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Mercury 135 Pro XS OptiMax Manual

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Thank You
for your purchase of one of the finest outboards available.
You have made a sound investment in boating pleasure.
Your outboard has been manufactured by Mercury Marine, a
world leader in marine technology and outboard
manufacturing since 1939. These years of experience have
been committed to the goal of producing the finest quality
products. This led to Mercury Marine's reputation for strict
quality control, excellence, durability, lasting performance,
and being the best at providing after the sale support.
Please read this manual carefully before operating your
outboard. This manual has been prepared to assist you in
the operation, safe use, and care of your outboard.
All of us at Mercury Marine took pride in building your
outboard and wish you many years of happy and safe
boating.
Again, thank you for your confidence in Mercury Marine.
EPA Emissions Regulations
Outboards sold by Mercury Marine in the United States are
certified to the United States Environmental Protection
Agency as conforming to the requirements of the regulations
for the control of air pollution from new outboard motors.
This certification is contingent on certain adjustments being
set to factory standards. For this reason, the factory
procedure for servicing the product must be strictly followed
and, wherever practicable, returned to the original intent of
the design. Maintenance, replacement, or repair of the
emission control devices and systems may be
performed by any marine engine repair establishment or
individual.
Engines are labeled with an Emission Control Information
decal as permanent evidence of EPA certification.
The engine exhaust from this product contains chemicals
known to the state of California to cause cancer, birth
defects or other reproductive harm.
eng
WARNING
!
i

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Summary of Contents for Mercury 135 Pro XS OptiMax

  • Page 1 This manual has been prepared to assist you in the operation, safe use, and care of your outboard. All of us at Mercury Marine took pride in building your outboard and wish you many years of happy and safe boating.
  • Page 2 Warranty Message The product you have purchased comes with a limited warranty from Mercury Marine, the terms of the warranty are set forth in the Warranty Information section of this manual. The warranty statement contains a description of what is covered, what is not...
  • Page 3 • Provides timely service for all Mercury Marine customers. • Offers extended service hours and mobile service, when appropriate. • Uses, displays, and stocks adequate inventory of genuine Mercury Precision Parts. • Offers a clean, neat shop with well organized tools and service literature.
  • Page 4 Description of Engines and Essential Requirements Engine Type Fuel Type Combustion Cycle ☒ Outboard engine ☒ Petrol ☒ 2 stroke Identification of Engines Covered by This Declaration of Conformity Unique engine EC Module H Name of engine family identification number: certificate starting serial number number...
  • Page 5 Name / function: Mark D. Schwabero, President, Mercury Outboard Date and place of issue:July 24, 2008 Fond du Lac, Wisconsin, USA...

  • Page 7: Table Of Contents

    WARRANTY INFORMATION Warranty Registration..............1 Transfer of Warranty..............2 Transfer of Mercury Product Protection (Extended Service Coverage) Plan United States and Canada......... 2 Outboard Limited Warranty............3 3 Year Limited Warranty Against Corrosion........ 7 Warranty Coverage and Exclusions.......... 11 U.S. EPA Emissions Limited Warranty........13 Emission Control System Components........
  • Page 8 Low Permeation Fuel Hose Requirement ......... 47 EPA Pressurized Portable Fuel Tank Requirements....47 Fuel Demand Valve (FDV) Requirement........48 Mercury Marine's Pressurized Portable Fuel Tank....48 Filling Remote Oil Tank............. 49 Filling Engine‑Mounted Oil Reservoir Tank....... 50 Filling Fuel Tank................ 51 Features and Controls Remote Control Features............
  • Page 9 Operation Pre‑Starting Check List.............. 60 Operating in Freezing Temperatures......... 60 Operating in Saltwater or Polluted Water........61 Operating at High Elevations............. 61 Setting Trim Angle While Running Engine at Idle Speed..62 Engine Break‑In Procedure............62 Starting the Engine..............63 Gear Shifting................
  • Page 10 Engine Will Not Start..............96 Engine Runs Erratically............. 97 Performance Loss..............97 Battery Will Not Hold Charge............. 97 OWNER SERVICE ASSISTANCE Local Repair Service..............98 Service Away from Home............98 Parts and Accessories Inquiries..........98 Service Assistance..............98 Mercury Marine Service Offices..........99...
  • Page 11 OUTBOARD INSTALLATION Important Information............... 101 Boat Horsepower Capacity............102 Start in Gear Protection............102 Selecting Accessories for Your Outboard........ 102 Fuel System................103 Installation Specifications............105 Lifting the Outboard..............105 Steering Cable ‑ Starboard Side Routed Cable....... 106 Steering Link Rod Fasteners........... 107 Determining Recommended Outboard Mounting Height..

  • Page 13: Warranty Information

    You may change your address at any time, including at time of warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and engine serial number to Mercury Marine’s warranty registration department.

  • Page 14: Transfer Of Warranty

    To transfer the warranty to the subsequent owner, send or fax a copy of the bill of sale or purchase agreement, new owner’s name, address, and engine serial number to Mercury Marine’s warranty registration department. In the United States and...

  • Page 15: Outboard Limited Warranty

    Transfer form. Submit to Mercury Product Protection a receipt/bill of sale, a completed Request of Transfer form, and a check payable to Mercury Marine in the amount of $50.00 (per engine) to cover the transfer fee. Plan coverage is not transferable from one product to another product or for non‑eligible applications.
  • Page 16 WARRANTY COVERAGE: Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified predelivery inspection process is completed and documented.
  • Page 17 Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser, in that case, shall pay for all related transportation charges and/or travel time.
  • Page 18 No individual or entity, including Mercury Marine authorized dealers, has been given authority by Mercury Marine to make any affirmation, representation or warranty regarding the product, other than those contained in this limited warranty, and...

