Mercury 100 FourStroke Manuals

Manuals and User Guides for Mercury 100 FourStroke. We have 6 Mercury 100 FourStroke manuals available for free PDF download: Service Manual, Operation Maintenance Installation Warranty Manual, Operation, Maintenance And Installation Manual, Operation And Maintenance Manual, Manual, Owner's Manual

Mercury 100 FourStroke Service Manual

Mercury 100 FourStroke Service Manual (574 pages)

Brand: Mercury | Category: Outboard Motor | Size: 15 MB

Table of Contents

Important 1 C

14
- Propeller Information
  3
- How to Use this Manual
  3
- Table of Contents
  14
- Serial Number Location
  15
- Conditions Affecting Performance
  15
- Weather
  15
- Boat
  16
- Engine
  16
- Fresh Water Submersion
  17
- Following Complete Submersion
  17
- Salt Water Submersion
  17
- Submerged While Running
  17
- Propeller Selection
  18
- Propeller Installation
  18
- Power Trim System
  19
- General Information
  19
- Power Trim Operation
  19
- Trim "In" Angle Adjustment
  20
- Compression Check
  20
- Painting Procedures
  21
- Cleaning & Painting Aluminum Propellers & Gear Housings
  21
- Decal Application
  22
- Decal Removal
  22
- Instructions for "Wet" Application
  22
Important 1 D

24
Electrical 2

38
Electrical 2

82
Electrical 2

109
- Special Tools
  110
- Specifications
  110
- Timing/Synchronizing/Adjusting (3 Cylinder Models)
  110
- Special Tools
  114
- Specifications
  114
- Throttle Cable Installation
  114
- Timing/Synchronizing/Adjusting (4 Cylinder Models)
  114
- Idle Adjustment
  118
- Throttle Cable Installation
  118
Electrical 2

120
Fuel System

147
- Notes
  148
- Jet 75-90 (3 Cyl.)
  149
- Jet-100-115-125 (4 Cyl.)
  150
- Fuel Pump (65 Jet/75/90)
  151
- Fuel Pump (80 Jet/100/115/125)
  155
- Testing
  157
- Theory of Operation
  157
- Troubleshooting Fuel Pump
  157
- Check Valve Reassembly
  158
- Fuel Pump - Cleaning/Inspection
  158
- Removal
  158
- Reassembly
  159
- Installation of Fuel Pump
  160
Fuel System

162
- Specifications
  163
- WME Carburetor Chart
  163
- Special Tools
  165
- Carburetor (WME-29/30/31/41/46/47/48/49)
  166
- Carburetor-WME-32/32A/33/34/40/40A
  172
- Carburetor-WME-50/51/52/79/80/81
  174
- Fuel System (Linkage)
  178
- Adjustments
  179
- Float Adjustment
  179
- Idle Mixture Screw Adjustment
  179
- Idle Speed Adjustment
  179
- Jet Orifice Size Chart
  180
- Main (High Speed) Jet Adjustment
  180
- High Altitude Jet Chart
  181
- Fuel System Troubleshooting
  182
- General Information
  182
- Problem: Engine Floods
  182
- Problem: Engine Runs too Rich
  182
- Problem: Fuel Blow Back out of Carburetor
  182
- Problem: Rough Idle
  182
- Problem: Engine Turns over but will Not Start or Starts Hard When Cold
  183
- Problem: Unable to Reduce Engine RPM to Slow Idle
  183
- Engine Idles Rough and Stalls -Engine Runs Uneven or Surges -Engine will Not Accelerate
  184
- Problem: Engine Runs too Lean
  184
- Problems
  184
- Inspection
  185
- Description for Four Cylinder Engines
  186
- Description for Three Cylinder Engines
  186
- Enrichener System
  186
- Enrichener Valve Hose Installation - Four Cylinder Engines
  186
- Enrichener Valve Hose Installation - Three Cylinder Engines
  186
- Acceleration Pump Circuit Operation - Four Cylinder Engines
  188
- Four Cylinder Engines
  188
Fuel System

