Mercury 115 efi User Manual Download

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Welcome Aboard!

Proper care and maintenance is an important part in keeping your Mercury Product operating at peak

efficiency for maximum performance and economy. The enclosed Owner's Registration Card is your key

to trouble-free family fun. Refer to your Operation and Maintenance Manual for full details of your warranty

coverage.
Details of your nearest dealer can be found on www.marinepower.com where country maps and full

contact information are displayed.
Is your engine properly registered for warranty purpose? Please check on www.marinepower.com. If

necessary, please contact your local dealer.
If the outboard motor’s serial number plate contains the CE mark in the lower left-hand corner, the

following statement applies:
This outboard motor manufactured by Mercury Marine, Fond du Lac, WI, USA or Marine Power Europe

Inc. Park Industrel, de Petit-Rechain, Belgium complies with the requirements of the following directives

and standards, as amended:

Recreational Craft Directive: 94/25/EC; std. ISO 8665, ISO 11547
Machinery Directive:

98/37/EC,

EMC Directive:

89/336/EC; std. EN50081-1, SAE J551 (CISPR Pub. 12),

EN 50082-1, IEC 61000 PT4-2, IEC 61000 PT4-3

Patrick C. Mackey
President, Mercury Marine, Fond du Lac, WI USA
European Regulations Contact:
Product Environmental Engineering Department, Mercury Marine, Fond du Lac, WI USA

75/90/115 EFI 4-Stroke

90-10215050 204

Summary of Contents for 115 efi

Page 1: ...ur local dealer If the outboard motor s serial number plate contains the CE mark in the lower left hand corner the following statement applies This outboard motor manufactured by Mercury Marine Fond du Lac WI USA or Marine Power Europe Inc Park Industrel de Petit Rechain Belgium complies with the requirements of the following directives and standards as amended Recreational Craft Directive 94 25 E...

Page 2: ...Performance Boat Operation 9 Outboard Remote Control Models 9 Remote Steering Notice 9 Lanyard Stop Switch 10 Protecting People In The Water 11 Passenger Safety Message Pontoon Boats And Deck Boats 12 Wave And Wake Jumping 12 Impact With Underwater Hazards 13 Safety Instructions For Hand Tilled Outboards 14 Exhaust Emissions 14 Selecting Accessories For Your Outboard 15 Safe Boating Suggestions 15...

Page 3: ...edule 38 Flushing The Cooling System 38 Top Cowl Removal And Installation 39 Exterior Care 40 Fuel System 40 Steering Link Rod Fasteners 41 Corrosion Control Anode 41 Propeller Replacement 43 Spark Plug Inspection and Replacement 45 Fuse Replacement 75 90 4 Stroke Models 46 Fuse Replacement 115 4 Stroke Models 47 Timing Belt Inspection 47 Battery Inspection 48 Lubrication Points 48 Checking Power ...

Page 4: ... Start Models 55 Engine Will Not Start 55 Engine Runs Erratically 55 Performance Loss 56 Battery Will Not Hold Charge 56 OWNER SERVICE ASSISTANCE Local Repair Service 57 Service Away From Home 57 Parts And Accessories Inquiries 57 Service Assistance 57 Mercury Marine Service Offices 57 ...

Page 5: ...d 2 To be eligible for warranty coverage the product must be registered with Mercury Marine At the time of sale the dealer should complete the warranty registration and immediately submit it to Mercury Marine via MercNET E mail or mail Upon receipt of this warranty registration Mercury Marine will record the registration 3 Upon processing the warranty registration Mercury Marine will send registra...

Page 6: ...ustomer upon proper re registration of the product CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is availble 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 Mercury Marine specified pre delivery inspection process is completed and docume...

Page 7: ... regarding events and circumstances covered by this warranty and those that are not see the Warranty Coverage section of the Operation and Maintenance Manual incorporated by reference into this warranty DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED THE IMPLIED WARRANTI...