  • Page 19: Year Limited Warranty Against Corrosion

    RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY. 3 Year Limited Warranty Against Corrosion WHAT IS COVERED: Mercury Marine warrants that each new Mercury, Mariner, Mercury Racing, Sport Jet, M Jet Drive, Tracker by Mercury Marine Outboard, Mercury MerCruiser...
  • Page 20 WARRANTY COVERAGE: Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified predelivery inspection process is completed and documented.
  • Page 21 Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser, in that case, shall pay for all related transportation charges and/or travel time.
  • Page 22 Mercury Precision Parts or Quicksilver MerCathode system and/or Galvanic Isolator. Corrosion damage caused by improper application of copper base antifouling paints is also not covered by this limited warranty.

  • Page 23: Warranty Coverage And Exclusions

    WARRANTY INFORMATION Warranty Coverage and Exclusions The purpose of this section is to help eliminate some of the more common misunderstandings regarding warranty coverage. The following information explains some of the types of services that are not covered by warranty. The provisions set forth following have been incorporated by reference into the Three Year Limited Warranty Against Corrosion Failure, the International Limited Outboard Warranty, and the United States and Canada Limited...
  • Page 24 8. Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. 9. Oils, lubricants, or fluids changed as a matter of normal...

  • Page 25: U.s. Epa Emissions Limited Warranty

    U.S. EPA Emissions Limited Warranty Consistent with the obligations created by 40 CFR Part 1045, Subpart B, Mercury Marine provides a five year or 175 hours of engine use, whichever occurs first, to the retail customer, that the engine is designed, built, and equipped so as to conform at...

  • Page 26: California Emissions Limited Warranty

    California, and which were manufactured for the 2001 model year and later. Mercury Marine, in compliance with those regulations, provides this limited warranty for the emission control systems (see the components listed in the Emission Control System...
  • Page 27 Mercury Marine for certification from the California Air Resources Board, for the period of time, and under the conditions, identified below.
  • Page 28 Purchaser shall not, unless requested by Mercury, ship the product or parts of the product directly to Mercury. WHAT MERCURY WILL DO: Mercury Marine's sole and...
  • Page 29 California Air Resources Board may be grounds for disallowing a warranty claim, at the discretion of Mercury Marine. Failures of warranted parts caused by the use of a nonexempted add‑on or modified part will not be covered.

  • Page 30: California Air Resources Board Explanation Of Your California Emission Control Warranty Statement

    Also included may be hoses, belts, connectors, and other emission‑related assemblies. Where a warrantable condition exists, Mercury Marine will repair your outboard engine at no cost to you, including diagnosis, parts, and labor.

  • Page 31: Emission Certification Star Label

    WARRANTY INFORMATION As the outboard engine owner, you should, however, be aware that Mercury Marine may deny you warranty coverage if your outboard engine or a part has failed due to abuse, neglect, improper maintenance, or unapproved modifications. You are responsible for presenting your outboard to a Mercury dealer authorized to service the product as soon as a problem exists.
  • Page 32 WARRANTY INFORMATION Three Stars ‑ Ultra Low Emission The Three Star label identifies engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2008 exhaust emissions standards or the Sterndrive and Inboard marine engine 2003‑2008 exhaust 42538 emission standards.

  • Page 33: General Information

    GENERAL INFORMATION Boater's Responsibilities The operator (driver) is responsible for the correct and safe operation of the boat and safety of its occupants and general public. It is strongly recommended that each operator (driver) read and understand this entire manual before operating the outboard.

  • Page 34: Boat Horsepower Capacity

    For additional information, obtain a copy of our Hi‑Performance Boat Operation booklet from your dealer, distributor, or Mercury Marine.

  • Page 35: Propeller Selection

    When choosing a propeller, a full selection of aluminum and stainless steel propellers specifically designed for your outboard are available through Mercury Marine. To view the entire product offering and find the correct propeller that is best suited for your application, visit www.mercmarinepropellers.com or see your...
  • Page 36 GENERAL INFORMATION Propellers are designated by the diameter, pitch, number of blades, and material. The diameter and pitch are stamped (cast) into the side or the end of the propeller hub. The first number represents the diameter of the propeller and the second number represents the pitch.
  • Page 37 RPM range when under normal full throttle operation. PROPELLER MATERIAL Most propellers manufactured by Mercury Marine are made from either aluminum or stainless steel. Aluminum is suitable for general purpose use and is standard equipment on many new boats.

  • Page 38: Outboard Remote Control Models

    GENERAL INFORMATION Outboard Remote Control Models The remote control connected to your outboard must be equipped with a start in neutral only protection device. This prevents the engine from starting when the shift is actuated in any position other than neutral. WARNING Starting the engine with the drive in gear can cause serious injury or death.

  • Page 39: Lanyard Stop Switch

    GENERAL INFORMATION WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod. This can cause a sudden, unexpected loss of boat control, resulting in serious injury or death due to occupants being thrown within or out of the boat.
  • Page 40 GENERAL INFORMATION The lanyard is a cord usually 122–152 cm (4–5 feet) in length when stretched out, with an element on one end made to be inserted into the switch and a snap on the other end for attaching to the operator. The lanyard is coiled to make its at‑rest condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects.
  • Page 41 GENERAL INFORMATION Important Safety Information: The purpose of a lanyard stop switch is to stop the engine when the operator moves far enough away from the operator's position to activate the switch. This would occur if the operator accidentally falls overboard or moves within the boat a sufficient distance from the operator's position.
  • Page 42 GENERAL INFORMATION WARNING Avoid serious injury or death from deceleration forces resulting from accidental or unintended stop switch activation. The boat operator should never leave the operator's station without first disconnecting the stop switch lanyard from the operator. Accidental or unintended activation of the switch during normal operation is also a possibility.

