98 Mercury 115 hp starter, battery, solenoid, issues. HELP it wont even start now

[Barnacle_Bill]

Re: 98 Mercury 115 hp starter, battery, solenoid, issues. HELP it wont even start no

Mercury just uses serial numbers for parts. OG100998 is a 1994, not a 1998.

 

[carholme]

Re: 98 Mercury 115 hp starter, battery, solenoid, issues. HELP it wont even start no

Your s/n comes up as:

MERCURY - (115 H.P. (1994 ))
Serial No: 0G100998 Model No: 1115412PT

Parts List for model 1115412PT:

100/115/125 H.P. 80 JET (4 CYLINDER) - Mercury, Mercruiser, Force, etc. Parts Lookup

Service manual P/N: 90-830234R04

If you do not have the manual, send me a PM with an email address and I will send you a copy.

Gerry

 

[bankbuster]

Re: 98 Mercury 115 hp starter, battery, solenoid, issues. HELP it wont even start no

THANK YOU! for the info on ser#/model#. Regulator was replaced a few weeks ago. Rectifier is due for delivery by Monday (6th). Starter arrived and has been installed. The old starter was definitely bad....the flywheel spins soooo much faster! WOW! It doesnt hesitate or drag anymore either. Luv it!.......but it still wont start. I tested (hope I did it right) the rectifier and could NOT find ANY continuity at all, thus the reason i bought a new one. I really have not tried starting it much just because I'm not sure where all that voltage goes when the rectifier is bad. I dont want to hurt it more than its hurt now. As soon as rec. gets here i will install it, try to start, and update here with outcome. Thanks.

 

[CharlieB]

Re: 98 Mercury 115 hp starter, battery, solenoid, issues. HELP it wont even start no

Your starting procedure can have a lot to do with how well your motor starts.

Pump the primer to a firm handshake, over squeezing the bulb can cause flooding and make the motor hard to start.

Raise the fast idle lever to open the throttle some. Be ready when the motor does start to reduce the throttle keeping the RPM near 2000 give or take a few 100

Turn the key ON, push the key in and hold it while cranking, once started re3lease the key but be ready, if the motor falters slows you must momentarily bump the enrichment again. You may have to do this a few times depending on how cold it is.

Once the motor builds a little heat and the speed stays steady start reducing throttle until at idle.

Once in gear remain at low to moderate speeds until motor is at full temp, WOT on a cold motor can cause a "cold seize" where the piston heats far too rapidly then the cooler cyl, and sticks. Not pretty.

 

[bankbuster]

Re: 98 Mercury 115 hp starter, battery, solenoid, issues. HELP it wont even start no

Hi All...Thanks. I am starting it pretty much like you advised. It has always started fairly easy and quick....if it has spark. I did get the rectifier yesterday and that is on now. So, new regulator, rectifier, and starter. Still NO park. It will probably start at some point so I still think the NO SPARK thing is intermittent. At this point it wont start so we'll just say NO SPARK. I did pull all plugs and all pistons are free. I did remove blk/ylw wire from switchbox..still no spark. Kill switch is fine. Is there a neutral switch in the throttle box? Ylw/red wires? Just wondering if I can test that somehow? I can use the warm up lever (while cranking) so does that mean nuetral switch is fine as it would not crank if that was an issue I assume....? So, Whats left to check. Coil packs....could they be intermittent and all at once? I doubt it so its probably not those....? Switchbox? Stator? Trigger Assembly? One of these three is surely my problem. Can the stator, trigger assembly, and/or switchbox be intermittent? Is there anyway to easily test 1 or all of these to narrow down my problem? One at a time is fine...the more I can test and exclude the closer I'll get to solving I guess. I would like to get a manual that best descibes "troubleshooting" and or "ignition/wiring" as this will be the extent of what I will be working on. If it ever needs rebuild on motor or lower unit that will be done at boat shop...not for me. Any advice for best manual? Also, I need a DVA meter....what type should I look for? Are they all the same? Expensive? I have a regular ohm/multimeter and a UEI DM200 Digital Multimeter.....dont really know if I need them or how to use but I can learn. Open to suggestions...Thanks, Jayson.

 

[bankbuster]

Re: 98 Mercury 115 hp starter, battery, solenoid, issues. HELP it wont even start no

forgot to add key switch.....could be a problem to I suppose?

 

[Lone Duck]

Re: 98 Mercury 115 hp starter, battery, solenoid, issues. HELP it wont even start no