Page 8: ...unless requested by Mercury ship the product or parts of the product directly to Mercury The warranty registration card is the only valid registration identificationand must be presented to the dealer at the time warranty service is requested in order to obtain coverage WHAT IS NOT COVERED This limited warranty does not cover routine maintenance items tune ups adjustments normal wear and tear dama...

Page 9: ...rformed including without limitation the replacement of sacrificial anodes use of specified lubricants and touch up of nicks and scratches in order to maintain warranty coverage Mercury Marine reserves the right to make warranty coverage contingent upon proof of proper maintenance WHAT MERCURY WILL DO Mercury s sole and exclusive obligation under this warranty is limited to at our option repairing...

Page 10: ...ATE TO STATE AND COUNTRY TO COUNTRY Warranty Coverage And Exclusions The purpose of this section is to help eliminate some of the more common misunderstandings regarding warranty coverage The following information explains some of the types of services that are not covered by warranty The provisions set forth following have been incorporated by reference into the Three Year Limited Warranty Agains...

Page 11: ...r operating with a racing type lower unit 11 Engine noise does not necessarily indicate a serious engine problem If diagnosis indicates a serious internal engine condition which could result in a failure condition responsible for noise should be corrected under the warranty 12 Lower unit and or propeller damage caused by striking a submerged object is considered a marine hazard 13 Water entering e...

Page 12: ...structions that should be followed DANGER DANGER indicates an imminently hazardous situation that if not avoided will result in death or serious injury WARNING WARNING indicates a potentially hazardous situation that if not avoided could result in death or serious injury CAUTION CAUTION indicates a potentially hazardous situation that if not avoided may result in minor or moderate injury or proper...

Page 13: ...0 1 from your dealer distributor or Mercury Marine ob00307 Outboard Remote Control Models The remote control connected to your outboard must be equipped with a start in neutral only protection device This prevents the engine from starting when the shift is actuated in any position other than neutral WARNING Avoid serious injury or death from a sudden unexpected acceleration when starting your engi...

Page 14: ...tal activation should the operator choose to move around in an area close to the normal operator s position If it is desired to have a shorter lanyard wrap the lanyard around the operator s wrist or leg or tie a knot in the lanyard ob00310 a b a Lanyard cord b Lanyard stop switch Read the following Safety Information before proceeding Important Safety Information The purpose of a lanyard stop swit...

Page 15: ...lso a possibility This could cause any or all of the following potentially hazardous situations Occupants could be thrown forward due to unexpected loss of forward motion a particular concern for passengers in the front of the boat who could be ejected over the bow and possibly struck by the gearcase or propeller Loss of power and directional control in heavy seas strong current or high winds Loss...

Page 16: ... or persons dangling their feet over the front edge could get their legs caught by a wave and pulled into the water ob00312 WARNING Avoid serious injury or death from falling over the front end of a pontoon or deck boat and being run over by the outboard Stay back from the front end of the deck and remain seated while the boat is in motion BOATS WITH FRONT MOUNTED RAISED PEDESTAL FISHING SEATS Ele...

Page 17: ...boat may also steer sharply to one side Impact With Underwater Hazards Reduce speed and proceed with caution whenever you drive a boat in shallow water areas or in areas where you suspect underwater obstacles may exist which could be struck by the outboard or the boat bottom The most important thing you can do to help reduce injury or impact damage from striking a floating or underwater object is ...

Page 18: ... area directly in front of the outboard while the boat is in motion If an underwater obstacle is struck the outboard will tilt up and could seriously injure anyone occupying this area Exhaust Emissions BE ALERT TO CARBON MONOXIDE POISONING Carbon monoxide is present in the exhaust fumes of all internal combustion engines This includes the outboards sterndrives and inboard engines that propel boats...

Page 19: ... or product failure Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system Acquire and read the installation operation and maintenance manuals for all your selected accessories Safe Boating Suggestions In order to safely enjoy the waterways familiarize yourself with local and other governmental boating regulati...

