... 48 ..............50 Gasoline Containing Alcohol ......48 Approved Power-Assisted Steering Engine Oil............

  • Page 56: Fuel Requirements

    Reformulated gasoline is required in certain areas of the USA and are acceptable for use in your Mercury MerCruiser engine. The two types of oxygenates used in these fuels are alcohol (ethanol) and ether (MTBE or ETBE). If ethanol is the oxygenate that is used in the gasoline in your area, refer to Gasoline Containing Alcohol.

  • Page 57: Engine Oil

    Catalysts damaged by lubricants containing high levels of phosphorus may not be covered by the MerCruiser Limited Warranty. If the Mercury Full Synthetic MerCruiser 20W‑40 oil is unavailable, you can use the following lubricants, listed in order of recommendation, for short periods of time: 1.

  • Page 58: Engine Specifications

    Spark plug gap 0.9 mm ± 0.1 mm (0.035 in. ± 0.004 in.) Fluid Specifications Engine IMPORTANT: All capacities are approximate fluid measures. Vazer 100 with Emissions Control Capacity Fluid Type Engine oil with filter 4 L (4.25 US qt) Mercury Full‑Synthetic MerCruiser 20W‑40...

  • Page 59: Approved Power Trim Fluids

    Section 4 - Specifications APPROVED POWER TRIM FLUIDS Description Part Number Power Trim and Steering Fluid 92‑858074K01 SAE Engine Oil 10W‑30 Obtain locally SAE Engine Oil 10W‑40 Approved Paints Description Part Number Mercury Light Gray Primer 92‑802878 52 Mercury Phantom Black 92‑802878Q 1 90-899883182 NOVEMBER 2007 Page 51...
  • Page 60 Section 4 - Specifications Notes: Page 52 90-899883182 NOVEMBER 2007...
  • Page 61 Section 5 - Maintenance Section 5 - Maintenance Table of Contents Owner/Operator Responsibilities......54 Removal............74 Dealer Responsibilities........54 Installation.............76 Maintenance............54 Flushing the Power Package......77 Do It Yourself Maintenance Suggestions... 55 General Information........77 Inspection............55 Sterndrive Water Pickup.......78 Maintenance Schedule—Sterndrive Models..56 Flushing Attachments (Non-Running Flush) Routine Maintenance........56 ..............78...

  • Page 62: Owner/Operator Responsibilities

    • Ensure that the boat is properly equipped. • Prior to delivery, make certain that the Mercury MerCruiser power package and other equipment are in proper operating condition. • Make all necessary adjustments for maximum efficiency. •...

  • Page 63: Do It Yourself Maintenance Suggestions

    Power‑assisted steering fluid Do It Yourself Maintenance Suggestions Present day marine equipment, such as your Mercury MerCruiser power package, are highly technical pieces of machinery. Electronic ignition and special fuel delivery systems provide greater fuel economies, but also are more complex for the untrained mechanic.

  • Page 64: Maintenance Schedule-Sterndrive Models

    Section 5 - Maintenance If necessary, remove the engine cover during some maintenance inspections and procedures. To remove the engine cover: 26209 engine cover 1. Lift the port side of the engine cover and detach the from the port side mounts. 2.

  • Page 65: Scheduled Maintenance

    Section 5 - Maintenance Task Interval Maintenance to Be Performed • Check the engine oil level. (You can extend this interval based on experience with the product.) • Check the sterndrive gear lube level. Each day start • Check the trim pump oil level. •...

  • Page 66: Maintenance Log

    Section 5 - Maintenance Task Interval Maintenance to Be Performed • Check the engine mounts for tightness and torque if necessary. • Inspect the condition of the spark plugs, spark plug wires, and the distributor cap and rotor, if equipped. Replace as necessary. If the condition of these components is satisfactory at inspection, repeat inspection every 100 hours or once a year, whichever occurs first.
  • Page 67 Section 5 - Maintenance Date Maintenance Performed Engine Hours 90-899883182 NOVEMBER 2007 Page 59...

