Merc 100 hp 1991

TenE307

Petty Officer 2nd Class
Joined
Feb 18, 2003
Messages
193
I just bought a fixer uper winter project.<br />It is a 160 Sea Ray with the 100 hp motor.<br />I have manual and am cleaning it up before big test.<br /><br />Initial test: (on muffs)<br />Started with new gas in tank<br />tried to keep running at 2500 rpms. <br />bulb was getting soft squease=burst power<br />temp guage was not rising after about ten minutes of on and off running.<br />Ran compression test:<br />top #1 - 100<br /> 2 - 100<br /> 3 - 90<br /> 4 - 100<br />shot a little seafoam into #3 and ended at 95.<br />Are the seals cylinders and pistons ok.<br />Took apart carbs. Looked great.<br />on the bottom of carbs they say should go 1-4<br />mine goes 1-1-3-4. is that a prob. doesnt look like it has been worked on.<br />I also have a dark brown and white wire comming out of enguine, and i cant see it on the diagrams.<br />after i get it back together i will try to run it agian.<br />after i repalced water impeller, i do not get neutral or reverse anymore. its always spinning. could that effect my starting and idleing.<br />Oh yeah. i almost forgot.<br />to start the motor you have to have the mercury switch disconnected, and connect it to kill it. would that effect running also.<br />Sorry for the long post thanks for any help.
 

TenE307

Petty Officer 2nd Class
Joined
Feb 18, 2003
Messages
193
Re: Merc 100 hp 1991

is this a good boat since just started last year with first boat (from grandpa).<br />got hooked now my 01 yukon sits in the driveway and $1000 boat takes up garage.
 

The Marine Doctor

Commander
Joined
Jul 25, 2003
Messages
2,177
Re: Merc 100 hp 1991

Sounds like you definately have a winter project.<br /><br />Brown/white wire is for the T+T guage.<br /><br />When you pushed the drive back up into place you did not align the shifter properly. You will have to take it back down and reinstall it.<br /><br />If you squeezed the fuel bulb and got more power..you probebly need some carb work and definately need a fuel pump rebuild. <br /><br />The Mercury switch you are refering to..is it mounted on the engine?<br /><br />If the compression stays around the 100 psi...that is how your engine will run...I would not expect to get the full 100hp out of it.<br /><br />Do not be surprised if you have to idle it up a little high to keep it running at low speed.<br /><br />TMD
 

TenE307

Petty Officer 2nd Class
Joined
Feb 18, 2003
Messages
193
Re: Merc 100 hp 1991

yes the mercury switch is on the enguine.<br />i have to disconnect the black and yellow wire to run it,<br />and connect it to kill it.<br />in the diagram of selocs manula it says mercury switch is where the wire goes.
 

The Marine Doctor

Commander
Joined
Jul 25, 2003
Messages
2,177
Re: Merc 100 hp 1991

If the Mercury switch you are refering to is about 1 1/2 inches long and a cylinder. That is to stop the engine from starting in the full tilt position. Your ign switch might need to be replaced if you cannot turn the engine off from the front.<br /><br />TMD
 

TenE307

Petty Officer 2nd Class
Joined
Feb 18, 2003
Messages
193
Re: Merc 100 hp 1991

i just tried to fix shifting prob.<br />took lower unit off and it seems the propeller<br />turns forward no matter what position the shifter is rotated.
 

The Marine Doctor

Commander
Joined
Jul 25, 2003
Messages
2,177
Re: Merc 100 hp 1991

If you had all 3 positions prior to removing the gearcase..then you must still have all 3.<br /><br />Did you turn the shifter rod with pliars or with your fingers. It should click into place.<br /><br />TMD
 

TenE307

Petty Officer 2nd Class
Joined
Feb 18, 2003
Messages
193
Re: Merc 100 hp 1991

in the manual it says to turn propeller one way in forard and the other way in reverse with both directions freely in neutral.<br />i only get the propeller moving easily in in one direction.<br />when i turn the driveshaft in neutral with my hand is there suppsed to be no turning of the propeller.<br />i turned shifter with my hands. off of motor.
 
Joined
Aug 10, 2003
Messages
9
Re: Merc 100 hp 1991

The 160 Seville is a terrific boat - the most beautiful wake for waterskiing - not so good for wakeboarding - it always climbs up on a plane eventually,and then the wake flattens out.<br /><br />The 100 is marginal power for heavier slalom skiers, but perfect for my family.<br /><br />One thing you definitely want to check out is the well that the gas tank sits in. Sea Ray forgot to install a drain in mine - and water will get in - and rot the floorboard and maybe the stringers too! <br /><br />Pop off the floor panel and check it out. <br /><br />You may be able to see if a drain is there by feeling down in the aft bilge, without opening anything up. There should be two drains - one from the ski locker and one from the gas tank well.
 

TenE307

Petty Officer 2nd Class
Joined
Feb 18, 2003
Messages
193
Re: Merc 100 hp 1991

i replaced the key switch.<br />because when i disconnected the wiring harness, and jumped the starter i got spark. replaced the key switch connected wiring harness. still no spark.<br />I finally had to cut the black and yellow wire from switch box to wiring harness. connected two wires and push button switch. which is now my kill switch.<br />now could it be the mercury switch.<br />plus also fixed shifting prob. thanks for help.
 

TenE307

Petty Officer 2nd Class
Joined
Feb 18, 2003
Messages
193
Re: Merc 100 hp 1991

my next step: (test)<br />taking black/yellow stripe wire off ignition.<br />jumping wire from ignition to cut black/yellow stripe past wire harness.<br />if i get spark i think i might have a bad wire from ignition to boat. <br />can anyone think of any other tests.
 

ronmold

Petty Officer 1st Class
Joined
Sep 8, 2003
Messages
240
Re: Merc 100 hp 1991

Your plan is sound, could be corrosion inside the molded plug harness (boat side).<br />Mercury switch must be bad ( or mounted upside down) remove & discard it but don't run the motor at full tilt (DUH) Use an ohm meter to test blk/yel wire to ground on boat harness with key ON, it should show open.
 

TenE307

Petty Officer 2nd Class
Joined
Feb 18, 2003
Messages
193
Re: Merc 100 hp 1991

got boat out for first trip this weekend. it floats!<br />after fixing kill switch, by wiring from werc switch to a press button switch.<br />tried to run motor in water, started and idled fine, but to get it running at WOT had to keep pressing primer bulb.<br />does this mean that i need to check fuel pump.<br />also had cover on first time since owned. i think it pinched a cable coming from the lower unit. is this pinch why i lost my rpm's. where does this enguine read my rpm's. trying to get motor running before winter.
 

TenE307

Petty Officer 2nd Class
Joined
Feb 18, 2003
Messages
193
Re: Merc 100 hp 1991

where is the rpm cable located. how does it read.<br />my manual doesnt say a thing about it.
 

TenE307

Petty Officer 2nd Class
Joined
Feb 18, 2003
Messages
193
Re: Merc 100 hp 1991

i found the wire for the rpm's. it is the grey one.<br />does anyone know how to run a test to see where i am losing the signal.
 
Top