Page 20: ...oper lookout by sight and hearing The operator must have an unobstructed view particularly to the front No passengers load or fishing seats should block the operators view when operating the boat above idle speed Never drive your boat directly behind a water skier in case the skier falls As an example your boat traveling at 40 km h 25 MPH will overtake a fallen skier 61 m 200 ft in front of you in...

Page 21: ... Clearance Cold 0 31 0 34 mm 0 011 0 014 in Recommended Spark Plug NGK LFR5A 11 NGK LFR6A 11 Spark Plug Gap 1 1 mm 0 043 in Gear Ratio 2 33 1 2 07 1 Recommended Gasoline Refer to Fuel Oil Recommended Oil Refer to Fuel Oil Gearcase Lubricant Capacity 710 ml 24 0 fl oz Engine Oil Capacity 5 liters 5 quarts Battery Rating Operation Above 0 C 32 F 465 Marine Cranking Amps MCA or 350 Cold Cranking AMPS...

Page 22: ...Identification ob00657 a b c d e f g h i j a Top cowl b Bottom cowl c Water pump indicator hole d Driveshaft housing e Anti ventilation plate f Trim tab g Auxiliary tilt switch h Transom brackets i Gearcase j Cooling water intake holes ...

Page 23: ...n and good performance If you install the outboard yourself follow instructions in the Outboard Installation Manual which is provided with the outboard The outboard must be secured to the transom with the four 12 7 mm 1 2 in diameter mounting bolts and locknuts provided Install two bolts through the upper set of holes and two bolts through the lower set of holes ob00658 MAXIMUM OUTBOARD MOUNTING H...

Page 24: ...hile maintaining maximum boat speed ob00323 If changing conditions cause the RPM to drop below the recommended range such as warmer more humid weather operation at higher elevations increased boat load or a dirty boat bottom gearcase a propeller change or cleaning may be required to maintain performance and ensure the outboards durability Check full throttle RPM using an accurate tachometer with t...

Page 25: ... Refer to your local dealer for recommendations Additional clearance may be required for railroad crossings driveways and trailer bouncing ob00660 IMPORTANT Do not rely on the power trim tilt system or tilt support lever to maintain proper ground clearance for trailering The outboard tilt support lever is not intended to support the outboard for trailering Shift the outboard to forward gear This p...

Page 26: ...r is recommended If gasoline containing alcohol is used or if you suspect the presence of alcohol in your gasoline increase your inspection of the fuel system visually checking for fuel leaks or abnormalities Gasoline containing alcohol may cause the following problems to your outboard and fuel system Corrosion of metal parts Deterioration of elastomers and plastic parts Wear and damage of interna...

Page 27: ... viscosity oil may be used at temperatures above 4 C 40 F b SAE 10W 30 viscosity oil is recommended for use in all temperatures Checking And Adding Engine Oil IMPORTANT Do not overfill Be sure that the outboard is upright not tilted when checking oil 1 Turn the engine off Have the outboard in a level operating position Remove the top cowl 2 Pull out the dipstick Wipe it with a clean rag or towel a...

Page 28: ...FUEL OIL 24 4 Push the dipstick back in all the way Reinstall the oil fill cap hand tight a b ob00661 c a Full mark b Add mark c Oil filler cap ...

Page 29: ...fer to General Information Lanyard Stop Switch f Throttle friction adjustment Console controls require cover removal for adjustment g Ignition key switch off on start h Fast idle lever Refer to Operation Starting the Engine i Throttle only button Refer to Operation Starting the Engine Warning System The outboard warning system incorporates a warning horn inside the boat The warning horn may be loc...

Page 30: ...and you are stranded stop the engine and allow it to cool down This will usually allow some additional low speed idle running time before the engine starts to overheat again LOW OIL PRESSURE The warning system will be activated if the oil pressure drops too low First stop the engine and check the oil level Add oil if necessary If the oil is at the recommended level and the warning horn continues t...

