Mariner 115 HP Outboard Service Manual – 70/75/80/90/100/115 HP 2-Stroke Workshop Repair PDF

Description

Mariner 115 HP Outboard Service Manual & Complete 2-Stroke Workshop Coverage

This Mariner 115 HP Outboard Service Manual is the full workshop publication used by marine mechanics to service, troubleshoot and rebuild Mariner two-stroke outboards across the 70, 75, 80, 90, 100 and 115 horsepower range. It covers three-cylinder and four-cylinder engines, both power trim designs, oil injection, carburetion, ignition, the gear housing, mid-section, shock absorber and the complete powerhead. Every procedure is written for a mechanic working with hand tools and Mercury Marine special tools, with the torque values, clearances and service limits you need to do the job correctly the first time.

File Details

• Manual type: Service / Workshop Manual
• Brand: Mariner (Mercury Marine)
• Covered models: 70, 75, 80, 90, 100, 115 HP outboards
• Engine type: 2-Cycle, 3-Cylinder (70/75/80/90) and 4-Cylinder (100/115)
• Language: English
• Document number: 90-13645–2
• File format: PDF (instant download)

Chapters Covered

• 1. General Information and Specifications
• 2. Electrical and Ignition (2A Ignition, 2B Battery/Charging/Starting, 2C Timing/Synchronizing/Adjusting, 2D Wiring Diagrams)
• 3. Fuel System and Carburetion (3A) and Oil Injection System (3B)
• 4. Powerhead (4A 3-Cylinder, 4B 4-Cylinder)
• 5. Lower Unit (5A Gear Housing, 5B Mid Section, 5C Shock Absorber)
• 6. Power Trim (6A Design I, 6B Design II, 6C Single Ram)
• 7. Outboard Motor Installation / Attachments (7A Engine Attachments, 7B Tiller Handle and Co-Pilot)

1. General Information and Specifications

Opens with the model-by-model specification tables – idle RPM (650-700 in forward gear), full throttle range (4750-5250 for 3-cylinder, 5000-5500 for the 90, 4750-5250 for 100/115), cylinder bore 3.375 in. (85.7mm), stroke 2.65 in. (67.3mm) on three-cylinder and 2.930 in. (74.4mm) on four-cylinder, gear ratios, fuel tank capacity 6.6 U.S. gallons, gear housing lubricant capacity 22.5 fl. oz. and the 50:1 / 80:1 gasoline-oil ratios. Also covers cowl removal, filling the oil injection system, trim “in” angle adjustment, manual tilt, connecting the engine wiring harness, ride-guide steering cable lubrication, and the full out-of-season storage and submersion recovery procedures.

2. Electrical and Ignition

The ignition section (2A) covers the CD breakerless system in detail: stator test, trigger test, ignition coil test, switch box, key switch continuity testing for COMMANDER and COMMANDER 2000 controls, and the complete ADI test sequence with DVA voltage charts for 3-cylinder and 4-cylinder stators. Section 2B handles the battery, charging system and starter motor – rectifier test, stator ohms test for 9/16/24 ampere alternators, tachometer terminal block tests, starter removal, disassembly, brush replacement, armature testing for shorts and ground, and starter solenoid testing. Section 2C gives timing pointer adjustment, carburetor synchronization, carburetor/oil pump synchronization, idle timing and maximum timing procedures. Section 2D contains the full engine and remote control wiring diagrams.

3. Fuel System and Oil Injection

Fuel pump operation and testing, anti-siphon valve troubleshooting, fuel pump disassembly and check valve reassembly, carburetor adjustments, float level setting (7/16 in. ± 0.015), low-speed mixture adjustment, WME carburetor specification sheet with main jet and bowl vent jet sizes, high-altitude rejetting charts, carburetor removal and disassembly. The oil injection section covers hose connections, oil pump drive system, carburetor/oil pump synchronization, bleeding air from the oil pump inlet and outlet, oil pump output test, low oil sensor test, warning horn system check, and the complete oil injection troubleshooting chart.

4. Powerhead

Powerhead repair for both three-cylinder and four-cylinder engines – flywheel removal and installation, stator and trigger removal, ignition coil and switch box service, crankcase cover removal, cylinder block inspection, honing procedure, check valve identification across the three designs, piston and piston ring cleaning, measuring piston skirt, crankshaft inspection, connecting rod alignment, reed block inspection, thermostat testing, and the complete step-by-step powerhead reassembly with the double torque pattern for crankcase cover bolts.

