2001-2010 Mercury 115 EFI 4-Stroke Outboard Motor Service Manual

Covers 115 EFI Outboards with procedures for fuel injection system, ignition, charging, starting, and maintenance. PN 90-881980R1

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Document Details

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Document Number / Seller:
27204 / Sharon Young
File Size:
17.65 MB
File Type:
PDF
Language:
English
Printable:
Yes
Category:
Outboard Motor
Last updated / verified
Oct 16, 2025

Models Covered & Key Technical Specifications

Mercury 115 EFI Outboard (90-881980R1) - 2001-2010

Covers ignition timing, fuel injection, charging, starting, and maintenance procedures.

  • Reference Working Temperature: 4° ATDC specifies the ignition timing for idle operation.
  • Approved Print Rate: 6200 rpm dictates the maximum engine speed.
  • Designated Unit Dimensions: 1.0-1.1 mm specifies the spark plug gap.
  • Certified Factory Torque: 18 lb-ft establishes the flywheel nut torque setting.
  • Fundamental Basic Injection Volume: 17 gph (65 L/h) signifies the fuel pump discharge rate.
  • Designated Basic Injection Volume: 7 psi (49 kPa) specifies the maximum fuel pump pressure.

Professional Workshop Service Manual & Technical Specifications

Mercury 115 EFI Outboard (2001-2010) Service Manual

Documentation-Type: Service Manual // Service-Level: Comprehensive / Technical Logic // Documentation-Type: Repair & Maintenance Data.

Service-Nexus Operational-Logic Calibration-Data
Engine Specifications Fuel System Operation Ignition System Parameters
Maintenance Schedule Charging & Starting System Troubleshooting Procedures
Wiring Diagrams EFI System Theory Troubleshooting Charts

Featuring a modular arrangement of comprehensive sections, this manual details the Electronic Fuel Injection system, ignition, charging and starting systems, and essential maintenance procedures for your Mercury 115 EFI Outboard (2001-2010). It provides clear, step-by-step instructions for component replacement, diagnostic testing, and routine upkeep, ensuring optimal performance and longevity.

Ignition System Overview

The manual thoroughly documents the ignition system, including its electronic control module (ECM), sensors, and ignition coils. It covers the theory of operation, component descriptions, and detailed test procedures for ensuring the ignition system functions correctly.

Fuel Injection System Details

Explanations of the electronic fuel injection system cover critical components such as fuel injectors, fuel rail, pressure regulator, and vapor separator. Procedures for removal, installation, and troubleshooting are provided for each element.

Maintenance and Troubleshooting Guide

This manual details inspection and maintenance schedules, covering everything from pre-use checks to long-term storage. Diagnostic procedures and troubleshooting tips are included to help identify and resolve issues efficiently.

... documents torque specifications for fasteners to ensure proper rotational loosening prevention.

FAQ

Assess the **critical** calibration settings for the ignition timing? keyboard_arrow_down

4° ATDC is the ignition timing for idle operation, and 20° BTDC for Wide Open Throttle (WOT).

What components have **required** clearance measurements? keyboard_arrow_down

0.039 - 0.043 in. (1.0 - 1.1 mm) specifies the spark plug gap, and 0.008 in. (0.2 mm) is the commutator undercut limit.

Confirm the **specified** torque specifications for key components? keyboard_arrow_down

140 lb-ft (190 Nm) is the specified torque for the flywheel nut, and 70 lb-in. (8 Nm) is required for the stator screw.

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Reviews (3)

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Rated 4 out of 5 stars
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The illustrations and detailed sections in this manual are fantastic. I feel more confident tackling repairs now. Customer support was also very responsive when I had questions!
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This manual made servicing my Mercury 115 EFI a breeze! The step-by-step instructions are clear and easy to follow. The download process was smooth and I received the link quickly after purchase.