  • Page 68: Engine Oil

    Section 5 - Maintenance Engine Oil NOTICE Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law. Use caution not to spill oil, coolant, or other fluids into the environment when using or servicing your boat. Be aware of the local restrictions governing the disposal or recycling of waste, and contain and dispose of fluids as required.

  • Page 69: Changing Oil And Filter

    2. Add the specified engine oil to bring the level up to, but not over, the Maximum mark on the dipstick. Engine Model Capacity Fluid Type Vazer 100 with Emissions Mercury Full‑Synthetic MerCruiser 4.02 liters (4.25 U.S. Quart) Control 20W‑40 3.

  • Page 70: Engine Oil Drain Pump

    Section 5 - Maintenance 4. Pull tether through the bilge drain. 7284 Bilge drain plug Oil drain hose plug Tether Oil drain hose Clip Bilge drain flange 5. Place the oil drain hose in a suitable container. 6. Remove the drain plug from the oil drain hose. 7.

  • Page 71: Changing The Oil Filter

    Section 5 - Maintenance 6. Connect the oil removal pump onto the barb fitting attached to the oil drain hose. 26316 Typical oil pump Engine oil drain hose Adapter fitting Pump drain hose 7. Pump the oil into an appropriate container until the crankcase is empty. 8.

  • Page 72: Power-Assisted Steering Fluid

    Section 5 - Maintenance 3. Coat the sealing ring on the new filter with engine oil and install. 26262 Oil filter Sealing ring Tube Ref No. Description Where Used Part No. SAE Engine Oil 30W Oil filter sealing ring. Obtain Locally 4.

  • Page 73: Filling

    Warm range Cold range 3. Fill with specified fluid as necessary. See Filling. IMPORTANT: If fluid is not visible in pump, contact your authorized Mercury MerCruiser dealer. Filling 1. Remove the fill cap and dipstick and observe the fluid level.

  • Page 74: Filling

    2. Fill to the "MAX" line with the specified coolant. Tube Ref No. Description Where Used Part No. Extended Life Antifreeze/ Closed Cooling System 92-877770K1 Coolant 3. Install the fill cap onto the coolant recovery bottle. Changing Contact your authorized Mercury MerCruiser dealer. Page 66 90-899883182 NOVEMBER 2007...

  • Page 75: Sterndrive Gear Lube

    IMPORTANT: If any water is visible at the bottom of the gear lube monitor or appears at the fill and drain plug hole, or if the gear lube appears discolored, contact your authorized Mercury MerCruiser dealer immediately. Both conditions may indicate a water leak in the sterndrive.
  • Page 76 Section 5 - Maintenance 2. Fill the monitor with the specified fluid so that the gear lube level is in the operating range. Do not overfill. 26280 Gear lube monitor Gear lube level at the "ADD" mark Gear lube monitor cap Gear lube level at the "OPERATING RANGE"...

  • Page 77: Changing

    Section 5 - Maintenance Changing 1. Remove the gear lube monitor from the bracket. 26288 Gear lube monitor Retaining strap 2. Empty the contents into a suitable container. 3. Install the gear lube monitor in the bracket. 4. Place the sterndrive in full trim limit up (out) position 5.
  • Page 78 IMPORTANT: If any water drained from the oil fill and drain hole, or if the gear lube appears milky, the sterndrive is leaking and should be checked immediately by your authorized Mercury MerCruiser dealer. 8. Lower the sterndrive so that the propeller shaft is level.

  • Page 79: Power Trim Fluid

    Section 5 - Maintenance 13. Ensure that the rubber gasket is inside the gear lube monitor cap and install the cap. Do not overtighten. 26217 Gear lube monitor cap NOTE: Oil capacity includes gear lube monitor. Model Capacity Fluid Type Vazer Drive 1892 ml (64 oz) High Performance Gear Lubricant...

  • Page 80: Filling

    Power Trim and Steering Fluid Power trim pump 92-858074K01 3. Install the fill cap. Changing Power trim fluid does not require changing unless it becomes contaminated with water or debris. Contact your authorized Mercury MerCruiser dealer. Page 72 90-899883182 NOVEMBER 2007...