Hi All...Thanks. I am starting it pretty much like you advised. It has always started fairly easy and quick....if it has spark. I did get the rectifier yesterday and that is on now. So, new regulator, rectifier, and starter. Still NO park. It will probably start at some point so I still think the NO SPARK thing is intermittent. At this point it wont start so we'll just say NO SPARK. I did pull all plugs and all pistons are free. I did remove blk/ylw wire from switchbox..still no spark. Kill switch is fine. Is there a neutral switch in the throttle box? Ylw/red wires? Just wondering if I can test that somehow? I can use the warm up lever (while cranking) so does that mean nuetral switch is fine as it would not crank if that was an issue I assume....? So, Whats left to check. Coil packs....could they be intermittent and all at once? I doubt it so its probably not those....? Switchbox? Stator? Trigger Assembly? One of these three is surely my problem. Can the stator, trigger assembly, and/or switchbox be intermittent? Is there anyway to easily test 1 or all of these to narrow down my problem? One at a time is fine...the more I can test and exclude the closer I'll get to solving I guess. I would like to get a manual that best descibes "troubleshooting" and or "ignition/wiring" as this will be the extent of what I will be working on. If it ever needs rebuild on motor or lower unit that will be done at boat shop...not for me. Any advice for best manual? Also, I need a DVA meter....what type should I look for? Are they all the same? Expensive? I have a regular ohm/multimeter and a UEI DM200 Digital Multimeter.....dont really know if I need them or how to use but I can learn. Open to suggestions...Thanks, Jayson.

Ok ! all the major start components you have replaced . Now! Disconnect the electronic cable from the helm to the engine at the engine, jump to the ignition ground wire with a wire that you can ground out to shut it off if it starts. Then jump across your solenoid to crank it. If it starts then your problem is from the plug forward to the helm. If it won,t start then the problem is still at the engine. Try and do this procedure when it will not start from the helm.

 

[CharlieB]

Re: 98 Mercury 115 hp starter, battery, solenoid, issues. HELP it wont even start no

The ignition switch in the OFF position connects the black/yellow to the solid black ground, this grounds the B/Y from the switchbox on the motor and kills spark.

Disconnect this same B/Y from the switchbox to the engine wiring harness, now test for spark. If you start the motor with this wire connected you will NOT be able to kill it.

Leave the B/Y kill wire disconnected and connect your Ohm meter to the B/Y at the engine wiring harness. Have a helper turn the ignition switch ON/OFF slowly about 25 times while you watch the meter. The needle should indicate continuity only with the switch OFF, if ever it shows with the switch ON, then replace the switch.

 

[Lone Duck]

Re: 98 Mercury 115 hp starter, battery, solenoid, issues. HELP it wont even start no

Keep it simple

 

[bankbuster]

Re: 98 Mercury 115 hp starter, battery, solenoid, issues. HELP it wont even start no

ok ....i was excited to go out this morning and perform the wiring harness test that Lone Duck mentioned above. First I wanted to make sure it would NOT start....and of course it started. So while waiting for it to NOT start, I started the kill switch test mentioned above by CharlieB. I disconnected the blk/ylw wire at switchbox, set meter to RX1K, pos lead to blk/ylw wire and grounded the neg lead. With KEY switch OFF and kill switch to EITHER RUN or OFF.....I get full continuity. With Key ON and kill switch OFF I get continuity. Key ON and kill switch set to RUN I get NO continuity. Is that right? Can I hook up the blk/ylw back to switchbox and perform same test..?...or will that even tell me anything? And now for the wiring harness test. Can I just use a jumper wire with alligator clips and jump a ground wire form the ground side of solenoid (or block, just any ground) and use positive lead from jumper cables from batter to pos. post on starter? And if it starts....just ground the small ground jumper to any ground to kill it? And for this test the blk/yellow wire stays connected right? Sorry....Im trying to learn as we go.

 

[Texasmark]

Re: 98 Mercury 115 hp starter, battery, solenoid, issues. HELP it wont even start no

i dont have one....not that I know of anyway

Yes you do. On Merc controls it is either a lever you lift at the rear of the control, or if you have a big black button with the shifter in N, push it in and hold it and then shift forward slightly. This makes the control throttle only. When finished going back to N makes the button pop out and the forward position is now both as it was.

You can scratch the paint to get at metal on a block bolt. Just scratch it till shiny and put the case of the plug against it. Sometimes it's real hard to see a spark in the daylight.

On your starting problem, you may not be spinning the engine over fast enough to get it to light off. Do you have a fresh battery and clean terminals from the battery terminals through the engine wiring posts?

Mark

 

[bankbuster]

Re: 98 Mercury 115 hp starter, battery, solenoid, issues. HELP it wont even start no

Hi Mark....ALL that you mentioned has been taken care of in earlier posts. My problem IS "intermittent spark". As of this moment, it will NOT start.
Tests--I just removed blk/yel wire and switchbox and NO spark.
I pulled the grn/wht and wht/grn from the stator and got full continuity is this right?

 

[bankbuster]

Re: 98 Mercury 115 hp starter, battery, solenoid, issues. HELP it wont even start no

Apparently the original black stators had issues and were replaced with the better "red" stators. There is an "adapter kit" with the red stator. Now after the above stator test I plugged the grn/white wires back in and followed them through the "adapter" and unplugged them at that point (just before switchbox). The wires change from grns/whites going into adapter to blues and whites coming out of adapter. I tested them and found NO continuity at that end. Not sure if the adapter is bad or that is how it should read. Yes the purple and white wires were removed form switchbox just while I was doing other tests. Just wanted to note that have otherwise been hooked up.