  • Page 43: Protecting People In The Water

    GENERAL INFORMATION Protecting People in the Water WHILE YOU ARE CRUISING It is very difficult for a person standing or floating in the water to take quick action to avoid a boat heading in his/her direction, even at slow speed. 21604 Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water.

  • Page 44: Passenger Safety Message - Pontoon Boats And Deck Boats

    GENERAL INFORMATION Passenger Safety Message ‑ Pontoon Boats and Deck Boats Whenever the boat is in motion, observe the location of all passengers. Do not allow any passengers to stand or use seats other than those designated for traveling faster than idle speed. A sudden reduction in boat speed, such as plunging into a large wave or wake, a sudden throttle reduction, or a sharp change of boat direction, could throw them over the front of the boat.

  • Page 45: Wave And Wake Jumping

    GENERAL INFORMATION BOATS WITH FRONT MOUNTED, RAISED PEDESTAL FISHING SEATS Elevated fishing seats are not intended for use when the boat is traveling faster than idle or trolling speed. Sit only in seats designated for traveling at faster speeds. Any unexpected, sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat.

  • Page 46: Impact With Underwater Hazards

    GENERAL INFORMATION WARNING Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat. Avoid wave or wake jumping whenever possible. There is another less common hazardous result from allowing your boat to launch off a wave or wake. If the bow of your boat pitches down far enough while airborne, upon water contact it may penetrate under the water surface and submarine for an instant.

  • Page 47: Exhaust Emissions

    Operating a boat or engine with impact damage can result in product damage, serious injury, or death. If the vessel experiences any form of impact, have an authorized Mercury Marine dealer inspect and repair the vessel or power package. Exhaust Emissions...
  • Page 48 GENERAL INFORMATION Early symptoms of carbon monoxide poisoning which should not be confused with seasickness or intoxication, include headache, dizziness, drowsiness, and nausea. WARNING Carbon monoxide poisoning can lead to unconsciousness, brain damage, or death. Keep the boat well ventilated while at rest or underway and avoid prolonged exposure to carbon monoxide.

  • Page 49: Selecting Accessories For Your Outboard

    The misuse of approved accessories or the use of nonapproved accessories can damage the product. Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system. Acquire and read the installation, operation and maintenance manuals for all your selected accessories.

  • Page 50: Safe Boating Suggestions

    GENERAL INFORMATION Safe Boating Suggestions In order to safely enjoy the waterways, familiarize yourself with local and other governmental boating regulations and restrictions, and consider the following suggestions. Use flotation devices. Have an approved personal flotation device of suitable size for each person aboard (it is the law) and have it readily accessible.
  • Page 51 GENERAL INFORMATION Be alert. The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing. The operator must have an unobstructed view particularly to the front. No passengers, load, or fishing seats should block the operator's view when operating the boat above idle speed.

  • Page 52: Recording Serial Number

    GENERAL INFORMATION Recording Serial Number It is important to record this number for future reference. The serial number is located on the outboard as shown. rial Numb XXXXXXXX XXXX RP M 23884 Serial number Model designation Year manufactured Certified Europe Insignia (as applicable) Specifications 150 Pro Models...
  • Page 53 GENERAL INFORMATION 150 Pro Models 175 Pro XS Standard gearcase 2.00:1 1.87:1 gear ratio High altitude 2.30:1 2.00:1 gearcase gear ratio Recommended Refer to Fuel and Oil gasoline Recommended oil Refer to Fuel and Oil Gearcase lubricant 665 ml (22.5 fl oz) capacity 1000 marine cranking amps (MCA) or 800 cold Battery rating...

  • Page 54: Component Identification

    GENERAL INFORMATION Component Identification 3403 Top cowl Bottom cowl Water pump indicator hole Driveshaft housing Anti‑ventilation plate Auxiliary tilt switch Transom brackets Gearcase Cooling water intake holes...

  • Page 55: Trailering Boat/Outboard

    TRANSPORTING Trailering Boat/Outboard Trailer your boat with the outboard tilted down in a vertical operating position. If additional ground clearance is required, the outboard should be tilted up using an accessory outboard support device. Refer to your local dealer for recommendations. Additional clearance may be required for railroad crossings, driveways, and trailer bouncing.

  • Page 56: Fuel And Oil

    FUEL RATINGS Mercury Marine engines will operate satisfactorily when using a major brand of unleaded gasoline meeting the following specifications: USA and Canada ‑ having a posted pump Octane Rating of 87 (R+M)/2 minimum.
  • Page 57 FUEL AND OIL The fuel system components on your Mercury Marine engine will withstand up to 10% alcohol content in the gasoline. We do not know what percentage your boat's fuel system will withstand. Contact your boat manufacturer for specific recommendations on the boat's fuel system components (fuel tanks, fuel lines, and fittings).

  • Page 58: Oil Recommendation - 135/150/175 (Standard) Models

    Recommended Oil Outboard Oil Mercury or Quicksilver Premium Plus 2‑Cycle TC‑W3 Outboard Oil is recommended for your engine. If Mercury or Quicksilver Premium Plus 2‑Cycle TC‑W3 Outboard Oil is not available, we recommend using Mercury Optimax/DFI or Quicksilver DFI 2‑Cycle Engine Oil or another brand of 2‑Cycle outboard oil that is NMMA Certified TC‑W3.

  • Page 59: Fuel Requirements

    FUEL AND OIL Fuel Requirements Do not use premixed gas and oil in this engine. The engine automatically receives extra oil during engine break‑in. Use a fresh supply of the recommended gasoline during engine break‑in and after engine break‑in. Avoiding Fuel Flow Restriction IMPORTANT: Adding components to the fuel supply system (filters, valves, fittings, etc.) may restrict the fuel flow.

