2005 Mercury 115hp ELPTO constant alarm

[wave_rider]

I'm on a family trip and we have taken the boat out a few times and it has worked well. Did notice the telltale wasn't flowing well at one point but then started flowing well again so figured it was ok (might need to replace the poppet valve soon, just replaced the impeller about a month ago) Also, I recently changed the thermostat, fuel filter, fuel/water separator, and lower unit oil. We went for a little swim and shut down the motor while swimming then when I started up the engine it started fine but almost immediately the engine alarm went off. I turned off the motor and the alarm started back up every time I put the key to run... Then I started it back up to get back home and the alarm stayed on the entire time, even in idle. It will throttle up fine and the telltale looked to be flowing well. There was plenty of oil in the oil tank, it was 3/4 full. Any ideas or suggestions of things to check, hoping to get back on the water before we head home but not holding my breath. Thanks in advance for any help, really appreciate it.

Engine is a 2005 115hp ELPTO Saltwater

 

[Bosunsmate]

Re: 2005 Mercury 115hp ELPTO constant alarm

See if the alarm goes off straight away again when its being cold for a good while, and also put your hand on the head if it takes a while for the alarm to come on to see if the head gets too hot,it shouldnt be scolding. Id also run a tank with premixed fuel and check that the oil tank is consuming oil correctly. Be sure to clean the sparkplugs later if the oil tannk is feeding in still ok
If you can run it on muffs and see if that changes it.
Also check the battery is charging with a mulitmeter or put in your car and check its charge level if that gets you a reading

 

[wave_rider]

Re: 2005 Mercury 115hp ELPTO constant alarm

Thanks for the help Bosunsmate. I actually put in new plugs a month ago too and I am still working on checking the other things you mentioned, thans for the suggestions. I let it sit overnight and constant alarm is still going off, so I am thinking it is a sensor, but not sure? Took a look and the two yellow wires that come of the alarm module are melted at the heatshrink connector and looks a little burned, same thing with another wire near the flywheel that is green with white stripe. Strange thing is the actual wires look fine and other heatshrink connections that were right next to those look completely normal too so not sure why those are burned?? I am going to replace those connections with new. Have any of you ever heard of wire connections burning like that? Is that a sign of an overheat or some sort of current spike or maybe just corrosion? Anyways thanks again for the suggestions Bosunsmate!

 

[Dave1027]

Re: 2005 Mercury 115hp ELPTO constant alarm

Those modules are a common failure. Mercury must have went with low bidder on that one. Either that or planned obsolescents. I'll bet they made a fortune on those.

 

[wave_rider]

Re: 2005 Mercury 115hp ELPTO constant alarm

Yeah I have seen quite a few posts about that module and the oil sensor going bad in my searches of the forum. So do you think the module is bad too and could have caused the burned wire connections? Should I just replace the wires and the module to be on the safe side or start with the wires and then move on to the module? Any way to test if the module has failed? Thanks

 

[Dave1027]

Re: 2005 Mercury 115hp ELPTO constant alarm

I don't have my book with me to give you the proper troubleshooting but suffice it to say, if there are no grounds on the sensor lines then it must be the alarm module that is at fault. I got fed up with replacing them and disconnected mine. Not saying that is what you should do.

 

[wave_rider]

Re: 2005 Mercury 115hp ELPTO constant alarm

Gotcha, thanks for your help... maybe that is what I will end up doing. Off to the Mercury dealer now to purchase some new heatshrink connectors... anyone know if there is anywhere else to get those really thick heatshrink connectors they use on the motor wiring?

 

[wave_rider]

Re: 2005 Mercury 115hp ELPTO constant alarm

Replaced all the burned connectors and alarm still goes off immediately when key is turned, constant alarm sound. However, if I disconnect the oil sensor it stops does this mean the oil sensor is bad? The reasons I am confused is the alarm is a constant tone and not a beeping on and off. I though the constant tone was for overheat and the beeping was for oil sensor. Any insight? Don't want to replace the wrong sensor. Thanks!

 

[wave_rider]

Re: 2005 Mercury 115hp ELPTO constant alarm

Just read something on the forum that the beeping on and off which I had read meant a bad oil sensor doesn't occur after a certain year of these outboards? Is this true that after a certain year both overheat and oil sensor produce a constant alarm? Thank you in advance for any help on this.

 

[CharlieB]

Re: 2005 Mercury 115hp ELPTO constant alarm

You actually have two seperate problems.

The YELLOW wires are the charging system, the stator leads to the voltage rectifier/regulator. It is often found that the bullet connectors do not have a good enough contact, causing excessive heat to darken and sometimes actually burn the wires and connectors. Some like to cut off the connectors and solder the wires together, coat that with good heat shrink and it will work perfectly.

Now, your original problem of the constant alarm even with the key ON and the motor NOT running.

Disconnect one or both of the light blue wires that come out from under the oil tank to the alarm module. If this stops the alarm the problem is an failure of the adhesive that holds the magnet to the bottom of the oil level float. The magnet falls to the bottom of the tank on or near to the magnetic switch and the system alarms.

Unfortunately this is an all to common fault, AND, since it is near impossible to repair, it is best to order a replacement oil tank assy.

 

[wave_rider]

Re: 2005 Mercury 115hp ELPTO constant alarm

Thanks so much CharlieB looks like it is the oil alarm. Also thanks for the info on the wires really appreciate it.