Page 31: ... or out beyond a neutral steering condition a pull on the steering wheel or tiller handle in either direction may result Failure to keep a continuous firm grip on the steering wheel or tiller handle when this condition exists can result in loss of boat control as the outboard can turn freely The boat can now spin out or go into a very tight maximum turn which if unexpected can result in occupants ...

Page 32: ...peller In excess can cause boat porpoising bouncing or propeller ventilation Cause engine overheating if any cooling water intake holes are above the water line TILTING OPERATION To tilt outboard shut off the engine and press the trim tilt switch or auxiliary tilt switch to the up position The outboard will tilt up until the switch is released or it reaches its maximum tilt position 1 Engage the t...

Page 33: ...nly If engine speed exceeds 2000 RPM the outboard will automatically return down to the maximum trim range Trim Tab Adjustment Propeller steering torque will cause your boat to pull in one direction This steering torque is a normal thing that results from your outboard not being trimmed so the propeller shaft is parallel to the water surface The trim tab can help compensate for this steering torqu...

Page 34: ...te the direction the boat turns more easily If adjustment is necessary loosen trim tab bolt and make small adjustments at a time If the boat turns more easily to the left move the trailing edge of trim tab to the left If the boat turns more easily to the right move the trailing edge of trim tab to the right Retighten bolt and retest ...

Page 35: ...he engine causing possible damage Operating In Salt Water Or Polluted Water We recommend that you flush the internal water passages of your outboard with fresh water after each use in salt or polluted water This will prevent a buildup of deposits from clogging the water passages Refer to Maintenance Flushing The Cooling System If you keep your boat moored in the water always tilt the outboard so t...

Page 36: ...ating of the engine 1 Check the engine oil level ob00667 2 Make sure the cooling water intake is submerged ob00668 3 Open fuel tank vent screw in filler cap on manual venting type fuel tanks ob00348 4 Squeeze the fuel line primer bulb several times until it feels firm ob00349 5 Set the lanyard stop switch to RUN position Refer to General Information Lanyard Stop Switch ob00350 6 Shift outboard to ...

Page 37: ...ntinue to crank the engine for starting Immediately start to reduce engine speed after engine starts 9 After engine starts check for a steady stream of water flowing out of the water pump indicator hole ob00331 IMPORTANT If no water is coming out of the water pump indicator hole stop engine and check cooling water intake for obstruction No obstruction may indicate a water pump failure or blockage ...

Page 38: ...stop at neutral position and allow the engine speed to return to idle Always shift outboard into gear with a quick motion After shifting outboard into gear advance the lever further to increase speed N R F ob00557 Stopping The Engine Reduce engine speed and shift outboard to neutral position Turn ignition key to OFF position ob00360 Emergency Starting If the starter system fails use the spare star...

Page 39: ... plug wire when starting or running the engine WARNING The exposed moving flywheel can cause serious injury Keep your hands hair clothing tools and other objects away from engine when starting or running the engine Do not attempt to reinstall the flywheel cover or top cowl when engine is running 4 Place the starter rope knot into the flywheel notch and wind the rope clockwise around the flywheel 5...

Page 40: ...OPERATION 36 7 Pull the starter rope to start the engine 3 4 a ob00670 a Location of rope knot in notch on flywheel ...

Page 41: ...uld result in personal injury death or product failure EPA Emissions EMISSION CERTIFICATION LABEL An emission certification label showing emission levels and engine specifications directly related to emissions is placed on the engine at time of manufacture EMISSION CONTROL INFORMATION TIMING IN DEGREES FAMILY FEL cc IDLE SPEED hp GAP g kW h Standard spark plug Suppressor spark plug This engine con...

