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Mercury 100 & 300 Hour Outboard Service Kits FAQs
Use a filter wrench to loosen the existing filter element and use caution when removing it as it will be filled with gasoline. A clear plastic or glass container is helpful to dump the filter and examine the contents. A small amount of debris is common, as is a small amount of water after the fuel has had a moment to settle. More significant amounts of water would warrant further investigation.
Move back to the engine and locate the filter element(s) on the engine. The scope of this service will only include the low-pressure fuel filter and fuel water separator if applicable by model. Mercury recommends that owners do not service their high-pressure fuel filters. Depending on your engine model, the water separator filter (or castle filter) may be removed by using a wrench, standard tools, and a little caution. Unplug the water-in-fuel sensor if applicable and spin the cap off of the housing. Replace the filter element with a fresh one, lube the o-ring with grease or oil, and carefully reinstall the cap.
Locate your Mercury engine’s primer bulb if applicable and use the primer to pump up the fuel system. You should feel and hear gasoline entering and filling the filter cup. Check for leaks and prime until the bulb becomes firm.
If you are not already regularly running Mercury Quickare and/or Quickleen through your Mercury fuel system, the 100-hour service interval is an excellent time for a “shock treatment.” Quickare is a fuel system cleaner and top-lube that will help to clean deposits from the tank, lines, carburetors, injectors, and pumps. It breaks up fuel system varnish and will help to prevent gumming.
Quickleen is a fuel system conditioner that also helps to remove carbon deposits. The standard dose is one ounce per ten gallons, but if you are not running the product regularly, you can double that ratio for more cleaning power. Pour the products into the fuel tank fill and run the boat. No additional work is needed. It is a great idea to inspect your fuel tank fill’s o-ring for damage when you add fuel or additives as a damaged o-ring can allow water from rain or boat washing into your fuel system.
Engine oil selection is critical to long life, so review the information in your owner’s manual to make certain you are using the correct products. Not all TCW3 oils are formulated the same, and different Mercury models do prefer specific oils. Mercury Marine offers a wide assortment of engine oil – both in blend and additives. If you are uncertain exactly which oil is best for your application, consult your owner’s manual.
If you do locate contamination in the oil tank, use a vacuum extractor to pull the remaining oil out of the tank for proper disposal. While good quality two-stroke oil is certainly expensive, running contaminated oil can lead to catastrophic failure. If you have never cleaned the bottom of your tank, prepare to be surprised by what you find.
Several laboratories provide performance testing of used oils, allowing you to learn more about the health of your engine. Blackstone Labs is one such provider, and they have a convenient mail-in kit that includes everything you need to submit an oil sample. They can also test gear oils, hydraulic fluids, and oils from your other vehicles or toys.
As the old oil is draining, you can work on removing the engine oil filter. Depending on your specific Mercury model, your filter may have a drain lip that helps to keep the mess to a minimum when you unscrew the old filter. However, most older engines do not have this feature. We suggest being prepared with plenty of absorbent rags or placing a small cup that is cut to size below the filter before removal. Using a PartsVu Maintenance Essentials filter wrench is the best way to loosen the filter. Remember when you reinstall the filter, over-tightening will only make your life more difficult when you are ready for the next service. Some technicians puncture the old filter allowing trapped oil to drain back into the block before removal, but this will ruin your ability to take the filter apart for further inspection.
Several laboratories provide performance testing of used oils, allowing you to learn more about the health of your engine. Blackstone Labs is one such provider, and they have a convenient mail-in kit that includes everything you need to submit an oil sample. They can also test gear oils, hydraulic fluids, and oils from your other vehicles or toys. Oil test results can tip you off to an accelerated wear condition inside of your engine long before any other symptoms show up. If you still want to know more about your engine, purchase an oil filter cutter and open the spent filter to look for evidence of contamination and metal dust or shavings.
Once you have inspected your spent oil and filter, set them aside for proper disposal. If you removed the drain screw to empty your oil, carefully reinstall the drain plug. The new oil filter should be removed from its package and the o-ring lubricated with a thin coat of fresh engine oil. Spin on the new oil filter and gently tighten to seat the o-ring without over-torquing.
Mercury Marine offers a wide assortment of engine oil – both in blend and viscosity. If you are uncertain as to which oil is best for your application, consult your owners’ manual. Loosen the yellow oil fill plug on the top of the engine and pour in fresh oil. We recommend adding slightly less than the stated capacity. With the engine trimmed down, check the oil level on the dipstick after allowing a few minutes for the oil to drain into the oil pan properly. Filling the oil to the lower level on the dipstick will help you to measure if the oil level changes over time with the engine in operation.
Note that fittings can be contaminated by salt – especially the ones near the steering tube – so replace them if they are too corroded to accept grease. Watch as you pump fresh grease into the fitting and see if old, dirty grease or water or both push out from the corresponding space. Ideally, these cavities are filled with clean grease all the time. A light coating of grease on the tip of the trim rams will reduce friction there as well. If your engine is equipped with stainless balls on the tips of the trim rams, work the balls to get the grease inside their cup.
If your prop was not removed for the gear lube change, remove the cotter pin or lock washer from the propeller and loosen the prop nut. Exercise extreme caution as prop blades can be very sharp. With the nut loosened, remove the propeller and associated prop hardware to inspect the propeller shaft.
Look for fishing line that may be behind the prop and near the prop shaft oil seals. Remove any line and if the seals are intact, apply a fresh coating of Mercury 2-4-C grease to the propeller shaft before reinstalling the prop. Tighten and use a new cotter pin to complete the installation if applicable.