191
- Notes
  192
- Oil Injection Components
  193
- Oil Injection Components (S/N-USA-0G301751/BEL-9885505
  193
- Description
  197
- Hose Connections
  197
- Oil Pump Drive System
  197
- And 4 Cylinder Oil Flow Diagram
  198
- Carburetor/Oil Pump Synchronization
  199
- Filling Oil Tank
  199
- Bleeding Air from Oil Injection System
  200
- Bleeding Air from Oil Pump Inlet Hose
  200
- Bleeding Air from Oil Pump Outlet Hose
  200
- Oil Pump Test
  200
- Low Oil Sensor Test
  201
- Warning Horn System
  201
- (Models with Warning Module)
  202
- Oil Injection System Troubleshooting Chart
  202
- Troubleshooting Chart
  202
- Troubleshooting the Oil Injection System
  202
Table of Contents

204
- Carbon Monoxide - CO
  205
- Controlling Emissions
  205
- Exhaust Emissions Standards
  205
- Hydrocarbons - HC
  205
- Oxides of Nitrogen - Nox
  205
- Stoichiometric (14.7:1) Air/Fuel Ratio
  205
- What Are Emissions
  205
- Outboard Hydrocarbon Emissions Reductions
  206
- Homogenized Charge
  207
- Stratified Charge
  207
- Stratified Vs Homogenized Charge
  207
- Dealer Responsibility
  208
- Emissions Information
  208
- EPA Emission Regulations
  208
- Manufacturer's Responsibility
  208
- Owner Responsibility
  208
- Decal Location for 1998 Models
  210
Powerhead

212
- Specifications
  213
- General Information
  214
- Tools for Powerhead Repair
  214
- Notes
  215
- Crankshaft, Pistons and Connecting Rods (3 Cyl.)
  216
- Cylinder Block (3 Cyl.) (USA-0G127499/BEL-9836632 & BELOW)
  218
- Cylinder Block (3 Cyl.) (USA-0G127500/BEL-9836633 & UP)
  222
- Induction Manifold and Reed Block (3 Cyl.)
  226
- Crankshaft, Pistons and Connecting Rods (4 Cyl.)
  228
- Cylinder Block and Crankcase (80 Jet/100/115/125)
  230
- Induction Manifold and Reed Block (80 Jet/100/115/125)
  234
- Throttle Lever and Linkage (65 Jet/75/90 Models)
  236
- Throttle Lever (Models 80Jet/100/115/125)
  238
- Powerhead Removal
  241
- Flywheel Removal
  246
- Powerhead Disassembly
  247
- Cleaning and Inspection
  252
- Cylinder Block and Crankcase Cover
  252
- Check Valves
  254
- Piston and Piston Rings
  254
- Connecting Rods
  256
- Crankshaft
  256
- Cylinder Cover, Exhaust Divider Plate and Exhaust Cover
  257
- Thermostat
  257
- Reed Blocks
  258
- Temperature Switch Test
  258
- General Information
  259
- Powerhead Reassembly and Installation
  259
- Assembling Rod to Piston
  260
- End Cap
  260
- Piston Ring Installation
  261
- Crankshaft Installation
  263
- Connecting Rod Cap Alignment
  266
- Crankcase Cover to Block
  267
- Cylinder Block Cover
  268
- Exhaust Plate Cover and Exhaust Divider Plate
  269
- Intake Manifold and Reed Block Installation
  271
- Accelerator Pump Installation (4 Cylinder Models)
  272
- Cylinder Bleed Hose Routing
  273
- Cylinder Bleed Hose Routing (1995 and Prior)
  274
- Cylinder Bleed Hose Routing (1996 and Newer)
  275
- Cylinder Fuel Enrichment/Accelerator Pump Hose Routing
  276
- And Newer 3 Cylinder Harness Routing (Without Oil Reservoir Installed)
  277
- And Newer 3 Cylinder Harness Routing (with Oil Reservoir Installed)
  278
- Cylinder Manual Start Harness Routing
  279
- And Newer 4 Cylinder Harness Routing
  281
- And Newer 4 Cylinder Harness Routing (with Oil Reservoir Installed)
  281
- Ignition Plate Installation
  282
- Trigger and Stator Installation
  283
- Stator Installation
  284
- Carburetor Installation
  286
- Temperature Sensor Installation
  286
- Flywheel Installation
  288
- Oil Reservoir Installation
  288
- Air Box Installation
  289
- Powerhead to Driveshaft Housing
  290
- Reinstall Bottom Cowl
  291
MID-Section