  • Page 81: Flame Arrestor And Pcv Valve

    Section 5 - Maintenance Flame Arrestor and PCV Valve Cleaning the Flame Arrestor WARNING Fuel is flammable and explosive. Ensure the key switch is off and the lanyard is positioned so that the engine cannot start. Do not smoke or allow sources of spark or open flame in the area while servicing.

  • Page 82: Positive Crankcase Ventilation Valve (Pcv)

    Section 5 - Maintenance Positive Crankcase Ventilation Valve (PCV) CHANGING NOTE: On Vazer 100 models, the PCV valve is non‑serviceable and is an internal component of the vacuum hose assembly. Fuel Filters WARNING Fuel is flammable and explosive. Ensure the key switch is off and the lanyard is positioned so that the engine cannot start.
  • Page 83 Section 5 - Maintenance 5. Disconnect and plug the fuel line from the inlet fitting on the pre‑engine fuel filter. 6. Remove the pre‑engine fuel filter from the fuel boost pump. 26260 Fuel boost pump Wrench Pre‑engine fuel filter IMPORTANT: Do not discard the fuel inlet fitting unless it is to be replaced. 7.

  • Page 84: Installation

    Section 5 - Maintenance Installation 1. Lubricate the sealing ring of the new water‑separating fuel filter. 26262 Water‑separating fuel filter Sealing ring Tube Ref No. Description Where Used Part No. Water-separating fuel filter SAE Engine Oil 30W Obtain Locally sealing ring 2.

  • Page 85: Flushing The Power Package

    9. Start the engine. Check for gasoline leaks around the fuel filter assemblies. If leaks exist, stop the engine immediately. Recheck the filter installation, clean spilled fuel and properly ventilate the engine compartment. If leaks continue, stop engine immediately and contact your authorized Mercury MerCruiser dealer. Flushing the Power Package General Information IMPORTANT: Flushing the power package is most effective when performed with the boat and sterndrive out of the water.

  • Page 86: Sterndrive Water Pickup

    Section 5 - Maintenance Sterndrive Water Pickup Mercury MerCruiser Vazer sterndrives only have side water pickups available. Side pickups require the flushing attachment (44357Q 2). 26220 Vazer sterndrive side water pickup Flushing Attachments (Non‑Running Flush) Quick Connect Flushing Attachment Contained in parts bag Connects to the attachment mounted on the engine.

  • Page 87: Flushing Attachments (Running Flush)

    Section 5 - Maintenance NOTE: This flushing procedure can be performed with the boat in or out of the water and provides flush water to all seawater passages located in the engine, sterndrive, and transom. 1. Lower the sterndrive to the full down (in) position. 2.

  • Page 88: Vazer Sterndrive Connection

    Section 5 - Maintenance Vazer Sterndrive Connection WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. Place a block of wood between the propeller blade and the anti‑ventilation plate.

  • Page 89: Lubrication

    Section 5 - Maintenance 5. Depress the throttle‑only button and slowly advance the throttle until the engine reaches 1300 RPM (± 100 RPM). 6. Observe the water temperature gauge to ensure that the engine is operating in the normal range. 7.
  • Page 90 3. Lubricate the steering pin. 26289 Steering pin Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Steering pin 92‑883725K01 Oil SAE25W‑40 4. On dual engine boats: Lubricate the tie bar pivot points. Tube Ref. No. Description Where Used Part No.

  • Page 91: Throttle Cable

    Pivot points Guide contact surface Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Throttle cable pivot points & 92‑883725K01 Oil SAE25W‑40 guide contact surfaces Shift Cable 1. Lubricate the pivot points and the guide contact surfaces.

  • Page 92: Sterndrive U-Joint Shaft Splines And O-Rings (Sterndrive Removed)

    Engine Coupler Spline Grease Coupler 92-802869A1 NOTE: Your Vazer 100 power package is equipped with a sealed engine coupler and Perm‑a‑Lube U‑joints. The sealed coupler and shaft splines can be lubricated without removing the sterndrive. The Perm‑a‑Lube U‑joints do not require lubrication.

  • Page 93: Propellers

    Section 5 - Maintenance Propellers Propeller Repair Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. Vazer Propeller Removal WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting.

