1991 Mercury 40hp Oil/ Overheat alarm fix

LakeMartinMan

Recruit
Joined
Jul 10, 2020
Messages
4
Hello all,
This is my first post on this forum, please inform me if I infringe on any forum rules by posting this topic here. I recently purchased a 1991 spectrum 1706 (16.5 ft) boat with a 4 cylinder 40hp mercury ELPTO motor. The motor is in fantastic condition, new power head, stator, power pack, plugs, etc.. mint condition. I had a problem with the overheat alarm going off that started after a 6 mile run up the lake about 2 weeks ago, it subsequently started to go off as soon as the key was turned to “on”. After much research and wrenching on the thing (no service manual, couldn’t find one and very little info on these motors on the web) I finally figured out that I (most likely) had a faulty wiring harness and a shot oil warning module in the motor. Adding this on this forum to potentially help anyone that may have alarm issues with their motor, I will lay out how I found this to be the issue. I must begin by saying that I have not yet replaced the oil warning module, so I am not 100% sure it is indeed the problem, but I am going to order one and post the update here. I began by making sure the alarm wires were all in good condition. Alarm wire for this motor is tan with a blue stripe. Checked that it was not the oil reservoir sensor, simply disconnected the two blue wires from the bottom of the oil tank and alarm still rang out. This particular motor also has an overheat sensor to the left of the top spark plug, checked to make sure it was not faulty and its wiring was good. No faulty wiring from either of these sensors and unplugging them did nothing to stop the alarm sounding. I deduced it must be the oil warning module- of course, unplugging this module will cut the alarm no matter what, so I will not know for sure until it is replaced. Also, I cut out the factory 8 pin plug harness and hard wired it together, and that fixed my shorting problem. Those wires were pretty corroded. Just adding this to an online forum, because 99% of the ones I read ended in solving their problem by disconnecting that oil reservoir sensor. Going to replace this module and see if that fixes my alarm problem. I could be wrong now, so any input suggesting it could be something else would be appreciated of course.
 

wn6ngp

Petty Officer 1st Class
Joined
Aug 12, 2012
Messages
211
My experience has been that the switch inside the tank is what fails. sadly, on the 125hp EFI motor I saw with this problem it was necessary to replace the whole tank. maybe there are some schemes to just repair the switch. I'm hoping my 90hp ELPTO 2000 year does not fail. If it does I'll probably just resort to topping off the oil tank every time get fuel.
 

LakeMartinMan

Recruit
Joined
Jul 10, 2020
Messages
4
So I have heard. I was surprised that it wasn’t the tank, I know those floats have a tendency to get waterlogged and the magnet on the bottom of them sometimes comes unattached. Seems to me like a design flaw, pretty much everyone I know with a mercury has had to replace that oil tank. Gotta replace the whole tank if that’s the case, what a pain.
 

Texasmark

Supreme Mariner
Joined
Dec 20, 2005
Messages
14,819
According to Faztbullet recently, to repair the switch the tank has to be separated to access the switch and then glued (proper glue for that purpose) back together. I just had the problem with my 2002 115 and just decided to make it a point to check my oil level before each outing. So I pulled the wires from the wiring harness in the engine where the remote cable connector mates to the engine, leaving the tan-tan/Lt. Blue stripe over temp wire intact.
 

LakeMartinMan

Recruit
Joined
Jul 10, 2020
Messages
4
I believe that is what I am going to do in the meantime. I have a temp. Sensor by the top spark plug, and it bypasses the oil warning module. Will it still send a signal up to my beeper if the motor actually does overheat if the oil warning module isn’t hooked up? I don’t want to run it without at least having an overheat sensor but I couldn’t care any less about the oil tank sensor. Top it up before I head out every time.
 

Texasmark

Supreme Mariner
Joined
Dec 20, 2005
Messages
14,819
OT is the engine tan wire. Just ensure it's plugged into the tan/light blue stripe wire in/on the wiring harness. I verified mine by grounding the tan/light blue wire and turning the ign. key to ON...got an immediate horn. Fine removed the ground and made the connection.
 
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