Mercury Outboards (40-115 HP)

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BoatCop
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Location: Parker, AZ

Mercury Outboards (40-115 HP)

#1 Post by BoatCop » Thu Sep 04, 2014 3:48 pm

Reading the Blessed post about the fuel problems on his Optimax made me decide to post about my recent glitch.

My 2012 Merc 90 EFI 4 stroke with 28.3 hours on it has given me 28.1 hours of flawless operation. (I've used it a lot more than that, but we drift and/or beach and swim a lot) :mrgreen:

The last .2 hours is where the glitch came in. We were out a few weeks ago and stopped for lunch after cruising, towing, swimming all morning and when we went to leave, the engine struggled to start and once started bogged down and seemed starved for fuel. Decided to head back to the ramp and it "ran", but couldn't get over 4,800 RPM. (WOT runs around 6,300).

Back at the ramp, left it idling at the dock while I went to back the trailer in. Back to the boat and it died as soon as I put it in gear and wouldn't re-start. Tried for about 20 minutes. No deal. Drifted into a slip, moored and told the dockmaster I was having issues and would be back to get it later. About an hour later, after a few calls around to local (supposed) Mercury shops and no real answers, went back and it started right up. I high tailed it to the ramp and onto the trailer before it died again.

Just picked it up today from my Merc Tech (thanks Lakeland Marine, Lake Havasu City). It seems that some engines were shipped with a faulty (prone to fail) Float Control Switch in the fuel system, and substandard seals (like Blessed) in the fuel pump. Mercury sent out a TSB (Technical Service Bulletin) about these issues, but didn't send an official recall because a small % fail and most will run for years with no issues. There's also a problem with the foam type air cleaner deteriorating, which was replaced with a newer metal mesh type.

In any event, the repairs were made 100% under Warranty and now I have no issues.

I would recommend that anyone with similar fuel issues on a 40-115 HP Merc (2 stroke or 4 stroke) 5 years or so old or less, take it to an authorized Mercury Service Center and have it checked out. If the engine is out of warranty, Mercury may still cover the repairs, since it's a known issue. Calling Mercury Customer Service direct and getting a warranty repair authorization beforehand may be more effective that having the shop do it for you. (have your engine serial number)

Even if you AREN'T experiencing issues, it would be a good idea to have the Tech check it out so you don't get stuck out on the water.

On another note, I also had them install the Merc Smartcraft System Monitor, so I can keep an eye on all engine systems and watch the hours for service interval.
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Alan
2012 22' Sun Tracker DLX Party Barge w/Merc 90 EFI 4 Stroke
2016 Chevy Tahoe
2009 GMC Sierra
2001 Jeep TJ Wrangler
1999 Southwind 34L MH
2 little Basset Hounds

crookedlaker
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Location: angola IN

Re: Mercury Outboards (40-115 HP)

#2 Post by crookedlaker » Fri Sep 05, 2014 4:55 am

How much did the Merc Smartcraft System Monitor system cost if you don't mind me asking,
looks like a nice system.
Mike
2017 Harris Sunliner 200
Tri-toon P+ Package
2017 Mercury 150 4 stroke

2014 Harris Cruiser 200 Sold!!
2014 Mercury 90 four stroke (120 HP via Simon Motorsports) Sold!!

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Tlowry
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Re: Mercury Outboards (40-115 HP)

#3 Post by Tlowry » Fri Sep 05, 2014 7:14 am

HERE is the bulletin Alan is speaking of. Looks like Merc could have gotten this straightened out by now. Really gives me the warm and fuzzies about my 14 90FS. :?
2014 Sun Tracker Fishin Barge 22 DLX w/ 2014 Merc 90 FS
1984 Mon Ark 20 w/ 2000 Merc 50 FS Bigfoot (now belongs to nephew)

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[url=https://www.flickr.com/photos/14121089@N06/][u]Some Pictures[/u][/url]

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dunny961
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Re: Mercury Outboards (40-115 HP)

