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End Cap OptiMax Air Compressor
Models Affected
MERCURY/MARINER
135/150 HP, 2.5 LITRE OPTIMAX
S/N 0G868674 Thru 0G925496
200/225 HP, 3.0 LITRE OPTIMAX
S/N 0G869454 Thru 0G925439
The air compressor end cap retaining bolts may become loose due to a machining error.
The loose bolts could allow the end cap to lift out of the compressor body causing an oil leak,
and/or loss of air pressure.
Owner Notification
A letter will be sent to every registered owner of an affected outboard. The letter will advise
the owner to return their outboard to their selling dealer or any authorized dealer for replace-
ment of the compressor end cap.
Dealer Outboard Inventory
Affected outboards in dealer inventory MUST BE reworked prior to customer delivery.
Service Parts Stock
Return all compressor end cap assemblies P/N 1173-828131A4 to Mercury Marine for
credit.
Correction
Replace the air compressor end cap assembly with P/N 1173-828131A5. The new assem-
bly includes the end cap, crankshaft, bearings, pulley flange, seals, and O-rings.
99-6 JUNE 1999
Printed in U.S.A. -
1999, Mercury Marine
ADVISORY
BULLETIN
No. 99-6
Page 1 of 6
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Related Manuals for Mercury OptiMax
Summary of Contents for Mercury OptiMax
- Page 1 Dealer Outboard Inventory Affected outboards in dealer inventory MUST BE reworked prior to customer delivery. Service Parts Stock Return all compressor end cap assemblies P/N 1173-828131A4 to Mercury Marine for credit. Correction Replace the air compressor end cap assembly with P/N 1173-828131A5. The new assem- bly includes the end cap, crankshaft, bearings, pulley flange, seals, and O-rings.
- Page 2 END CAP OPTIMAX AIR COMPRESSOR Disassembly Remove flywheel cover Use 3/8-inch (9.5 mm) drive on belt tensioner arm to relieve belt tension, and remove belt. Remove the 5 bolts that retain the pulley to the pulley flange. 57489 57784 2.5 Liter 3.0 Liter...
- Page 3 END CAP OPTIMAX AIR COMPRESSOR Remove the 4 bolts that retain the end cap to the compressor body. 57809 End cap retaining bolts (4) While rotating the pulley flange alternately clockwise and counterclockwise about 1/8 to 1/4 turn, pull outward on the pulley flange. Continue rotating until the end cap assem- bly has been removed from the compressor body.
- Page 4 END CAP OPTIMAX AIR COMPRESSOR Reassembly Lubricate end cap O-ring and O-ring contact area in compressor body with two cycle oil. Slide the new end cap assembly into the compressor body, keeping the connecting rod journal lined up with the open end of the connecting rod, until the crankshaft just enters the open end of the connecting rod.
- Page 5 After the end cap has been replaced, place a WHITE paint dot on the compressor body near the bar code identification. Warranty The normal 2 year Optimax warranty applies. Complete warranty claim listing. Outboard serial number Qty. 1 End cap assembly P/N 1173-828131A5 Eight tenths (0.8) hour labor...
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Page 6: What You Should Do
Dear Mercury Marine Customer: Our records indicate that you are the owner of a Mercury Marine outboard included in a recall. Due to an air compressor manufacturing error, the air compressor end cap retaining bolts may become loose. The loose bolts could allow the end cap to lift out of the compressor body caus- ing an oil leak, and/or loss of air pressure.
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