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  1. R

    Mercury 1995 115 runs at WOT, dies below 1200 RPM

    I put the OEM switch box back on the motor and took it out fishing today, RL wire connected. The motor acted the same way as with the new switch box. So the problem is apparently with the RL and not SB. I told the vendor to cancel his freebie offer of a different SB. The RL is only 3 years old...
  2. R

    Mercury 1995 115 runs at WOT, dies below 1200 RPM

    Sorry, I mistook your answer. You know what a switch box is, you just never had a problem with one. D'oh!
  3. R

    Mercury 1995 115 runs at WOT, dies below 1200 RPM

    Mercury calls it a switch box, others call it a power pack. It's the module that's mounted on the starboard side where all the wires connect; stator, trigger, RL, etc. When my rig was new it would do 52 on the speedo, now it's just 45 and sometimes slower. RPMs at WOT are 5200 with the RL...
  4. R

    Mercury 1995 115 runs at WOT, dies below 1200 RPM

    I was never aware of the RL doing anything in almost 29 years until I replaced the switch box and stator. After I did, when I hit 5000 RPM the engine fell on its face, then recovered, then fell on its face, etc. If the rev limiter was working before, preventing me from exceeding 5250 RPMs it...
  5. R

    Mercury 1995 115 runs at WOT, dies below 1200 RPM

    Hi Mark, we were right about disconnecting the RL. I've posted the results in the other forum but I'll post again here for documentation: Went to the lake today and had success in running at WOT with the rev limiter disconnected. The motor ran up to 5250 with no stalling or other problems. I...
  6. R

    Mercury 1995 115 runs at WOT, dies below 1200 RPM

    I totally agree. I have disconnected the grounding wire for the rev limiter (black w/yellow) and after Memorial Day flotilla goes home on Monday I'll take it down to the lake and try it again. Other than this problem the new parts are great. They have breathed new life into the motor. It starts...
  7. R

    Mercury 1995 115 runs at WOT, dies below 1200 RPM

    Well, there seems to be a hitch. It starts and runs just fine, very fast start up. I rode around on plane to 35 MPH, about 4,000 RPM. I opened it up and as soon as it hit 5,000 RPM it stalled, not died, just stalled, and I immediately throttled back and the motor idled. I started up again and...
  8. R

    Mercury 1995 115 runs at WOT, dies below 1200 RPM

    It was definitely the stator. I replaced it and the switch box then went out to the driveway with the ear muffs and muffler. It fired on the first turn of the key. I let it run about 5 minutes until the water was warm, turned it off for a couple of minutes then started up again. No problems. I'm...
  9. R

    Mercury 1995 115 runs at WOT, dies below 1200 RPM

    I ran a comparison test between the wires on both old and new stators. I found a seller on Amazon that provided the range of S/N that their product supported and I asked them to test between the red and blue wires. I do find a difference between the old and new in a couple of places. One has...
  10. R

    Mercury 1995 115 runs at WOT, dies below 1200 RPM

    The new stator arrived and the test between the red and blue wires reads the same as the old one; infinite resistance. That's very discouraging
  11. R

    Mercury 1995 115 runs at WOT, dies below 1200 RPM

    Parts ordered. I removed the flywheel and the stator. Bench tested between red and blue wires on the stator and still have infinite resistance. I did a continuity test between the connectors and point of entry to the stator for both wires and that's good. The problem has to be in the stator...
  12. R

    Mercury 1995 115 runs at WOT, dies below 1200 RPM

    Somehow I get things in my head that don't belong there. It gets worse with age. :oops: At least I can still take things apart and put them back together. The tools to remove the flywheel should arrive today. I've been looking for the stator, which is no longer available from Mercury, and found...
  13. R

    Mercury 1995 115 runs at WOT, dies below 1200 RPM

    Went on the fishing trip, had a good time, motor never started, not even a pop. Weather was warmer in Alabama than Kentucky. There weren't any 58° mornings like I had here, where the motor would start. The coldest it got was 63° and a black motor in full sun doesn't help. I don't know if that...
  14. R

    Mercury 1995 115 runs at WOT, dies below 1200 RPM

    V=L di/dt :) Where: v = instantaneous voltage across the inductor L = inductance in henries (H) di/dt = instantaneous rate of current change in amperes per second (A/s) Above my pay grade. You must be an electrician :) I agree that at idle you produce less voltage (or amperage)...
  15. R

    Mercury 1995 115 runs at WOT, dies below 1200 RPM

    There is a LOT of rain predicted for our fishing trip. Having the motor acting up is going to make this "unfun" to be sure. I may try to do some testing while I have it down there but usually we just meet-great-fish and drink (a lot less drinking these days). We have guys coming from different...
  16. R

    Mercury 1995 115 runs at WOT, dies below 1200 RPM

    I may have plugged in the onboard charger when this picture was taken but I did check charging status while it was running, before plug in. It was definitely charging. I will check it again on the trip and get another picture. Batteries will discharge with higher humidity, which we have in...
  17. R

    Mercury 1995 115 runs at WOT, dies below 1200 RPM

    My battery charges when the motor is running. I have 3 LED voltmeters mounted in the rear hatch so I can keep an eye on the batteries. This is a grab from a video while the motor was running, started from cold. I was thinking that if the stator tests bad, I might replace the trigger also, since...
  18. R

    Mercury 1995 115 runs at WOT, dies below 1200 RPM

    Okay, thanks Mark. Like I said earlier I'm getting ready for a fishing trip next week and don't have time to do anything else to it right now. I think the flywheel is tapped. I found a review for the flywheel puller by someone who had a 95 115 Mercury and he said it fit his and he was able to...
  19. R

    Mercury 1995 115 runs at WOT, dies below 1200 RPM

    Thanks, Mark. Excellent information. I typed DVM when I meant DVA; oops, senior moment. You are way ahead of me on the timing light brightness but it definitely makes sense. I used the old timing light on an old West Bend long ago. Did the top cylinder and it was nice and bright. Did the bottom...
  20. R

    Mercury 1995 115 runs at WOT, dies below 1200 RPM

    BTW, I squirted some gas mix into the top 2 carbs, plastic cover on, plastic cover off. Nothing, just cranked. I was thinking of maybe a shot of starting fluid in each
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