  • Page 60: Fuel Demand Valve (Fdv) Requirement

    46273 Vent/water drain holes Mercury Marine's Pressurized Portable Fuel Tank Mercury Marine has created a new portable pressurized fuel tank that meets the preceding EPA requirements. These fuel tanks are available as an accessory or are provided with certain portable outboard models.

  • Page 61: Filling Remote Oil Tank

    FUEL AND OIL Since sealed fuel tanks are not openly vented, they will expand and contract as the fuel expands and contracts during heating and cooling cycles of the outside air. This is normal. REMOVING THE FUEL CAP Fuel cap Manual vent screw Tab lock 46290...

  • Page 62: Filling Engine-Mounted Oil Reservoir Tank

    FUEL AND OIL IMPORTANT: Always make sure the oil tank caps are threaded on tight. An air leak will prevent oil flow to the engine. 2723 Filling Engine‑Mounted Oil Reservoir Tank NOTE: Filling this tank is only necessary if the oil level should ever drop and the low oil warning system is activated.

  • Page 63: Filling Fuel Tank

    FUEL AND OIL Filling Fuel Tank WARNING Avoid serious injury or death from a gasoline fire or explosion. Use caution when filling fuel tanks. Always stop the engine and do not smoke or allow open flames or sparks in the area while filling fuel tanks.

  • Page 64: Features And Controls

    FEATURES AND CONTROLS Remote Control Features Your boat may be equipped with one of the Mercury Precision or Quicksilver remote controls shown. If not, consult your dealer for a description of the functions and operations of the remote control. 26800 Control handle ‑...

  • Page 65: Warning System

    FEATURES AND CONTROLS Warning System The outboard warning system incorporates a warning horn inside the boat. The warning horn may be located inside the remote control or connected to the ignition key switch. 27755 Horn inside remote control Horn connected to ignition key switch WARNING HORN SIGNALS When the key switch is turned to the "ON"...
  • Page 66 FEATURES AND CONTROLS Warning Horn Function Sound Description Cooling Continuous Engine Guardian System is activated. Power System limit will vary with level of overheat. Shift Problem outboard into neutral and check for a steady stream of water coming out of the water pump indicator hole.

  • Page 67: Power Trim And Tilt

    The horn will turn off when throttle speed is within the allowable limit. Consult your dealer for assistance. SMARTCRAFT PRODUCT A Mercury SmartCraft System instrument package can be purchased for this outboard. A few of the functions the instrument package will display are engine RPM, coolant temperature, battery voltage, fuel consumption and engine operating hours.
  • Page 68 FEATURES AND CONTROLS POWER TRIM OPERATION With most boats, operating around the middle of the trim range will give satisfactory results. However, to take full advantage of the trimming capability there may be times when you choose to trim your outboard all the way in or out. Along with an improvement in some performance aspects comes a greater responsibility for the operator, and this is being aware of some potential control hazards.
  • Page 69 FEATURES AND CONTROLS WARNING Operating the boat at high speeds with the outboard trimmed too far under can create excessive bow steer, resulting in the operator losing control of the boat. Install the trim limit pin in a position that prevents excessive trim under and operate the boat in a safe manner.
  • Page 70 FEATURES AND CONTROLS 3. Disengage the tilt support lever by raising the outboard off the support lever and rotating the lever down. Lower the outboard. Tilt support lever Knob 27778 MANUAL TILTING If the outboard cannot be tilted using the power trim/tilt switch, the outboard can be manually tilted.
  • Page 71 FEATURES AND CONTROLS 3. Operate the engine at slow speed only. If engine speed exceeds 2000 RPM, the outboard will automatically return down to the maximum trim range. AUXILIARY TILT SWITCH The auxiliary tilt switch can be used to tilt the outboard up or down using the power trim system.

  • Page 72: Pre-Starting Check List

    OPERATION Pre‑Starting Check List • Operator knows safe navigation, boating, and operating procedures. • An approved personal flotation device of suitable size for each person aboard and readily accessible (it is the law). • A ring type life buoy or buoyant cushion designed to be thrown to a person in the water.

  • Page 73: Operating In Saltwater Or Polluted Water

    Wash the outboard exterior and flush out the exhaust outlet of the propeller and gearcase with fresh water after each use. Each month, spray Mercury Precision or Quicksilver Corrosion Guard on external metal surfaces. Do not spray on corrosion control anodes as this will reduce the effectiveness of the anodes.

  • Page 74: Setting Trim Angle While Running Engine At Idle Speed

    OPERATION Setting Trim Angle While Running Engine at Idle Speed The exhaust relief hole on the outboard may become submerged if the outboard is trimmed full‑in while running at idle speed. This will cause exhaust restriction, rough idle, excessive smoke, and fouled spark plugs.

  • Page 75: Starting The Engine

    OPERATION The engine automatically receives extra oil during the first hours of operation. For most boaters this extra oil mode will be complete in about ten hours. BREAK-IN PROCEDURE 1. For the first hour of operation, allow the engine to warm up for 30–60 seconds.
  • Page 76 OPERATION 1. Lower the outboard to the vertical operating position. Make sure all cooling water intake holes are submerged. 3405 2. Open fuel tank vent screw (in filler cap) on manual venting type fuel tanks. 19748 3. Position the fuel line primer bulb so the arrow on the side of the bulb is pointing up.
  • Page 77 OPERATION 5. Shift outboard to neutral (N) position. 26838 6. For initial start of a new engine or for an engine that ran out of fuel, or was drained of fuel, the fuel system should be filled as follows: a. Squeeze the fuel line primer bulb until it feels firm. b.