  • Page 94: Vazer Propeller Installation

    Section 5 - Maintenance 4. Slide the propeller and attaching hardware from the propeller shaft. 6215 Propeller shaft Drive sleeve Thrust hub Locking tab washer Flo‑Torq II drive hub Propeller nut Propeller Vazer Propeller Installation NOTICE Operating the engine with a loose propeller can damage the propeller, the drive, or drive components.
  • Page 95 Section 5 - Maintenance 2. Install the propeller with the attaching hardware as shown. 6215 Propeller shaft Drive sleeve Thrust hub Locking tab washer Flo‑Torq II drive hub Propeller nut Propeller 3. Install and torque the propeller nut. 4826 Wood block Propeller nut under socket Propeller NOTE: The propeller torque stated is a minimum torque value.

  • Page 96: Corrosion Protection

    Refer to the Marine Corrosion Protection Guide. Mercury MerCruiser power packages are equipped with anodes to help protect them from galvanic corrosion under moderate conditions. However, for severe conditions (i.e. when using a stainless steel propeller, docking/mooring in areas with rapid water flow, etc.),...

  • Page 97: Vazer Sterndrive Corrosion Protection Components

    Section 5 - Maintenance Vazer Sterndrive Corrosion Protection Components To help control the effects of galvanic corrosion, Mercury MerCruiser sterndrives come with several sacrificial anodes and other corrosion protection devices. For a more comprehensive explanation of corrosion and corrosion protection refer to the Marine Corrosion Protection Guide.

  • Page 98: November

    Section 5 - Maintenance Description Location Figure Mounted on the front on each of the trim Front trim cylinder anodes cylinders. 26226 Mounted on the rear on each of the trim Rear trim cylinder anodes cylinders. 26227 Mounted on the underside of the lower Gearcase anodic plate gearcase.

  • Page 99: Mercathode Kit (If Equipped)

    MerCathode reference electrode The system should be tested to ensure adequate output. The test should be performed where the boat is moored using a Quicksilver Reference Electrode and Test Meter. Contact your authorized Mercury MerCruiser dealer. 90-899883182 NOVEMBER 2007 Page 91...

  • Page 100: Painting Your Power Package

    • Avoid any electrical interconnection between the paint and the Mercury MerCruiser product, anodic blocks, or MerCathode system by allowing a minimum of 40 mm (1‑1/2 in.) unpainted area on the transom of the boat around these items. 26265...

  • Page 101: Checking

    Section 5 - Maintenance NOTE: Image shown with front mount removed for clarity only. 26263 Belt routing Alternator pulley Crankshaft pulley Idler Power steering pump pulley Automatic tensioner Serpentine belt Checking 1. Inspect the drive belt for proper tension and for the following: •...

  • Page 102: Battery

    Section 5 - Maintenance See your authorized MerCruiser dealer for service if these conditions exist. CAUTION Rapid release of the belt tensioner, or allowing the tensioner to snap back quickly, could cause injury or product damage. Relieve the spring tension slowly.

  • Page 103: Supplying Cooling Water To The Engine

    Section 5 - Maintenance Supplying Cooling Water to the Engine NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation. Certain maintenance procedures require you to operate the engine.

  • Page 104: Supplying Cooling Water To The Engine (Boat In The Water)

    Section 5 - Maintenance Supplying Cooling Water to the Engine (Boat in the Water) NOTE: When operating the engine with the boat in the water, no external source of water is needed. 1. Place the sterndrive in the full down (in) position. 2.

  • Page 105: Section 6 - Storage

    Table of Contents Cold Weather (Freezing Temperature) Engine and Fuel System Preparation....99 Extended Storage..........98 Battery Storage..........100 Draining the Vazer 100 Seawater System..98 Power Package Recommissioning....100 Preparing the Power Package for Extended Storage............98 90-899883182 NOVEMBER 2007 Page 97...

  • Page 106: Cold Weather (Freezing Temperature) And Extended Storage

    Seawater System and drain the seawater section of the cooling system. Draining the Vazer 100 Seawater System The Vazer 100 has a self draining seawater system. Removing the boat from the water and placing the sterndrive in the full down (in) position will allow the self draining system to drain all seawater from the engine and the sterndrive.