Page 42: ...After that inspect spark plugs every 100 hours or once yearly Replace spark plugs as needed See Spark Plug Inspection and Replacement Inspect thermostat visually for corrosion and broken spring Make sure thermostat closes completely at room temperature 1 Check engine fuel filter for contaminants See Fuel System Check engine timing setup 1 Check corrosion control anodes Check more frequently when u...

Page 43: ...ear fitting Partially open the water tap 1 2 maximum Do not open the water tap all the way as this allows a high pressure flow of water IMPORTANT Do not run engine above idle when flushing 4 Shift outboard into neutral Start the engine and flush the cooling system for at least 5 minutes Keep engine speed at idle 5 Stop the engine Turn off the water and remove hose Reinstall the propeller ob00671 T...

Page 44: ...ed area Inspect any completed service work for sign of fuel leakage FUEL LINE INSPECTION Visually inspect the fuel line and primer bulb for cracks swelling leaks hardness or other signs of deterioration or damage If any of these conditions are found the fuel line or primer bulb must be replaced ENGINE FUEL FILTER Inspect the sight bowl for water accumulation The sight bowl is equipped with a float...

Page 45: ...otentially violent action can cause occupants to be thrown overboard exposing them to serious injury or death ob00676 a b c d a Special washer head bolt 10 849838 b Flat washer 2 c Nylon insert locknut 11 826709113 d Nylon insert locknut 11 826709113 Description Nm lb in lb ft Special washer head bolt 27 20 Nylon insert locknut d 27 20 Nylon insert locknut c Tighten until seats then back off 1 4 t...

Page 46: ...sion control anodes one on each side A third anode is installed on the bottom of the transom bracket assembly ob00677 a b a Anode 2 on each side of gearcase b Anode on transom bracket assembly NOTE Do not remove center bolt until cover has been removed from engine Three anodes are installed in the engine Remove anodes at locations shown Install each anode with rubber seal and cover Tighten bolts t...

Page 47: ...lug leads when you are servicing the propeller 1 Shift outboard to neutral N position N ob00351 IMPORTANT Refer to Spark Plug Inspection and Replacement for removing spark plug leads 2 Remove spark plug leads to prevent engine from starting ob00375 3 Straighten the bent tabs on the propeller nut retainer ob00376 4 Place a block of wood between gearcase and propeller to hold propeller and remove pr...

Page 48: ...hub propeller nut retainer and propeller nut onto the shaft ob00382 a b c d e f a Propeller nut b Propeller nut retainer c Rear thrust hub d Continuity washer e Propeller f Forward thrust washer 8 Flo Torq II Drive Hub Propellers Install forward thrust hub replaceable drive sleeve propeller thrust hub propeller nut retainer and propeller nut onto the shaft b c a d f e ob00421 a Propeller nut b Pro...

Page 49: ...er the engine cowl To avoid damaging spark plug boots do not use any sharp object or metal tool such as pliers screwdriver etc to remove spark plug boots 1 Remove the spark plug leads Twist the rubber boots slightly and pull off ob00375 2 Remove the spark plugs to inspect Replace spark plug if electrode is worn or the insulator is rough cracked broken blistered or fouled ob00679 3 Set the spark pl...

Page 50: ...s on the outboard are protected from overload by fuses in the wiring If a fuse is blown try to locate and correct the cause of the overload If the cause is not found the fuse may blow again 1 Remove the plastic cover and open the fuse holder Look at the silver colored band inside the fuse If band is broken replace the fuse Replace fuse with a new fuse with the same amperage rating 20 20 30 30 ob00...

Page 51: ...e fuse If band is broken replace the fuse with a new fuse with the same amperage rating a b c d e f g h h ob00691 a Electrical cover b Fuse puller c Good fuse d Blown fuse e Fuse holder f Fuses 30A 2 g Fuses 20A 2 h Spare fuses Timing Belt Inspection Inspect the timing belt and have it replaced by an authorized dealer if any of the following conditions are found 1 Cracks in the back of the belt or...