  • Page 78: Gear Shifting

    OPERATION NOTE: The electronic starting system will automatically prime (choke) the engine and increase idle speed for starting. 9. Check for a steady stream of water flowing out of the water pump indicator hole. IMPORTANT: If no water is coming out of the water pump indicator hole, stop engine and check cooling water intake holes for obstruction.

  • Page 79: Stopping The Engine

    OPERATION • After shifting outboard into gear, advance the lever further to increase speed. 27237 Stopping the Engine Reduce engine speed and shift outboard to neutral position. Turn ignition key to "OFF" position. 26843...

  • Page 80: Maintenance

    We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants. EPA Emissions Regulations All new outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency, as conforming to the requirements of the regulations for the control of air pollution from new outboard motors.

  • Page 81: Inspection And Maintenance Schedule

    MAINTENANCE EMISSION CERTIFICATION LABEL An emission certification label, showing emission levels and engine specifications directly related to emissions, is placed on the engine at the time of manufacture. EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO CALIFORNIA AND U.S. EPA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES REFER TO OWNERS MANUAL FOR REQUIRED MAINTENANCE, SPECIFICATIONS, AND ADJUSTMENTS IDLE SPEED (in gear):...
  • Page 82 MAINTENANCE • Inspect the outboard for tightness to the boat transom. If any looseness of the outboard or mounting fasteners exist, retorque the outboard mounting fasteners to the specified torque. When looking for signs of looseness, look for loss of outboard transom bracket material or paint caused by movement between the outboard mounting fasteners and the outboard transom brackets.
  • Page 83 MAINTENANCE • Replace compressor air intake filter. See Compressor Air Intake Filter. • Inspect alternator belt. See Alternator Belt Inspection. • Retorque the outboard mounting fasteners that fasten the outboard to the boat transom. Tighten the fasteners to the specified torque. Description lb‑in.

  • Page 84: Flushing The Cooling System

    MAINTENANCE Flushing the Cooling System Flush the internal water passages of the outboard with fresh water after each use in salt, polluted, or muddy water. This will help prevent a buildup of deposits from clogging the internal water passages. NOTE: Engine can be stopped, or running at idle speed, when flushing the cooling system.

  • Page 85: Cleaning Care For Top Cowl

    MAINTENANCE 2. Lift up the rear cowl latch. Remove the top cowl. 27817 INSTALLATION 1. Lower top cowl into position over engine. 2. Push down the rear cowl latch to lock down the rear and push in the front cowl latch to lock down the front. Cleaning Care for Top Cowl IMPORTANT: Dry wiping (wiping the plastic surface when it is dry) will result in minor surface scratches.

  • Page 86: Fuel System

    MAINTENANCE b. Push rear of the cover down onto the rear pin and air intake tube for the air compressor. c. Insert vent hose into hole. IMPORTANT: Make sure the flywheel cover is pushed down on the air intake tube for the air compressor. 29395 Front flange Air intake tube...
  • Page 87 MAINTENANCE FUEL LINE INSPECTION Visually inspect the fuel line and primer bulb for cracks, swelling, leaks, hardness, or other signs of deterioration or damage. If any of these conditions are found, the fuel line or primer bulb must be replaced. WATER SEPARATING FUEL FILTER NOTE: The warning system will turn on when water in the fuel filter reaches the full level.

  • Page 88: Steering Link Rod Fasteners

    MAINTENANCE Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using a special washer head bolt ("a" ‑ Part Number 10‑849838) and self‑locking nylon insert locknuts ("c" and "d" ‑ Part Number 11‑826709113). These locknuts must never be replaced with common nuts (nonlocking) as they will work loose and vibrate off, freeing the link rod to disengage.

  • Page 89: Fuse Replacement

    MAINTENANCE Description lb‑in. lb‑ft Tighten until it seats, then back off 1/4 Nylon insert locknut "c" turn Assemble steering link rod to steering cable with two flat washers and self‑locking nylon insert locknut. Tighten locknut until it seats, then back nut off 1/4 turn. Assemble steering link rod to engine with special washer head bolt and self‑locking nylon insert locknut.

  • Page 90: Corrosion Control Anode

    MAINTENANCE Open the fuse holder and look at the silver colored band inside the fuse. If band is broken, replace the fuse. Replace fuse with a new fuse with the same rating. Good fuse Blown fuse Main power relay ‑ 15 amp fuse Spare fuse slot Ignition system circuit ‑...

  • Page 91: Battery Inspection

    MAINTENANCE The gearcase has two corrosion control anodes, one on each side. A third anode is installed on the bottom of the transom bracket assembly. 3398 Anode (2) on each side of gearcase Anode on transom bracket assembly Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting capability.
  • Page 92 MAINTENANCE • Do not use deep‑cycle batteries. Engines must use a marine starting battery with 1000 MCA, 800 CCA, or 180 Ah. • When connecting the engine battery, hex nuts must be used to secure battery leads to battery posts. Torque nuts to specification.

  • Page 93: Propeller Replacement

    MAINTENANCE Propeller Replacement WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting.
  • Page 94 5. Pull propeller straight off shaft. If propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. 6. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with PTFE.
  • Page 95 MAINTENANCE IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft (especially in saltwater), always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals and also each time the propeller is removed. 7.

  • Page 96: Spark Plug Inspection And Replacement

    MAINTENANCE 10. Secure propeller nut by bending three of the tabs into the thrust hub grooves. 26945 Spark Plug Inspection and Replacement WARNING Damaged spark plug boots may emit sparks which can ignite fuel vapors under the engine cowl, resulting in serious injury or death from a fire or explosion.