  • Page 107: Engine And Fuel System Preparation

    Section 6 - Storage 8. Store the battery according to the manufacturer's instructions. Engine and Fuel System Preparation WARNING Fuel is flammable and explosive. Ensure the key switch is off and the lanyard is positioned so that the engine cannot start. Do not smoke or allow sources of spark or open flame in the area while servicing.

  • Page 108: Battery Storage

    Section 6 - Storage 8. Allow the engine to cool down. 9. Replace the water separating fuel filter element. Refer to Section 5. 10. Disconnect the remote fuel tank and reconnect the fuel line to the fuel inlet fitting. Battery Storage Whenever the battery will be stored for an extended period of time, be sure the cells are full of water and the battery is fully charged and in good operating condition.

  • Page 109: Section 7 - Troubleshooting

    Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Diagnosing EFI Problems......... 102 Low Engine Oil Pressure......104 Engine Guardian System........102 Battery Will Not Come Up On Charge..104 Troubleshooting Charts........102 Remote Control Operates Hard, Binds, Has Starter Motor Will Not Crank Engine, Or Cranks Excessive Free-play or Makes Unusual Sounds Slow............102...

  • Page 110: Diagnosing Efi Problems

    Section 7 - Troubleshooting Diagnosing EFI Problems Your authorized Mercury MerCruiser dealer has the proper service tools for diagnosing problems on Electronic Fuel Injection (EFI) Systems. The Electronic Control Module (ECM) on these engines has the ability to detect some problems with the system when they occur, and store a Trouble Code in the ECM's memory.

  • Page 111: Engine Runs Rough, Misses And/Or Backfires

    Boat bottom fouled or damaged. Clean or repair as necessary. Ignition problem. See Engine Runs Rough, Misses or Backfires. Engine overheating. See Excessive Engine Temperature. Have EFI System checked by an authorized Mercury MerCruiser EFI System fault dealer. Excessive Engine Temperature Possible Cause Remedy Water inlet or seacock closed.

  • Page 112: Low Engine Oil Pressure

    Loose or missing shift and throttle linkages. see authorized Mercury MerCruiser dealer immediately. Straighten cable or have authorized Mercury Shift or throttle cable kinked. MerCruiser dealer replace cable if damaged beyond repair. Steering Wheel Turns Hard Or Jerky Possible Cause Remedy Low power steering pump fluid level.

  • Page 113: Power Trim Does Not Operate (Motor Operates But Sterndrive Unit Does Not Move)

    Section 7 - Troubleshooting Power Trim Does Not Operate (Motor Operates But Sterndrive Unit Does Not Move) Possible Cause Remedy Trim pump oil level low. Fill pump with oil. Drive unit binding in gimbal ring. Check for obstruction. 90-899883182 NOVEMBER 2007 Page 105...
  • Page 114 Section 7 - Troubleshooting Notes: Page 106 90-899883182 NOVEMBER 2007...
  • Page 115 Section 8 - Customer Assistance Information Section 8 - Customer Assistance Information Table of Contents Owner Service Assistance........ 108 Parts And Accessories Inquiries ..109 Local Repair Service ........108 Resolving A Problem ........109 Service Away From Home ......108 Mercury Marine Service Offices ....

  • Page 116: Section 8 - Customer Assistance Information

    These are but a few of the many special modifications that are required in Mercury MerCruiser marine engines to provide long life and dependable performance. 1. Quicksilver parts and accessories are engineered and built by Mercury Marine, specifically for Mercury MerCruiser sterndrives and inboards.

  • Page 117: Parts And Accessories Inquiries

    Resolving A Problem Satisfaction with your Mercury MerCruiser product is very important to your dealer and to us. If you ever have a problem, question or concern about your power package, contact your dealer or any authorized Mercury MerCruiser dealership. If additional assistance is required, take these steps: 1.

  • Page 118: Ordering Literature

    • Year built United States and Canada For information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature contact your nearest dealer or contact Mercury Marine Publications P.O. Box 1939...

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