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MERCURY 115 HP OUTBOARD FOURSTROKE Service Manual
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🏷️ Basic Information Vehicle Identification Make: Mercury Marine Model: 115 HP FourStroke Outboard Model Variant: 115 EFI FourStroke (inline-4 cylinder) Production Years Covered: 2001-2010 model years, as covered by this...
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🏷️ Basic Information
Vehicle Identification
Make:
Mercury Marine
Model:
115 HP FourStroke Outboard
Model Variant:
115 EFI FourStroke (inline-4 cylinder)
Production Years Covered:
2001-2010 model years, as covered by this service manual set
Engine Family:
Mercury 115 FourStroke EFI, based on the Yamaha F115 powerhead design
Application:
Outboard propulsion for aluminum and fiberglass fishing boats, pontoons, and runabouts
Serial Number Location:
Port side of the swivel bracket on the transom bracket assembly
Engine Type:
Four-stroke, inline 4-cylinder, 16 valves
Displacement:
1741 cc (106.2 cu in)
👋 Introduction
Market Position
Target Audience:
Recreational boaters, fishing boat owners, and marine technicians servicing mid-size four-stroke outboards
Model Class:
Mid-range horsepower class, 115 HP, suitable for boats 16-22 ft
Competitive Advantage:
Four-stroke fuel economy and quiet operation versus comparable two-stroke outboards, with EFI for consistent starting and reduced emissions
Key Features:
Electronic fuel injection, four-stroke durability, quiet idle, no oil-in-fuel mixing required
Maintenance Advantage:
Standard 100-hour and annual service intervals align with other four-stroke outboards in its class
Emissions:
Designed to meet EPA 2006 and later emission standards for spark-ignition marine engines
📋 Manual Details
Publication Information
Manual Type:
Complete factory-style service and repair manual
Coverage Areas:
Engine mechanical, fuel and EFI systems, ignition and electrical, cooling, lubrication, mid-section, gearcase, and rigging
Page Count:
Approximately 400-600 pages depending on edition
Language:
English
Format:
PDF
Delivery Method:
Instant download after purchase
Binding:
Digital
File Organization:
Bookmarked by section for navigation
Searchability:
Fully searchable text
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Cylinder head, valves, pistons, rings, connecting rods, crankshaft, cylinder block, and timing chain
Fuel System:
Fuel pump, fuel filter, vapor separator, high-pressure fuel pump, fuel injectors, and throttle body
EFI Electronic Control:
ECM, sensors, wiring, and diagnostic procedures
Ignition System:
Ignition coils, spark plugs, and ignition timing
Charging System:
Stator, rectifier/regulator, and battery charging circuit
Starting System:
Starter motor, neutral start switch, and starting circuit
Cooling System:
Water pump, impeller, thermostat, and cooling passages
Lubrication System:
Oil pump, oil filter, and oil pressure monitoring
Mid-Section:
Swivel bracket, tilt tube, transom brackets, and trim/tilt system
Gearcase:
Forward, neutral, and reverse gears, clutch dog, propeller shaft, and water pump housing
Trim and Tilt:
Hydraulic trim/tilt unit, pump motor, and fluid
Rigging and Controls:
Remote control cables, throttle and shift linkage, and steering
Procedures Included
Diagnostic Procedures:
Troubleshooting charts, EFI diagnostic codes, and electrical tests
Disassembly and Assembly:
Step-by-step procedures with torque sequences
Adjustments:
Valve clearance, throttle cable, shift cable, and idle speed
Scheduled Maintenance:
Break-in, 20-hour, 100-hour, and annual service
Technical Depth
Torque Specifications:
Complete torque tables for critical fasteners
Clearances:
Valve clearance, piston-to-bore, ring end gap, and gear backlash
Wiring Diagrams:
Full electrical schematics
Special Tools:
Required tools and part numbers
Parts Information
Part Numbers:
Referenced where applicable in procedures
Exploded Views:
Illustrations for major assemblies
Component Identification:
Callouts on diagrams for rebuild and replacement
📊 Manual Specifications
File & Compatibility
File Format:
PDF (searchable, bookmarked, zoomable)
Compatibility:
Windows, macOS, Linux, iOS, and Android — any device with a PDF reader
Requirements:
A PDF reader application (e.g. Adobe Acrobat Reader, free)
Searchability:
Fully text searchable for fast lookup of any topic
Print & Binding
Print Quality:
High-resolution digital pages, printable at full clarity
Binding Type:
N/A — digital download, no physical binding
Paper Type:
N/A — digital download, no physical paper
⚙️ Engine Specifications
Engine Options
Primary Engine:
115 HP FourStroke EFI, inline 4-cylinder, 1741 cc (106.2 cu in)
Bore and Stroke:
79.0 mm x 88.8 mm (3.11 in x 3.50 in)
Valve Train:
DOHC, 4 valves per cylinder, 16 valves total
Fuel Delivery:
Electronic fuel injection (EFI)
Fuel Type:
Unleaded gasoline, 87 octane minimum
Fuel Tank Recommendation:
Use fresh fuel; avoid ethanol blends above 10 percent where possible
Oil Type:
Four-stroke marine oil, NMMA FC-W certified