  • Page 97: Compressor Air Intake Filter

    MAINTENANCE 3. Set the spark plug gap to specification. 26947 Spark Plug Spark plug gap 0.80 mm (0.030 in.) 4. Before installing spark plugs, clean off any dirt on the spark plug seats. Install plugs finger‑tight, and then tighten 1/4 turn or torque to specifications.

  • Page 98: Alternator Belt Inspection

    • Belt surfaces rough or uneven. • Signs of wear on edges or outer surfaces of belt. 29398 Lubrication Points 1. Lubricate the following with Quicksilver or Mercury Precision Special Lubricant 101. Tube Description Where Used Part No. Ref No.
  • Page 99 MAINTENANCE • Trim rod ball ends ‑ Turn the ball ends to work the lubricant into the ball sockets. 28458 2. Lubricate the following with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with PTFE. Tube Description Where Used Part No.
  • Page 100 MAINTENANCE Tube Description Where Used Part No. Ref No. Alternator belt tensioner pivot 2-4-C with shaft, swivel bracket, tilt 92-802859A 1 PTFE support lever, tilt tube, steering cable • Alternator belt tensioner pivot shaft ‑ Lubricate through fitting. 29399 • Swivel bracket ‑ Lubricate through fitting. •...

  • Page 101: Checking Power Trim Fluid

    MAINTENANCE WARNING Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control. Completely retract the end of the steering cable before applying lubricant. • Steering cable ‑ Rotate steering wheel to fully retract the steering cable end into the outboard tilt tube.

  • Page 102: Gearcase Lubrication

    2. Remove fill cap and check fluid level. The fluid level should be even with the bottom of the fill hole. Add Quicksilver or Mercury Precision Lubricant Power Trim and Steering Fluid. If not available, use automotive automatic transmission fluid (ATF).
  • Page 103 3399 GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 666 ml (22.5 fl oz). GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver High Performance Gear Lubricant. CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE 1. Place outboard in a vertical operating position. 2. Remove vent plug.

  • Page 104: Submerged Outboard

    MAINTENANCE 4. Stop adding lubricant. Install the vent plug and sealing washer before removing the lubricant tube. 5. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer. Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the water.

  • Page 105: Storage Preparation

    Adding Fuel Stabilizer will help prevent the formation of varnish and gum in the gasoline. The Mercury Precision Quickleen product will help clean and lubricate the fuel injectors.

  • Page 106: Protecting Internal Engine Components

    STORAGE 4. Premix the following in a container: • 8 cc (0.27 oz) or two teaspoons of Mercury Precision Quickleen lubricant. • 8 cc (0.27 oz) or two teaspoons of Mercury Precision Fuel Stabilizer. 5. Pour this mixture in a new water separating fuel filter. Install the fuel filter.

  • Page 107: Protecting External Outboard Components

    Lubricate all outboard components listed in Maintenance ‑ Inspection and Maintenance Schedule. • Touch up any paint nicks. See your dealer for touch‑up paint. • Spray Quicksilver or Mercury Precision Lubricants Corrosion Guard on external metal surfaces (except corrosion control anodes). Tube Description Where Used Part No.

  • Page 108: Troubleshooting

    TROUBLESHOOTING Starter Motor Will Not Crank the Engine POSSIBLE CAUSES • Blown 20 amp fuse in the starting circuit. Refer to Maintenance. • Outboard is not shifted to neutral position. • Weak battery or battery connections are loose or corroded. •...

  • Page 109: Engine Runs Erratically

    TROUBLESHOOTING Engine Runs Erratically POSSIBLE CAUSES • Spark plugs fouled or defective. Refer to Maintenance section. • Incorrect setup and adjustments. • Fuel is being restricted to the engine. a. Engine fuel filter is obstructed. Refer to Maintenance section. b. Fuel tank filter obstructed. c.

  • Page 110: Owner Service Assistance

    If you are away from your local dealer and the need arises for service, contact the nearest authorized dealer. Refer to the Yellow Pages of the telephone directory. If, for any reason, you cannot obtain service, contact the nearest Mercury Marine Service Office. Parts and Accessories Inquiries All inquiries concerning genuine replacement parts and accessories should be directed to your local authorized dealer.

  • Page 111: Mercury Marine Service Offices

    • The name and address of your dealership • Nature of problem Mercury Marine Service Offices For assistance, call, fax, or write. Please include your daytime telephone number with mail and fax correspondence. United States, Canada English ‑ (920) 929‑5040...
  • Page 112 OWNER SERVICE ASSISTANCE Asia, Singapore Telephone (65) 65466160 Brunswick Asia Pacific Group T/A Mercury Marine Singapore Pte Ltd 29 Loyang Drive (65) 65467789 Singapore, 508944...

  • Page 113: Outboard Installation

    IMPORTANT: Oil must be NMMA certified TC‑W3 2‑Cycle oil. Periodically consult with your dealer to get the latest gasoline and oil recommendations. If Mercury Precision or Quicksilver 2‑Cycle Outboard Oil is not available, substitute another brand of 2‑Cycle outboard oil that is NMMA Certified TC‑W3. The use of an inferior 2‑Cycle outboard oil can reduce engine durability.

  • Page 114: Boat Horsepower Capacity

    The remote control connected to the outboard must be equipped with a start in neutral only protection device. This prevents the engine from starting in gear. Selecting Accessories for Your Outboard Genuine Mercury Precision or Quicksilver Accessories have been specifically designed and tested for this outboard.

