2002 Mercury 115hp issues

adam7

Petty Officer 3rd Class
Joined
Jul 30, 2010
Messages
97
Hello everyone, new boat owner here. Two weeks ago I bought a 2002 Key West 1900CC with a 2002 Mercury 115hp 4cyl outboard. Over the last two weekends I had a few issues that I thought I'd ask about.

The motor typically doesn't start on the first try, sometimes the idle can be a little shaky and it won't stay running without some attention after a week of sitting on the trailer. Do I just need to find the right amount of choke until it warms up enough?

As far as the starting issues, I wanted to flush the motor yesterday, so I had the hose all hooked up and primed the bulb, but when I turned the key it just clicked. The gauge on the console was reading 12-14 volts, the battery connections appear tight, but the positive terminal connection looked a little rusty/corroded. Is it simply a battery issue, or could it be the starter? Turning the key enough times got it to crank, twice, but the idle issue kept it from running more than 60 seconds. I've replaced car starters, if it comes to that will I find any surprises on an outboard vs a 4cyl auto engine?

I gave up after 30 minutes because it was about 107 degrees outside, could the heat have had something to do with it? When I bought the boat it had been sitting for a while, could I just be working out the cobwebs from it being unused? I should point out that when we were out on the water it didn't give me this much trouble (it would crank on the 2nd or 3rd try if not the first). But I remember a used Accord I got that started fine for the first month before I realized the starter was on its last legs and I had to knock it with a hammer to get it to turn over. Could this be a similar situation?

I'm going to have to re-pack the bearings on one of the trailer wheels this weekend (lost the dust cap and losing all the grease), I figured I'd get a battery terminal brush to try and clean that up too. If I still have starting problems I'm going to assume its the starter. Anything else I should look at?

Thanks,
Adam
 

Dave1027

Lieutenant Junior Grade
Joined
May 25, 2010
Messages
1,081
Re: 2002 Mercury 115hp issues

Clean your battery terminals and cable connectors and post back result. Don't assume you have a bad starter just yet.


Cold start your motor like this:

Pump primer bulb till full and hard.
Set throttle to 1/4 in neutral
Turn key to on
Push in key (choke) and turn to start in one motion
After the engine starts adjust throttle as needed

Mine starts instantly when I use the above method.
 

adam7

Petty Officer 3rd Class
Joined
Jul 30, 2010
Messages
97
Re: 2002 Mercury 115hp issues

Should the water hose be supplying enough volume during the flush to have the water pump ejecting that stream of water? I don't think it ran long enough when I was trying, I think right at the end it started to come out, but I'm not sure now that I think about it. At least not like it does when on the water.
 

HD Fatboy?

Seaman
Joined
Jul 8, 2010
Messages
57
Re: 2002 Mercury 115hp issues

when mine is on the hose it takes a tiny bit more time for water to show at the pee hole than on the water. My 115 is a 1996, but search my username, I had very similar issues, fixed the non starting problem.
 

Barnacle_Bill

Admiral
Joined
Feb 8, 2004
Messages
6,469
Re: 2002 Mercury 115hp issues

Make SURE all connections are clean and tight. If OK, try jumping the starter solenoid. Just because it clicks does not mean its good.
 

adam7

Petty Officer 3rd Class
Joined
Jul 30, 2010
Messages
97
Re: 2002 Mercury 115hp issues

when mine is on the hose it takes a tiny bit more time for water to show at the pee hole than on the water. My 115 is a 1996, but search my username, I had very similar issues, fixed the non starting problem.
Are you referring to the fueling issues you had under the 'runs terrible' thread? I'm not sure that's the problem here, I haven't seen any extra fuel yet, but I'll keep it in mind. For the moment I'm focusing on the ignition problems. I had the motor checked by a dealer before purchasing, and they said the ignition checked out. Since I had it out on the water 4 days already I figured they were right. It was when it was on the trailer and I was trying to flush the motor that this problem really made itself apparent.
 

adam7

Petty Officer 3rd Class
Joined
Jul 30, 2010
Messages
97
Re: 2002 Mercury 115hp issues

I cleaned up the positive battery terminal and all the leads connecting to it, which was looking fairly bad. The starter still won't catch. It clicks, and I can see it (with the top off) trying to engage just a little, but nothing. The connections on the motor side are immaculate. So I don't know, but now I missed my first weekend on the water and it was only the 3rd since I owned it :(
 

adam7

Petty Officer 3rd Class
Joined
Jul 30, 2010
Messages
97
Re: 2002 Mercury 115hp issues

Dropped it off at the dealer that looked at it initially. They say the starter solinoid is dead, which is what I jumped to initially. Good thing its not the whole starter, this should be a cheap fix.
 

adam7

Petty Officer 3rd Class
Joined
Jul 30, 2010
Messages
97
Re: 2002 Mercury 115hp issues

Solenoid replaced and it runs like a champ. Took it out on Saturday and had no problems tooling around Beaufort. I still haven't tried going past the opening to the sound yet, I figured I should make sure everything is working well before I risk it.
 
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