#4 Post by dunny961 » Fri Sep 05, 2014 9:06 am

crookedlaker wrote:How much did the Merc Smartcraft System Monitor system cost if you don't mind me asking,
looks like a nice system.
Mike

X2 on the Smartcraft setup.... I've been curious about it awhile now, but wanted someone else to take the plunge first!!! :biggrin2
2011 Sun Tracker Fishin' Barge 21 "Laid Off Sick"
90 Mercury Fourstroke
2006 Chevy 2500HD SBCC 4X4 w/Duramax

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dunny961
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Re: Mercury Outboards (40-115 HP)

#5 Post by dunny961 » Fri Sep 05, 2014 9:13 am

BoatCop, I've dealt with both issues on my Merc. Last summer, I removed the cowling to check my fuel filters thinking they were the starting issue I had, and noticed that my air filter was only a plastic skeleton without any foam on it. Apparently, when there is a fuel float issue and flooding, it sends all the excess fuel and fumes back into the filter through a vent hose and that is what dissentegrates the filter. Nice to hear they started using a wire mesh to keep everything together.
2011 Sun Tracker Fishin' Barge 21 "Laid Off Sick"
90 Mercury Fourstroke
2006 Chevy 2500HD SBCC 4X4 w/Duramax

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BoatCop
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Re: Mercury Outboards (40-115 HP)

#6 Post by BoatCop » Fri Sep 05, 2014 12:48 pm

The Smartcraft gauge, wiring harness and install cost me around $500.00. It may seem a little expensive, but what's it worth to you to protect a $9,000+ engine/$25,000+ boat?

I probably could have bought and installed it myself for half that, but don't have the time and the boat was already at the shop. I'd rather they do it anyway just to deflect any later warranty claim denials.

This monitors and displays:

RPM
Engine Hours
Oil temp
Oil Pressure
Engine water temp
Engine water pressure
Sea water temp
Fuel pressure
Fuel used
Fuel flow (GPH)
Fuel level
Fuel range (if calibrated to your tank)
Battery voltage
Vessel speed
Trim position

Plus warnings/alarms for:
Engine overheat
Low oil level
Low oil pressure
Low water pressure
Water in the fuel
Engine overspeed
Engine malfunction (fault codes)
Alan
2012 22' Sun Tracker DLX Party Barge w/Merc 90 EFI 4 Stroke
2016 Chevy Tahoe
2009 GMC Sierra
2001 Jeep TJ Wrangler
1999 Southwind 34L MH
2 little Basset Hounds

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dunny961
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Re: Mercury Outboards (40-115 HP)

#7 Post by dunny961 » Sat Sep 06, 2014 7:14 am

Thanks for the info. That's a little cheaper than I figured it was gonna be. Sounds like a winter time project for the boat shop!
2011 Sun Tracker Fishin' Barge 21 "Laid Off Sick"
90 Mercury Fourstroke
2006 Chevy 2500HD SBCC 4X4 w/Duramax

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mitchwilldoit
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Re: Mercury Outboards (40-115 HP)

#8 Post by mitchwilldoit » Sun Sep 07, 2014 8:02 pm

Is there another place where where the serial # can be found besides the transom mount mine is warn off. a stamp on the block perhaps.
thanks

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BoatCop
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Re: Mercury Outboards (40-115 HP)

#9 Post by BoatCop » Mon Sep 08, 2014 7:23 am

mitchwilldoit wrote:Is there another place where where the serial # can be found besides the transom mount mine is warn off. a stamp on the block perhaps.
thanks
The serial # is stamped on the block. Also check on the freeze plugs. They may be more accessible than than the block#.
Alan
2012 22' Sun Tracker DLX Party Barge w/Merc 90 EFI 4 Stroke
2016 Chevy Tahoe
2009 GMC Sierra
2001 Jeep TJ Wrangler
1999 Southwind 34L MH
2 little Basset Hounds

crookedlaker
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Re: Mercury Outboards (40-115 HP)