 

[bankbuster]

Re: 98 Mercury 115 hp starter, battery, solenoid, issues. HELP it wont even start no

These are the two wires that are coming from stator going into switchbox and the reading....and NO, i dont know what im doing but im trying. Just hoping that someone sees something that is definitely not right!

 

[CharlieB]

Re: 98 Mercury 115 hp starter, battery, solenoid, issues. HELP it wont even start no

............. I disconnected the blk/ylw wire at switchbox, set meter to RX1K, pos lead to blk/ylw wire and grounded the neg lead. With KEY switch OFF and kill switch to EITHER RUN or OFF.....I get full continuity. With Key ON and kill switch OFF I get continuity. Key ON and kill switch set to RUN I get NO continuity. Is that right? ..............

This is correct, now repeat this test another 25 times as when an ignition switch STARTS to go bad it does not short every time.

This is a 'Ground-to-Kill' switchbox, when the B/Y wire gets grounded, anywhere, spark does not happen.

This is why it is critical that you repeat the test many # of times, to see if it does fail.

Otherwise it is critical that you test immediately when you encounter the 'no spark' condition.

Do NOT attempt to test the B/Y from the switchbox, cranking it is HOT and will bite you!

 

[bankbuster]

Re: 98 Mercury 115 hp starter, battery, solenoid, issues. HELP it wont even start no

Ok....lets get real. These can be a teadious, complex and lengthly diagnosis. So, After spending $150 on parts, testing everything "I" can, and missing da*n near all the spring spawn, and most importantly....worrying to much on whether I'm hurting things more than I'm helping........I took the boat to the shop. For those that have been helping......THANK YOU! I'm sure with more time this issue would be resolved but I am "jonesin' to fish and the weather is PERFECT! I have learned alot and we will soon know even more. The shop asked many questions and I was actually able to answer them (and understand them) which I would NOT have been able to do prior to this thread...again..THANKS! Sorry to those that were "in this" to solve and I give out a "Your welcome" to those who are ready to see this nearly 100 reply thread come to a close. lol. Shop said give them a few days and they'll let me know. I will update then so stay tuned...Jayson.

 

[CharlieB]

Re: 98 Mercury 115 hp starter, battery, solenoid, issues. HELP it wont even start no

......... new regulator, rectifier, and starter. Still NO park. It will probably start at some point so I still think the NO SPARK thing is intermittent. At this point it wont start so we'll just say NO SPARK. I did pull all plugs and all pistons are free. I did remove blk/ylw wire from switchbox..still no spark.......... Switchbox? Stator? Trigger Assembly? One of these three is surely my problem. Can the stator, trigger assembly, and/or switchbox be intermittent? Is there anyway to easily test 1 or all of these to narrow down my problem? One at a time is fine...the more I can test and exclude the closer I'll get to solving I guess. I would like to get a manual that best descibes "troubleshooting" and or "ignition/wiring" as this will be the extent of what I will be working on. If it ever needs rebuild on motor or lower unit that will be done at boat shop...not for me. Any advice for best manual? Also, I need a DVA meter....what type should I look for? Are they all the same? Expensive? I have a regular ohm/multimeter and a UEI DM200 Digital Multimeter.....dont really know if I need them or how to use but I can learn. Open to suggestions...Thanks, Jayson.

With the B/Y disconnected at the switchbox you eliminated all wiring harness', ignition switch and lanyard switch, leaving the bare basic ignition system, stator, trigger, and switchbox.

An intermittant 'no spark' condition here is usually caused by slow cranking speed, the stator needs a minimum 300 RPM to generate sufficient voltage to operate the switchbox, and for the triggers to generate the minimum needed to trigger the switchbox.

Since new battery, cables, and starter motor, about the only thing left is the switchbox, but before ordering any NON REFUNDABLE electrical part you should DVA test the stator and triggers to ensure they are generating their required voltage.

Sorry it has taken so long and you gave up.

You need a DVA Adaptor to use with your meter. You can build one cheaply or find one on Ebay.

Simple, easy to make DVA adapter for standard Multimeter?/ 374544

 

[bankbuster]

Re: 98 Mercury 115 hp starter, battery, solenoid, issues. HELP it wont even start no

No problem CharlieB. I am having the shop do just a diagnostic cehck to determine exactly what is faulty. Once I find out I will test myself to learn and try to make sense of all of it. this should help me in the future. I hope to have them diagnos the problem and then I will do the reapirs. Kind-of-a backwards approach but I should learn something from it. I should hear something this week...stay tuned.

 

[GONEFUSHING]

Re: 98 Mercury 115 hp starter, battery, solenoid, issues. HELP it wont even start no

Hello there Im new to this form, but am very familiar with this exact problem. I have the same problem with my 96 mercury 115hp 2stroke(2+2). What was the final problem on this motor. I believe it is the switchbox on my motor. Would be nice to get a reply but I don't think so being its such a older thread. well i too am dyin to fish please respond with what the mech said.

 

[Cyblet]

Re: 98 Mercury 115 hp starter, battery, solenoid, issues. HELP it wont even start no

I should hear something this week...stay tuned.

I just started experiencing the exact same thing you are/were going through. Same motor too. I'd love to know if you ever got it resolved and if so, what it was.