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    2004 mecury 115hp saltwater engine fly not turning all the way

    If the flywheel will not turn, with the spark plugs removed and the gearcase removed, you have serious engine issues. If it is not something obvious like something jamming the flywheel, it is likely a connecting rod has broken or disassembled itself.
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    Two Layers of 3/4 CSM versus One Layer of 1.5 CSM

    CSM is strong in all directions. Not as strong as the equivalent weight of cloth, provided it's fibers are laid at a bias. Clearly 5/8 plywood with CSM is stronger than 1/2 plywood with the same CSM layer.
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    Mercury 90 horsepower tilt

    Actually relays supply ground to the PTT motor, when not energized, and +12VDC when energized. They are different than solenoids. However, you do need to check the wiring and especially the connections to make sure your relays get a good ground and good +12VDC for the secondary windings. The...
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    I/O with stiff steering under load. Normal?

    That is normal, which is why most (I had thought all) I/Os came with power steering. You can adjust the zinc anode above and behind the prop to help. There are 3 different kinds. Small fin, large fin and no fin. You will want the large fin anode, if it will fit on your OD, with the prop...
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    how to troubleshoot kill/ignition switch merc '90 115hp o/b

    The stator feeds voltage to the switchbox. It sounds like time to ohm out the stator. A Mercury Factory service manual is your best choice. BTW, voltage on the black/yellow wire is bad. If the stator ohms out OK, the switchbox is the next possible culprit.
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    Two Layers of 3/4 CSM versus One Layer of 1.5 CSM

    You will want access to your fuel tank. On some newer boats, the OEM casts a cover cored with 3/4" wood, over the fuel tank. That way, about 8 screws allow full access and removal of the tank. You look to have joists over the fuel tank. It would be best if the cover didn't need them. My...
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    Shifting Forward, RPMs rise before engaging

    It sounds like your shift cable is not adjusted correctly, or something is wrong with the shifter. Take a look at the shift cable, while someone moves the control into forward (motor off). The shift cable should move immediately as the throttle handle moves. If it does, the cable is...
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    Transom Paint

    Most one part urethane paints are labeled for top side use only. They do not hold up when submerged for an length of time. Two part urethanes are made for below the waterline use.
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    Two Layers of 3/4 CSM versus One Layer of 1.5 CSM

    Fiberglass cloth and resin do add a lot of strength, plus waterproofing. Not sure where you get your info. 1/2" plywood is usually strong enough for boat decks. Remember, it is the span of the plywood across the stringers and frames, that dictate the thickness required. Most stringers are...
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    Looking for a light, all around anchor

    People use light duty line (1/4" cotton) instead of zip ties. Whatever you use, have more of it on board, just in case you need to anchor again.
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    MERCURY CONTROL BOXES

    Merc did like to make wiring harnesses work for multiple motors. During the 70's Merc was changing from battery powered CDI ignition to ADI. They made sure to have both the power wire and killer wire in the harnesses, so they would work for both types of ignition. So you could replace a 1975...
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    how to troubleshoot kill/ignition switch merc '90 115hp o/b

    Disconnect the black/yellow (killer) wire at the switchbox, or at the ign switch. If spark returns, that wire is being grounded somewhere to kill the spark. The insulation can rub off and ground it.
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    Coolant outlet

    Most OB thermostats open at about 140*F. Telltale should not be warmer than that.
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    MERCURY CONTROL BOXES

    Interesting. The first (top) diagram looks to be the expected wiring colors. On the emergency kill switch(as you circled), and you will see black and black/yellow wires. The second diagram emergency switch has the black and yellow/black wires on it. Both diagrams look to have the same title...
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    MERCURY CONTROL BOXES

    I am surprised about the colors of the kill and choke wires on the control side. The new Ign kill wire was always black/yellow. The old wire color was orange or salmon. The new wire color for the choke is yellow/black. The old color was grey. New wire color for starter solenoid is...
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    Gear lube for 60 HP

    Gee, you are making a mountain... Use a full synthetic marine gear oil. Any brand will work fine, if rated for mechanical gearshift motors. Regular dino marine gear oil will work fine as well. Change it every year, using new gaskets on the vent and fill screws. That is much more important...
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    Looking for a light, all around anchor

    Normally a 19 footer would have an 8-10lb fluke anchor and 5 feet of chain. I "lunch hook" could be lighter and a "storm anchor" would be heavier, say 12-15LB.
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    Having motor issues? Check this

    Gee, what was the color of the wire that had the bad pin?
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    Transom Paint

    Not sure Brightside will last for 4 days submerged. Perfection will last indefinitely submerged. Gelcoat is not that hard to apply. You can spray it with the correct orifice (2.0MM?) It can be rolled as well.
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    Any lasting proven method of painting a prop ??

    Gee, with rattle can primer and rattle can paint (plus sanding) the paint stayed on...at least until I hit bottom.
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