293
MID-Section

318
- Special Tools
  319
- Power Trim Components (Black Fill Plug) (S/N-USA-0G360002/BEL-9934136 & BELOW)
  320
- Description
  322
- Power Trim - General Information
  322
- Trailering Outboard
  322
- Trimming Characteristics
  322
- Tilting Outboard up and down Manually
  323
- Trim "In" Angle Adjustment
  323
- Determining if Problem Is Electrical or Hydraulic 5B-6
  324
- Problem Chart
  324
- Troubleshooting
  324
- Date Code Location
  325
- Hydraulic System Troubleshooting
  325
- Leak down Check - Pump and Manifold Assembly
  326
- Preliminary Checks
  326
- Reassembly
  327
- Power Trim Partial Leak down at Maximum Trim
  328
- Leak down Check - Manual Release Valve
  329
- Leak down Check - Pilot Valve Assembly
  329
- Leaks Past Ball and Seat - Piston Assembly
  329
- Power Trim Rocker Arm
  330
- Troubleshooting Flow Diagram
  331
- Troubleshooting Flow Diagram
  332
- COMMANDER 2000 Side Mount Remote Control (Power Trim/Tilt Electric Start with Warning Horn) Wiring Diagram
  333
- Electrical System Troubleshooting
  333
- Power Trim System Wiring Diagram
  334
- Troubleshooting the "Down" Circuit
  335
- Troubleshooting the "Up" Circuit
  335
- Troubleshooting the "Down" and "Up" Circuits* (All Circuits Inoperative)
  336
- Power Trim System Removal
  337
- Power Trim System Disassembly
  342
- Trim Rod Removal
  342
- Trim Rod Disassembly
  343
- Trim Motor Removal
  344
- Reservoir Assembly Removal
  345
- Trim Motor Disassembly
  345
- Manifold Removal
  346
- Motor and Electrical Tests/Repair
  347
- Solenoid Test
  347
- Trim Pump Motor Test
  347
- Armature Tests
  348
- Motor Disassembly
  348
- Motor Repair
  349
- Manifold Installation
  351
- Power Trim System Reassembly
  351
- Reassembly
  351
- Reservoir Installation
  352
- Motor Installation
  353
- Trim Rod Reassembly
  354
- Trim Rod Installation
  355
- Power Trim Unit Installation
  356
- Purging Power Trim Unit
  356

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Mercury 100 FourStroke Operation And Maintenance Manual

Mercury 100 FourStroke Operation And Maintenance Manual (93 pages)

Brand: Mercury | Category: Outboard Motor | Size: 1 MB

Table of Contents

Mercury 100 FourStroke Manual

Mercury 100 FourStroke Manual (89 pages)

Brand: Mercury | Category: Outboard Motor | Size: 1 MB

Table of Contents

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Mercury 100 FourStroke Operation Maintenance Installation Warranty Manual

Mercury 100 FourStroke Operation Maintenance Installation Warranty Manual (141 pages)

Brand: Mercury | Category: Outboard Motor | Size: 6 MB

Table of Contents

Mercury 100 FourStroke Operation, Maintenance And Installation Manual

Mercury 100 FourStroke Operation, Maintenance And Installation Manual (129 pages)

