Service Checklist
Mercury
For our first time customers or customers who are at their first 100hr service. This first part of the list applies to you. We perform these items as Mercury does not themselves but recommend it to prevent bolt failure and corrosion. The items below are performed every 100 or 300 hour service interval depending their label. Depending if you have an L6, V8,V10, or V12 some steps may vary.
First 100 HR Service:
Grease all side chap bolts (wire wheel all corrosion off bolts before greasing)
Grease pop-it valve bolts, torque to 44 inch/lbs. (one bolt at a time)
Grease upper chap bolts
Grease front chap plate bolts
Grease lower cowl cable bolts and cable
Grease upper cowl cables
Anti-seize spark plugs, torque to 20 ft/lbs.
Seal pencil coils, torque to 70 inch/lbs.
Disassemble, clean, and re-grease air cooler
Re-route wiring and hoses from rig tube to prevent chaffing
Every 100 HR Service:
Wash interior of upper and lower cowlings
Drain lower units, pressure test to 15 psi
Lower unit drain plug seals, torque to 60 inch/lbs.
Remove prop hub, check for ware and tare. Re-grease and
torque prop hub to 55 ft/lbs.
Drain engine oil, including a second drain. Drain plug seal,
torque to 88 inch/lbs.
Clean all anodes, grease bolts
Grease trim ram and trim tab seals
Replace inline fuel filter
Remove #6/#8/#10 (depending design) coil, check spark plugs for fouling and anti-seize torque to 20 ft/lbs.
Torque coils to 70 inch/lbs.
Remove thermostats, clean housing, copper, and pin. Grease O-ring and pin, torque to 70 inch/lbs.
Check Belts
Check tensioner pulleys
Check supercharger for play, or resistance
Replace engine oil filter, check for double gasket. Clean and lightly grease seal surface
Check isolator clamp, replace if not updated stainless
Grease lower cowl cables, check for correct adjustment
Check steering ram lock tabs
Check steering lines for dry-rot, check fittings for cracks and tightness, split loom and secure if not already done
Replacing Fuel/water separators
Clean and grease gas fill O-rings, check for cracking in the O-ring
Check bilge pump float switches
Clean motors, compress air dry. Spray motor and flywheel with corrosion guard
Run motors, check for leaks and codes. Check water pressure and voltage
Wash deck of boat, transom, and motors
Every 300 HR Service:
The 300 hr service will always include everything from the 100 hr service in addition:
Water pump kit, check for any objects in water intake, and proper installation of pump fins
Replace pop-it valves, torque to 44 inch/lbs.
Replace sparkplugs, anti-seize, and torque to 20 ft/lbs.
Replace prop nuts, torque to 55 ft/lbs.
Yamaha
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Mercury
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Suzuki
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Yamaha • Mercury • Suzuki •
Yamaha
Every 100 HR Service:
Clean interior of upper cowling
Drain lower units, pressure test to 10 psi. Check for any air leaks at prop shaft and drive shaft seals
Fill lower unit with HD Yamalube, make sure motor is level for correct fill
Lower unit drain plug seals, torque to 60 inch/lbs
Remove prop, check for worn hub, torque prop to spec
Drain engine oil, including a second drain. Drain plug seal if applicable
Remove and clean all external anodes, replace if heavily corroded, grease bolts.
Remove all internal zincs from motors. Clean housing of corrosion, clean anodes and grease bushing. Re-install and torque to 140 inch/lb
Grease primary and secondary trim ram and trim tab weather seals. Grease all zerk fittings with Yamaha grease. Thoroughly clean all extra grease that comes out
Grease throttle/shift cables if applicable. Grease shift actuator assembly is applicable
Replace inline fuel filter if applicable
Replace inline fuel filter o-ring.
Remove #6 or #8 coil, check spark plugs for fouling, uneven burn, or worn electrode. Anti-seize and torque to 18 ft/lbs
Torque coils to 70 inch/lbs
Remove thermostats, clean housing, copper, and pin. Checkfor operational heat sync, torque to 70 inch/lbs
Check Belts for dry-rot, stretch, or missing chunks.