  • Page 115: Fuel System

    OUTBOARD INSTALLATION Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with this outboard or outboard operating system. Acquire and read the installation, operation, and maintenance manuals for all selected accessories. Fuel System...
  • Page 116 OUTBOARD INSTALLATION FUEL DEMAND VALVE (FDV) REQUIREMENT Whenever a pressurized fuel tank is used, a fuel demand valve is required to be installed in the fuel hose between the fuel tank and primer bulb. The fuel demand valve prevents pressurized fuel from entering the engine and causing a fuel system overflow or possible fuel spillage.

  • Page 117: Installation Specifications

    OUTBOARD INSTALLATION 4. Turn the key switch to the "ON" position again for three seconds. 5. Continue this procedure until the fuel line primer bulb stays firm. Installation Specifications 18552 Minimum transom opening Engine centerline for dual engine ‑ 66.0 cm (26 in.) Minimum Transom Opening Single engine 84.8 cm (33‑3/8 in.)

  • Page 118: Steering Cable - Starboard Side Routed Cable

    OUTBOARD INSTALLATION 2. Thread the lifting eye into the flywheel hub for a minimum of five turns. Lifting eye 28495 3. Connect a hoist to the lifting eye. 4. Lift the outboard and place it on the boat transom. Lifting Eye 91‑90455‑‑1 Threads into the flywheel to remove the powerhead...

  • Page 119: Steering Link Rod Fasteners

    OUTBOARD INSTALLATION 2. Insert steering cable into tilt tube. 3725 3. Torque nut to specification. 3727 Description lb‑in. lb‑ft 47.5 Steering Link Rod Fasteners IMPORTANT: The steering link rod that connects the steering cable to the engine must be fastened using a special washer head bolt (P/N 10‑849838) and self‑locking nylon insert locknuts (P/N 11‑826709113).
  • Page 120 OUTBOARD INSTALLATION WARNING Improper fasteners or improper installation procedures can result in loosening or disengagement of the steering link rod. This can cause a sudden, unexpected loss of boat control, resulting in serious injury or death due to occupants being thrown within or out of the boat.
  • Page 121 OUTBOARD INSTALLATION 2. Assemble the steering link rod to the engine with the special washer head bolt "a" and self‑locking nylon insert locknut "b." 3. Torque the head bolt, then the locknut to specifications. Description lb‑in. lb‑ft Cable coupler nylon insert locknut Tighten locknut until it seats, then "d"...

  • Page 122: Determining Recommended Outboard Mounting Height

    OUTBOARD INSTALLATION Determining Recommended Outboard Mounting Height 63.5 cm (25 in.) 60.9 cm (24 in.) 58.4 cm (23 in.) 56.0 cm (22 in.) 53.3 cm (21 in.) 50.8 cm (20 in.) 48.2 cm (19 in.) 24305 The solid line is recommended to determine the outboard mounting height The broken lines represent the extremes of known successful outboard mounting height dimensions...
  • Page 123 OUTBOARD INSTALLATION 1. Mark four mounting holes on the transom using the transom drilling fixture. Drill guide holes Transom drilling fixture Transom centerline 2757 Transom Drilling Fixture 91‑98234A2 Aids in engine installation by acting as a template for engine mounting holes. 5489 2.

  • Page 124: Fastening The Outboard To The Transom

    OUTBOARD INSTALLATION Fastening the Outboard to the Transom MOUNTING BOLTS Outboard Transom Mounting Hardware ‑ Supplied with Outboard Part Number Part Name Description ½‑20 x 4.50 in. long (2.25 in. 10‑67755‑1 Outboard mounting bolt thread) 11‑826711‑17 Nylon insert locknut ½‑20 12‑28421 Flat washer 1‑1/2 in.
  • Page 125 OUTBOARD INSTALLATION CHECKING BOAT TRANSOM CONSTRUCTION IMPORTANT: Determine the strength of the boat transom. The outboard mounting locknuts and bolts should be able to hold 75 Nm (55 lb‑ft) of torque without the boat transom yielding or cracking. If the boat transom yields or cracks under this torque, the construction of the transom may not be adequate.
  • Page 126 OUTBOARD INSTALLATION 1. Apply marine sealer to the shanks of the bolts, not to the threads. 2. Fasten the outboard with the correct mounting hardware. Tighten the locknuts to the specified torque. IMPORTANT: Ensure a minimum of two full threads of the mounting bolts extend beyond the locknut after tightening.

  • Page 127: Electrical, Hoses, And Control Cables

    OUTBOARD INSTALLATION Description lb‑in. lb‑ft Outboard mounting locknuts and bolts ‑ metal lift plates and setback brackets Electrical, Hoses, and Control Cables FRONT CLAMP DISASSEMBLY Remove screws and open the front clamp assembly. Screw (2) Front clamp 7644...
  • Page 128 OUTBOARD INSTALLATION REMOTE WIRING HARNESS Route the remote 14 pin boat harness through the front clamp. Connect remote harness to the 14 pin connector on the engine harness. 11033 14 pin connector Remote 14 pin boat harness BATTERY INFORMATION WARNING Failure to properly secure the battery leads can result in a loss of power to the Digital Throttle and Shift (DTS) system, leading to serious injury or death due to loss of boat control.

  • Page 129: Single Outboard

    OUTBOARD INSTALLATION IMPORTANT: Battery cable size and length is critical. Refer to engine installation manual for size requirements. The decal needs to be placed on or near the battery box for future service reference. One 5/16 in. and one 3/8 in. hex nut is supplied per battery for wing nut replacement.
  • Page 130 OUTBOARD INSTALLATION Dual Outboards Connect a common ground cable (wire size same as engine battery cables) between negative (–) terminals on starting batteries. 15497 Red sleeve ‑ Positive (+) Black sleeve ‑ Negative (–) Ground cable Cranking battery FUEL HOSE AND OIL HOSE CONNECTIONS Fuel Hose Connection Fuel hose size ‑...
  • Page 131 OUTBOARD INSTALLATION 2. Connect the remote oil hoses to the engine hose connections. Fasten hose connections with cable ties. Hose clamp Cable tie Oil hose without blue stripe Oil hose with blue stripe Remote fuel hose 3767 SPEEDOMETER AND WATER PRESSURE TUBING CONNECTIONS NOTE: This applies to models without SmartCraft gauges.

