1994 Merc 115 will not run below 1800 rpm.

firecop1

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May 7, 2018
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Hello all, I am new to the forum. My 1994 Merc 115 ran fine to my first spot. 1.5 hours later I tried to start it and it wouldn't stay running. Finally ran but only if I went wide open throttle and then it would only go to 2100 rpm and bog down. Below 1800 rpm it dies. Runs in neutral from 1800 - 5000 rpm, still dies under 1800. Replaced fuel line, bulb, fuel pump kit with oem parts and replaced plugs. Compression is good 130ish on all four. Pulled the plugs today and found bottom two were wet and black, and top two were damp and unburnt. Checked spark and have weak fire on bottom two cyl and no fire on top two. Where do I start. Thanks
 

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racerone

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Dec 28, 2013
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Fact----The motor only runs on the top 2 cylinders below about 1800 RPM.----Ignition system supplies spark to all 4 all the time.-----Bottom 2 carburetors kick in once about 1800RPM is reached.-----Do not wind it up in neutral as it is bad for bearings !----Is the starter and battery in good condition ??
 

firecop1

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May 7, 2018
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New battery fully charged. Starter in good working order. No spark at any time on the top two cyl.
 

Texasmark

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Dec 20, 2005
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New battery fully charged. Starter in good working order. No spark at any time on the top two cyl.

Yeah but how about the interconnect wiring. When starting that engine you need about 150-200 amps....maint. manual quotation. at 12v divided by 200 amps, the tolerable resistance in the circuit is essentially zero!

Get a voltmeter and check the voltage at the starter red input ⅜" terminal and ground at the metal band on the starter , or starter case if metallic.....or engine block...easier to get to. Crank the engine over and if you don't have 10v or better at the terminals while cranking with a new fully charged battery of adequate amperage, time to check your wiring for corroded (usually) or loose connections.

Usually after cranking attempts that extend over a period of time, the place where you have a bad connection will be warm to hot...reason is resistance of the connection squared times current is power dissipated like in a light bulb and things get hot. Take all connections apart, clean them up and put them back together with adequate torqueing...want them tight but you don't want to be stripping any threads.

I realize that the supply voltage doesn't differentiate between which plugs get voltage and which don't. That's a different problem. I had the 3 cyl 90 and it didn't start well when I had a bad CDI which wouldn't fire a plug. If you lost 2 in starting, you may have your problem. I know of the 2-4-2 thing with the 4 cyls, but don't know if the fuel starvation of the bottom two is also when starting............I never liked that thing and that's why I went with 3 rather than 4 cyls.
 

Chris1956

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Mar 25, 2004
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Gee, A lot of Mercs have separate low speed and high speed windings on the stator. You might ohm them out and see if the low speed winding is good.
 

flyingscott

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Apr 8, 2014
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You need to go to www.cdielectronics.com for the testing procedures for your ignition system. What I think is happening is the top 2 cylinders are not working all the work is being done by the bottom 2. That explains why it only runs above 1800 rpm and does not reach full rpms. That motor ONLY starts and idles on the top 2 cylinders. The bottom 2 do not do anything until 1800 rpm.
 

firecop1

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May 7, 2018
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Thanks, I have printed off the troubleshooting for my engine from CDI's website. WIll update after I test.
 
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