5. Lower Unit – Gear Housing, Mid Section and Shock Absorber

Gear housing removal and disassembly, propeller removal, draining and inspecting gear lubricant, water pump service including impeller inspection and wear limits, bearing carrier disassembly, propeller shaft inspection, drive shaft wear sleeve installation, pinion gear depth determination and forward gear backlash measurement, shift shaft service, trim tab adjustment, gear housing pressure test and the full reassembly sequence. Mid-section covers swivel bracket, transom bracket and exhaust plate components with exploded views and torque tables. The shock absorber section covers removal, inspection, rebuild kit and installation.

6. Power Trim

Three separate power trim systems are covered – Design I (side fill reservoir), Design II (aft fill reservoir) and Single Ram. Includes general operating information, trimming characteristics, manual tilting, trim “in” angle adjustment, filling and purging, hydraulic and electrical system troubleshooting charts with numbered test points, wiring diagrams, power trim assembly removal and installation, “UP” and “DOWN” pressure checks with the test gauge kit, trim rod removal and repair, tilt ram disassembly and reassembly, pump replacement, motor disassembly, armature tests and brush replacement.

7. Outboard Motor Installation and Attachments

Steering cable and steering link rod installation for Ride-Guide and Super Ride-Guide systems, dual front and opposite side cable routing, steering eyes and coupler installation, tension adjustment, trim tab installation and adjustment, remote control installation, shift cable and throttle cable adjustment to the engine, engine wiring harness connection and cable routing, and mounting the outboard on the transom including recommended mounting height, centerline location and mounting hole drilling. The tiller handle section covers the tiller arm, shift lever, Co-Pilot installation and the complete tiller handle reassembly.

Why This Mariner 2-Stroke Outboard Workshop Manual Belongs in Your Shop

A two-stroke Mariner outboard lives or dies by the tolerances it is assembled to. Ignition timing that is off by a couple of degrees, a lean fuel mixture at wide-open throttle, a mis-synchronized oil pump or a gear housing assembled without the correct pinion depth and backlash – each of these is a rebuild waiting to happen. This Mariner 115 HP outboard service manual gives you the actual numbers the factory published: DVA voltage ranges for the stator and trigger, primary coil resistance, carburetor main jet sizes for every model and altitude, piston skirt diameter for standard and oversize pistons, rod bolt torque with the additional 90° turn, crankcase cover double torque pattern, pinion gear depth feeler gauge value and forward gear backlash range.

The manual also tells you which components to inspect and how. Cracked impeller blades, grooved water pump plates over 0.030 in., scored cylinder bores more than 0.003 in. out of round, worn driveshaft splines, seized needle bearings, chipped reed petals, stuck check valves, failed thermal overload switches and the three different bleed check valve designs are all covered with the specific wear criteria and replacement criteria a working mechanic needs. Detonation is treated as its own subject with the causes enumerated – over-advanced timing, low octane fuel, incorrect propeller pitch, lean mixture, wrong spark plug heat range, cooling system deterioration and combustion chamber deposits – plus the visual evidence of piston damage.

Every wiring diagram, every hydraulic troubleshooting chart and every exploded view is in the file. You get the complete ignition system test chart, the full starting circuit flow chart with numbered test points, the power trim electrical troubleshooting trees for both the trailer-button and non-trailer-button remote controls, the trim indicator gauge and trim sender wiring diagrams, and the gear housing exploded parts views with every torque specification called out in lb. in., lb. ft. and N·m.

IMAGES PREVIEW

Because this is an instant PDF download, there is no shipping, no waiting and no risk of a damaged book arriving at your bench. Open the file on a laptop, tablet or phone in the garage, at the dock or on the water. Print the pages you need for a specific job – the pinion depth chart, the carburetor specification sheet, the torque table for the crankcase cover – and keep the rest of the Mariner outboard repair manual clean on your device. Whether you are tuning a 70 HP three-cylinder, synchronizing carburetors on a 100 HP four-cylinder, rebuilding the gear housing on a 115 HP or rebuilding the power trim on any of these engines, the correct procedure and the correct specification are already in this file.