Replace engine oil filter, check for double gasket. Clean and
lightly grease seal surface.
Fill engine with Yamalube engine oil
Check steering ram lock tabs
Check steering lines for dry-rot, check fittings for cracks and
tightness, split loom and secure if not already done
Replace fuel/water separators, boat side. Make note of any debris or water in the fuel
Clean and grease gas fill O-rings, check for cracking in the O-ring to prevent water from entering gas tanks
Check bilge pump float switches to ensure they work properly
Clean throttle body screen from crank case oil blow by
Clean motors, compress air dry. Spray motor and flywheel with
corrosion guard. Make sure lower cowl drains are free and
clear of debris
Run motors, check for leaks and codes. Check water pressure,
and voltage
Wash deck of boat, transom, and motors free of any foot or
hand prints and grease.
Every 300 HR Service:
The 300 hr service will always include everything from the 100 hr service in addition:
Water pump kit, check for any objects in water intake, and
proper installation of pump fins. Clean all mating surfaces of
old gasket material. Grease bolts and torque
Replace sparkplugs, anti-seize, and torque to 18 ft/lbs
Torque coils to 70 inch/lbs
Replace prop nut cotter pins, torque to spec
Suzuki
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Yamaha
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Mercury
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Suzuki • Yamaha • Mercury •
Suzuki
Every 100 HR Service:
Clean Interior of upper cowling
Drain lower units, pressure test to 10 psi. Check for any air leaks at prop shaft and drive shaft seals
Fill lower unit with OEM oil, make sure motor is level for correct fill
Lower unit drain plug seals, torque to 60 inch/lbs
Remove prop, check for worn hub, torque prop to spec
Remove lower unit and grease driveshaft splines
Drain engine oil, including a second drain. Drain plug seal if applicable
Remove and clean all external anodes, replace if heavily corroded, grease bolts
Remove all internal zincs from motors. Clean housing of corrosion, clean anodes and grease bushing. Re-install and torque to 140 inch/lb
Remove lower unit and grease driveshaft splines
Grease primary and secondary trim ram and trim tab weather seals
Grease all zerk fittings with grease. Thoroughly clean all extra grease that comes out
Grease throttle/shift cables if applicable. Grease shift actuator assembly is applicable
Replace inline fuel filter if applicable
Replace inline fuel filter o-ring
Remove #4 or #6, check spark plugs for fouling, uneven burn, or worn electrode. Anti-seize and torque to 18 ft/lbs
Torque coils to 70 inch/lbs
Remove thermostats, clean housing, copper, and pin. Check for operational heat sync, torque to 70 inch/lbs
Check Belts for dry-rot, stretch, or missing chunks
Replace engine oil filter, check for double gasket. Clean and lightly grease seal surface
Fill engine with OEM engine oil
Check steering ram lock tabs
Check steering lines for dry-rot, check fittings for cracks and tightness, split loom and secure if not already done
Replace fuel/water separators, boat side. Make note of any debris or water in fuel
Clean and grease gas fill O-rings, check for cracking in the O-ring to prevent water from entering gas tanks
Check bilge pump float switches to ensure they work properly
Clean throttle body screen from crank case oil blow by
Clean motors, compress air dry. Spray motor and flywheel with corrosion guard. Make sure lower cowl drains are free and clear of debris
Run motors, check for leaks and codes. Check water pressure, and voltage
Wash deck of boat, transom, and motors free of any foot or hand prints and grease
Every 300 HR Service:
The 300 hr service will always include everything from the 100 hr service in addition:
Water pump kit, check for any objects in water intake, and proper installation of pump fins. Clean all mating surfaces of old gasket material. Grease bolts and torque.
Replace sparkplugs, anti-seize, and torque to 18 ft/lbs
Torque coils to 70 inch/lbs
Replace prop nut cotter pins, torque to spec