#10 Post by crookedlaker » Wed Sep 10, 2014 5:08 am

does installation of the smartcraft gauge disable your existing gauges or do they remain functional

Thanks

Mike
2017 Harris Sunliner 200
Tri-toon P+ Package
2017 Mercury 150 4 stroke

2014 Harris Cruiser 200 Sold!!
2014 Mercury 90 four stroke (120 HP via Simon Motorsports) Sold!!

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BoatCop
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Re: Mercury Outboards (40-115 HP)

#11 Post by BoatCop » Wed Sep 10, 2014 7:15 am

Existing gauges remain functional. The gauge wiring harness has a separate plug directly into the computer ECM.
Alan
2012 22' Sun Tracker DLX Party Barge w/Merc 90 EFI 4 Stroke
2016 Chevy Tahoe
2009 GMC Sierra
2001 Jeep TJ Wrangler
1999 Southwind 34L MH
2 little Basset Hounds

mmcneice
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Re: Mercury Outboards (40-115 HP)

#12 Post by mmcneice » Wed Sep 10, 2014 10:37 am

Thanks for the information, Boatcop. Had the exact same two issues (filter and float) happen to me over the Labor Day weekend with my 2011 115 FS :(. Boat mechanic is waiting to hear back from Mercury on warranty coverage.

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teecro
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Re: Mercury Outboards (40-115 HP)

#13 Post by teecro » Sat Jun 04, 2016 7:16 pm

BoatCop wrote:Existing gauges remain functional. The gauge wiring harness has a separate plug directly into the computer ECM.
After getting fooled by the "simulator" feature on this gauge I didn't get to use it too much before returning to work last time off ship but I thought that I recalled the gauge reading for water pressure. But when I checked again last time home I noted that this is not reading. Have good water pressure out the pee hole... Also I can't get the Trim/Tilt reading to work, I can program it but on display it does not work. Wondering if this is because I have a trim/till gauge in dash already?
T CRO
2017 Berkshire CTS 24 RFX with Yamaha F150/Simomized 200
2015 Caravelle 16 EBo with Mercury 90

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teecro
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Re: Mercury Outboards (40-115 HP)

#14 Post by teecro » Sat Jun 04, 2016 7:23 pm

BoatCop wrote:... This monitors and displays:

RPM yes
Engine Hours yes
Oil temp yes
Oil Pressure yes
Engine water temp no
Engine water pressure no
Sea water temp no
Fuel pressure no
Fuel used yes
Fuel flow (GPH) yes
Fuel level not using
Fuel range (if calibrated to your tank) not using
Battery voltage yes
Vessel speed not using
Trim position having issue with
T CRO
2017 Berkshire CTS 24 RFX with Yamaha F150/Simomized 200
2015 Caravelle 16 EBo with Mercury 90

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BoatCop
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Re: Mercury Outboards (40-115 HP)

#15 Post by BoatCop » Sun Jun 05, 2016 2:26 pm

teecro wrote:
BoatCop wrote:Existing gauges remain functional. The gauge wiring harness has a separate plug directly into the computer ECM.
After getting fooled by the "simulator" feature on this gauge I didn't get to use it too much before returning to work last time off ship but I thought that I recalled the gauge reading for water pressure. But when I checked again last time home I noted that this is not reading. Have good water pressure out the pee hole... Also I can't get the Trim/Tilt reading to work, I can program it but on display it does not work. Wondering if this is because I have a trim/till gauge in dash already?
I would do a master re-set on the gauge and re-program it. I was having some issues with mine also, and a reset and programming, going step by step in the book, made everything read correctly again.
Alan
2012 22' Sun Tracker DLX Party Barge w/Merc 90 EFI 4 Stroke
2016 Chevy Tahoe
2009 GMC Sierra
2001 Jeep TJ Wrangler
1999 Southwind 34L MH
2 little Basset Hounds

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