  • Page 132: Shift And Throttle Cable

    OUTBOARD INSTALLATION Make the water pressure gauge hose connection to this tubing as follows: 7728 Speedometer water pickup tube Water pressure tube Coupler Plug Barb hose fitting Speedometer hose Water pressure tube Shift and Throttle Cable COUNTERROTATION OUTBOARDS Counterrotating (left‑hand) gearcases can be identified by a "L" stamped into the end of the propeller shaft.
  • Page 133 OUTBOARD INSTALLATION IMPORTANT: If the counterrotation outboard is rigged similar to a standard rotation outboard OR if a standard rotation outboard is rigged similar to a counterrotation outboard, the reverse gear and bearing in the gearcase must function as forward gear. The reverse gear/bearing is not designed to carry the sustained loads that are generated when running under constant high RPM and thrust conditions.
  • Page 134 OUTBOARD INSTALLATION a. Move the remote control handle from neutral into forward and advance the handle to the full speed position. Ensure that the throttle control lever is touching the throttle control lever stop screw. b. Slowly return the handle back to the neutral detent position.
  • Page 135 OUTBOARD INSTALLATION 3. Mark the center on the shift cable midway between the forward and reverse marks. 4361 Center mark 4. Align the cable end guide against this center mark when installing the cable to the engine. 5. Position the remote control and outboard into neutral position.
  • Page 136 OUTBOARD INSTALLATION 1. Align the shift cable end guide with the center mark as instructed in Locating the Center Point of the Shift Cable. 4362 Center mark 2. Place the shift cable end guide on the anchor pin and adjust the cable barrel so that it slips freely into the barrel holder.
  • Page 137 OUTBOARD INSTALLATION d. Return the remote control handle to neutral. If the propeller shaft does not turn freely without drag, adjust the barrel closer to the cable end guide. Repeat steps a through d. 5. Return the safety stop switch to the "RUN" position. スロットルケーブルの取付け...
  • Page 138 OUTBOARD INSTALLATION 3. 取付けたスロットルケーブルのアイドルストップスクリュ がストッパーに突当たるように、スロットルケーブルバレル を調整します。 4366 スロットルケーブルバレル アイドルストップスクリュ 4. スロットルケーブルの調整を下の要領で点検します: a. リモートコントロールを数回シフトさせ、 スロットルリン ケージを作動させます。 必ずプロペラシャフトを回転さ せながら、リバースにシフトします。 b. リモートコントロールをニュートラルに戻します。 アイ ドル調整スクリュとアイドルストップの間に薄い紙を当 てます。 紙を軽い抵抗をもって破かずに取外すことがで きる場合、プレロードは適切です。 必要な場合は、ケー ブルバレルを再調整します。...

  • Page 139: Front Clamp Reassembly

    OUTBOARD INSTALLATION IMPORTANT: アイドルストップスクリュは、アイドルストップ に接触していなければなりません。 7740 アイドルストップスクリュ アイドルストップ 5. ケーブルラッチでバレルホルダーを所定の位置に固定しま す。 Front Clamp Reassembly IMPORTANT: Sufficient slack must exist in engine wiring harness, battery cables, fuel hose, and oil hoses routed between clamp and engine attachment point, to relieve stress and prevent hoses from being kinked or pinched.

  • Page 140: Oil Injection Set-Up

    OUTBOARD INSTALLATION 2. Fasten clamp together with two screws. Screw (2) Front clamp 7644 Oil Injection Set‑Up FILLING THE OIL TANKS 1. Remove the fill cap from the remote oil tank and fill the tank with the recommended oil. Install the fill cap and tighten securely.
  • Page 141 OUTBOARD INSTALLATION 3. If the oil level is less than 118 ml (4 oz), loosen the vent cap. Use a squirt can and fill the tank with at least 118 ml (4 oz) of the recommended oil. Tighten the vent cap. Engine‑mounted oil reservoir tank Vent cap...
  • Page 142 OUTBOARD INSTALLATION 2. Position the fuel primer bulb so the arrow on the side of the bulb is pointing up. Squeeze the fuel hose primer bulb until it feels firm. 27348 3. Turn the ignition key switch to the "ON" position. 26846 4.

  • Page 143: Propeller Installation

    OUTBOARD INSTALLATION Propeller Installation WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting.

  • Page 144: Trim In Pin

    OUTBOARD INSTALLATION Description lb‑in. lb‑ft Propeller nut 4. Secure propeller nut by bending three of the tabs into the thrust hub grooves. 26945 Trim In Pin WARNING Operating the boat at high speeds with the outboard trimmed too far under can create excessive bow steer, resulting in the operator losing control of the boat.
  • Page 145 OUTBOARD INSTALLATION However, once on plane, the engine should be trimmed to a more intermediate position to avoid a bow‑down planing condition called plowing. Plowing can cause bow steering or oversteering and inefficiently consumes horsepower. Tilt pin (not included with engine) 2688 Stainless Steel Tilt Pin 17‑49930A 1...

  • Page 146: Maintenance Log

    MAINTENANCE LOG Maintenance Log Record all maintenance performed on your outboard here. Be sure to save all work orders and receipts. Date Maintenance Performed Engine Hours...

This manual is also suitable for:

150 pro xs optimax175 pro xs optimax150-175 pro xs optimax

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