Brand: Mercury | Category: Outboard Motor | Size: 6 MB

Table of Contents

Read this Manual Thoroughly
3
Safety Alerts
3
California Proposition
4
Warranty Message
4
Copyright and Trademark Information
5
Table of Contents
7
Important Safety Information
11
Boater's Responsibilities
11
Boat Horsepower Capacity
11
Exhaust Emissions
11
Outboard Mounting Notice
14
Outboard Remote Control Models
14
Remote Steering Notice
15
Lanyard Stop Switch
15
Staying Safe Around the Outboard
18
Safe Operating Practices
18
Impact with Underwater Hazards
24
General Information
27
Specifications 75-115 Fourstroke
27
Specifications 75-115 Seapro
28
Specifications 115 Pro XS
29
Lithium-Ion Cranking Battery Requirements
30
Component Identification
31
Propeller Selection
31
Recording Serial Number
32
Selecting Outboard Accessories
33
Outboard Installation
35
Important Installation Information
35
Mercury Marine Validated Outboard Mounting Hardware
35
Transom Fastening Hardware
36
Accessories Mounted to the Transom Clamp Bracket
36
Fuel System
39
Transom Cutout and Mounting Holes
40
Checking Boat Transom Construction
44
Installing the Outboard
44
Steering Link Rod Installation
49
Rigging the Engine
50
Battery Cable Connections
59
Trim in Pin
60
Transporting
63
Aquatic Invasive Species (AIS)
63
Trailering the Boat and Outboard
63
Fuel and Oil
65
Fuel Requirements
65
Fuel Additives
66
Fuel Demand Valve (FDV) Requirement
66
Fuel Tank
67
Low Permeation Fuel Hose Requirement
68
Quick-Disconnect Fuel Hose Fitting
69
Engine Oil Recommendations
70
Checking and Adding Engine Oil
70
Features and Controls
73
Remote Control Features
73
Warning System
73
Power Trim and Tilt
75
Trim Tab Adjustment
78
Operation
81
Engine Break-In Procedure
81
Important Daily Inspection before each Use
81
Prestarting Checklist
81
Starting the Engine
82
Gear Shifting
84
Stopping the Engine
85
Operating at High Elevations
85
Operating in Freezing Temperatures
85
Operating in Saltwater or Polluted Water
86
Operating in Shallow Water
86
Setting Trim Angle While Running Engine at Idle Speed
87
Fuel Supply Module Priming Procedure
87
Maintenance
91

Mercury 100 FourStroke Owner's Manual

Mercury 100 FourStroke Owner's Manual (87 pages)

4-Stroke

Brand: Mercury | Category: Outboard Motor | Size: 9 MB

Table of Contents

Declaration of Conformity
1
Table of Contents
3
Warranty Information
7
Transfer of Warranty
7
Warranty Registration United States and Canada
7
Warranty Registration Outside the United States and Canada
7
Fourstroke Outboard Limited Warranty United States, Canada and Europe
8
Fourstroke Outboard Limited Warranty
9
Year Limited Warranty against Corrosion
11
Warranty Coverage and Exclusions
12
General Information
14
Boater's Responsibilities
14
Before Operating Your Outboard
14
Boat Horsepower Capacity
14
High-Speed and High-Performance Boat Operation
15
Outboard Remote Control Models
15
Remote Steering Notice
15
Outboard Mounting Notice
16
Propeller Selection
16
Lanyard Stop Switch
17
Protecting People in the Water
18
Boats Having an Open Front Deck
19
Passenger Safety Message - Pontoon Boats and Deck Boats
19
Wave and Wake Jumping
19
Impact with Underwater Hazards
20
Exhaust Emissions
21
Be Alert to Carbon Monoxide Poisoning
21
Selecting Accessories for Your Outboard
22
Safe Boating Suggestions
22
Recording Serial Number
23
80/100/115 Specifications - International
23
Component Identification
25
Transporting
26
Trailering Boat/Outboard
26
Fuel and Oil
27
Fuel Recommendations
27
Filling Fuel Tank
28
Engine Oil Recommendations
28
Checking and Adding Engine Oil
28
Features and Controls
30
Remote Control Features
30
Warning System
30
Warning Horn Signals
30
Power Trim and Tilt
32
Power Trim Operation
33
Auxiliary Tilt Switch
35
Shallow Water Operation
35
Pre-Starting Check List
36
Operating in Freezing Temperatures
36
Operating in Salt Water or Polluted Water
36
Setting Trim Angle While Running Engine at Idle Speed
36
Engine Break-In Procedure
37
Starting the Engine - Remote Control Models
37
Warming up Engine
39
Gear Shifting
39
Stopping the Engine
39
Maintenance
41
Outboard Care
41
EPA Emissions
41
Owner Responsibility
41
Inspection and Maintenance Schedule
42
Flushing the Cooling System
43
Top Cowl Removal and Installation
43
Flywheel Cover Removal and Installation
44
Cleaning Care for Top and Bottom Cowls
45
Cleaning Care for the Powerhead (Saltwater Use)
45
Battery Inspection
46
Air Filter
46
Fuel System
47
High Pressure Fuel Filter
48
Corrosion Control Anode
50
Propeller Replacement
50
Spark Plug Inspection and Replacement
53
Fuse Replacement
54

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