Page 52: ... with a nonconductive shield to prevent accidental shorting of battery terminals Lubrication Points 1 Lubricate the following with Quicksilver or Mercury Precision Lubricants Anti Corrosion Grease or 2 4 C with Teflon Propeller Shaft Refer to Propeller Replacement for removal and installation of the propeller Coat the entire propeller shaft with lubricant to prevent the propeller hub from corrodin...

Page 53: ...e outboard tilt tube before adding lubricant Adding lubricant to steering cable when fully extended could cause steering cable to become hydraulically locked A hydraulically locked steering cable will cause loss of steering control possibly resulting in serious injury or death 3 Lubricate the following with light weight oil Steering Link Rod Pivot Points Lubricate pivot points ob00686 Checking Pow...

Page 54: ...PROCEDURE 1 Tilt the outboard up to the trailer position 2 Turn the steering on the outboard so that the drain hole is facing downward Remove drain plug and drain engine oil into an appropriate container Lubricate the seal on the drain plug with oil and reinstall ob00436 CHANGING OIL FILTER 1 Place a rag or towel below the oil filter to absorb any spilled oil 2 Unscrew old filter by turning the fi...

Page 55: ...ricant or it may be mixed with the lubricant giving it a milky colored appearance If water is noticed have the gearcase checked by your dealer Water in the lubricant may result in premature bearing failure or in freezing temperatures will turn to ice and damage the gearcase Examine the drained gearcase lubricant for metal particles A small amount of fine metal particles indicates normal gear wear ...

Page 56: ...ole At this time install the front vent plug and sealing washer 4 Continue adding lubricant until it appears at the rear vent hole 5 Stop adding lubricant Install the rear vent plug and sealing washer before removing lubricant tube 6 Remove lubricant tube and reinstall cleaned fill drain plug and sealing washer a d ob00442 e c b a Front vent plug b Front vent hole c Rear vent hole d Rear vent plug...

Page 57: ...bilizer follow instructions on container into a separate container and mix with approximately one quart one liter of gasoline Pour this mixture into fuel tank Place the outboard in water or connect flushing attachment for circulating cooling water Run the engine for ten minutes to fill the engine fuel system Protecting External Outboard Components Lubricate all outboard components listed in Mainte...

Page 58: ...STORAGE 54 Store the battery in a cool dry place Periodically check the water level and recharge the battery during storage ...

Page 59: ...ine is disconnected or kinked d Primer bulb not squeezed e Primer bulb check valve is faulty f Fuel filter is obstructed Refer to Maintenance section g Fuel pump failure h Fuel tank filter obstructed Blown 20 Amp fuse EFI Models Refer to Maintenance section Ignition system component failure Wiring or electrical connection faulty Spark plugs fouled or defective Refer to Maintenance section Engine R...

Page 60: ... adjustments or setup Boat overloaded or load improperly distributed Excessive water in bilge Boat bottom is dirty or damaged Battery Will Not Hold Charge POSSIBLE CAUSES Battery connections are loose or corroded Low electrolyte level in battery Worn out or inefficient battery Excessive use of electrical accessories Defective rectifier alternator or voltage regulator ...

Page 61: ...very important to your dealer and to us If you ever have a problem question or concern about your outboard product contact your dealer or any authorized Mercury Marine dealership If additional assistance is required take these steps 1 Talk with the dealership s sales manager or service manager If this has already been done then contact the owner of the dealership 2 Should you have a question conce...

Page 62: ...striel de Petit Rechain B 4800 Verviers Belgium Fax 32 87 31 19 65 Mexico Central America South America Caribbean Telephone 954 744 3513 Mercury Marine 11650 Interchange Circle North Miramar FL 33025 U S A Fax 954 744 3535 Japan Telephone 81 053 423 2500 Mercury Marine Japan Anshin cho 283 1 Hamamatsu Shizuoka ken Japan 435 0005 Japan Fax 81 053 423 2510 Asia Singapore Telephone 5466160 Mercury Ma...

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