Oil Capacity:
4.3 L (4.5 US qt) with filter change
Starting:
Electric start
Full Throttle RPM Range:
5000-6000 RPM
Horsepower:
115 HP at the propeller shaft
Cooling:
Water-cooled, thermostatically controlled
🔧 Transmission
Drive and Gearcase
Standard Transmission:
Forward, neutral, and reverse mechanical gearcase with dog clutch
Gear Ratio:
2.15:1
Shift Mechanism:
Remote mechanical shift cable
Optional Transmission:
N/A - single gearcase configuration for this model
Lubrication:
Gearcase lubricant, marine grade
Gearcase Oil Capacity:
Approximately 0.9 L (0.95 US qt)
Propeller Shaft:
Spline-driven propeller with rubber hub
Trim and Tilt:
Power trim and tilt standard
Steering:
Mechanical or hydraulic steering compatible
📐 Dimensions
Exterior
Shaft Lengths Available:
20 in (508 mm) long shaft and 25 in (635 mm) extra-long shaft
Overall Length:
Approximately 685 mm (27 in) from mounting bracket to rear of cowling
Cowl Width:
Approximately 500 mm (20 in)
Overall Height:
Varies with shaft length, approximately 1270 mm (50 in) for long shaft model
Transom Mounting:
Standard clamp or bolt-on transom bracket
Weights
Curb Weight:
Approximately 178 kg (392 lb) for 20 in shaft model
Weight Variation:
Extra-long shaft adds approximately 4-5 kg (9-11 lb)
Dry Weight:
Approximately 168 kg (370 lb)
🛡️ Safety Features
Engine Safety
Overheat Protection:
Temperature sensor triggers warning horn and power reduction
Low Oil Pressure:
Warning system alerts operator and limits RPM
Over-Rev Protection:
ECM limits RPM at upper full-throttle range
Neutral Start:
Engine will not start unless in neutral
Operator Safety
Emergency Stop Switch:
Lanyard kill switch standard
Tiller Handle:
Available configuration with safety lanyard
Cowling Latch:
Secure latches prevent accidental opening
Ratings
Crash Test Information:
N/A - outboard engines are not crash-tested as vehicles
Emissions Compliance:
EPA 2006 and later standards
💡 Technology Features
Engine Management
Engine Control Module:
EFI ECM manages fuel and ignition
Sensors:
MAP, intake air temperature, engine coolant temperature, throttle position, and crankshaft position
Diagnostics:
Service check connector and warning horn fault codes
Idle Control:
Electronic idle speed control
Controls and Instrumentation
Gauges:
Compatible with Mercury analog and digital gauges
Warning Horn:
Audible alerts for overheat, low oil, and sensor faults
Trim Gauge:
Optional trim position indicator
Driver Assistance
N/A:
N/A - outboard engine, no driver assistance systems
🔧 Maintenance
Service Intervals
Break-In Service:
20 hours or first 3 months
Oil and Filter Change:
Every 100 hours or annually, whichever comes first
Gearcase Lubricant:
Every 100 hours or annually
Water Pump Impeller:
Inspect at 100 hours, replace every 300 hours or 3 years
Spark Plugs:
Replace every 100 hours or annually
Fuel Filter:
Replace annually or every 100 hours
Valve Clearance:
Inspect every 200 hours or 2 years
Timing Chain:
No scheduled replacement under normal use
Anodes:
Inspect every 100 hours, replace as needed
Fluid Specifications
Engine Oil:
NMMA FC-W 10W-30 or 10W-40 marine four-stroke oil
Gearcase Lubricant:
Mercury Gear Lube or equivalent marine gearcase lubricant
Fuel:
Unleaded 87 octane minimum, up to 10 percent ethanol
Known Issues and Wear Items
Water Pump Impeller:
Common wear item, especially in sandy or shallow water
Fuel Injectors:
May require cleaning or replacement on high-hour engines
Thermostat:
Can stick open or closed causing temperature issues
Trim and Tilt Seals:
May leak with age
Corrosion:
Anode maintenance critical in saltwater use
📚 Vehicle History
Brand Heritage
Manufacturer:
Mercury Marine, a division of Brunswick Corporation
Founded:
1939 in Fond du Lac, Wisconsin
Reputation:
Major manufacturer of outboard motors, sterndrives, and marine engines
Engine Design Origin:
115 FourStroke powerhead derived from Yamaha F115 four-stroke design under an OEM agreement
Model Evolution
Introduction:
FourStroke 115 introduced in early 2000s to replace two-stroke models
EFI Adoption:
Electronic fuel injection used throughout the production run
Updates:
Minor updates to ECM calibration and corrosion protection over the years
Successor:
Later replaced by newer Mercury 115 FourStroke models with updated powerheads
Production Location
Final Assembly:
Fond du Lac, Wisconsin, USA
Powerhead Origin:
Yamaha Marine, Japan, for early production
🏆 Awards & Recognition
Industry Recognition
NMMA Certification:
Meets NMMA and EPA requirements for marine engines
Customer Satisfaction:
Recognized for reliability in the mid-range four-stroke outboard class
Innovation:
Part of Mercury's transition to clean four-stroke outboard technology
Model Era Recognition
Class Standing:
Competitive with other 115 HP four-stroke outboards of its era
Longevity:
Known for long service life with proper maintenance
Resale Value:
Maintains reasonable resale value in the used outboard market
Media Reviews:
Generally positive reviews for fuel economy and quiet operation