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Mercury 135 Optimax User Manual

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See also: Service Manual , Operation & Maintenance Manual
Welcome Aboard!
Proper care and maintenance is an important part in keeping your Mercury Product operating at peak efficiency
for maximum performance and economy. The enclosed Owner's Registration Card is your key to trouble‑free
family fun. Refer to your Operation and Maintenance Manual for full details of your warranty coverage.
Details of your nearest dealer can be found on www.marinepower.com where country maps and full contact
information are displayed.
Is your engine properly registered for warranty purpose? Please check on www.marinepower.com. If
necessary, please contact your local dealer.

Declaration of Conformity

This outboard motor's serial number plate contains in the lower corner left hand corner either the CE mark
alone or the CE mark accompanied by a notified body number. This outboard motor manufactured by Mercury
Marine, Fond du Lac, WI, USA or Marine Power Europe Inc. Park Industriel, de Petit‑Rechain, Belgium
complies with the requirements of the following directives by meeting the associated standards, as amended:
If the CE mark is accompanied by a notified body number, the following Recreational Craft Directive applies:
Recreational Craft Directive:
Owner's manual (A.2.5)
Handling characteristics (A.4)
Outboard engine starting (A.5.1.4)
Fuel tanks (A.5.2.2)
General steering system
Exhaust emission requirements (B.2)
Owner's manual (B.4)
Noise emission levels (C.1)
The notified body responsible for surveillance of the quality system under Full Quality
Assurance Module H of Directive 2003/44/EC is:
Det Norske Veritas
Norway
Notified Body Number: 0575
If the CE mark is not accompanied by a notified body number, the following Recreational Craft Directive
language applies:
Recreational Craft Directive:
Owner's manual (A.2.5)
Handling characteristics (A.4)
Outboard engine starting (A.5.1.4)
Fuel tanks (A.5.2.2)
2003/44/EC amending 94/25/EC
ISO 10240
ISO 8665
ISO 11547
ISO 13591; ISO 8469
ABYC P‑17
ISO 8178
ISO 8665
ISO 14509
ISO 10240
ISO 8665
ISO 11547
ISO 13591; ISO 8469
i
94/25/EC

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  • Page 1: Declaration Of Conformity

    Welcome Aboard! Proper care and maintenance is an important part in keeping your Mercury Product operating at peak efficiency for maximum performance and economy. The enclosed Owner's Registration Card is your key to trouble‑free family fun. Refer to your Operation and Maintenance Manual for full details of your warranty coverage.
  • Page 2 EN 61000‑6‑2; EN 61000‑4‑2; EN Electrostatic discharge testing 61000‑4‑3 This declaration is issued under the sole responsibility of Mercury Marine and Marine Power Europe. Patrick C. Mackey President, Mercury Marine, Fond du Lac, WI USA European Regulations Contact: Regulations and Product Safety Department, Mercury Marine,...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Warranty Information Transfer Of Warranty.............................. 1 Warranty Registration United States And Canada....................1 Warranty Registration Outside The United States And Canada................1 Optimax Outboard Limited Warranty United States, Canada, Europe, Confederation of Independent States, Middle-East and Africa............................2 3 Year Limited Warranty Against Corrosion......................
  • Page 4 TABLE OF CONTENTS Features and Controls Remote Control Features............................. 23 Warning System..............................23 Power Trim And Tilt.............................. 25 Operation Pre-Starting Check List............................29 Operating In Freezing Temperatures........................29 Operating In Salt Water Or Polluted Water......................29 Operating at High Elevations..........................29 Setting Trim Angle While Running Engine at Idle Speed..................
  • Page 5 Engine Will Not Start............................53 Engine Runs Erratically............................53 Performance Loss..............................54 Battery Will Not Hold Charge..........................54 OWNER SERVICE ASSISTANCE Local Repair Service............................55 Service Away From Home............................ 55 Parts And Accessories Inquiries........................... 55 Service Assistance............................... 55 Mercury Marine Service Offices........................... 55...

  • Page 7: 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. Your dealer can also process this change of information.

  • Page 8: Optimax Outboard Limited Warranty United States, Canada, Europe, Confederation Of Independent States, Middle-East And Africa

    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. If the service provided is not covered by this warranty, purchaser shall pay for all related labor and material, and any other expenses associated with that service.

  • Page 9: Year Limited Warranty Against Corrosion

    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 2 Jet Drive, Tracker by Mercury Marine Outboard, MerCruiser Inboard or sterndrive engine (Product) will not be rendered inoperative as a direct result of corrosion for the period of time described below.
  • Page 10 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. If the service provided is not covered by this warranty, purchaser shall pay for all related labor and material, and any other expenses associated with that service.

  • Page 11: Warranty Coverage And Exclusions

    Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. Oils, lubricants or fluids changed as a matter of normal maintenance is customer's responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration.

  • Page 12: 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 13: High-Speed And High-Performance Boat Operation

    For additional information, obtain a copy of our Hi‑Performance Boat Operation booklet from your dealer, distributor, or Mercury Marine. ob00307 Outboard Remote Control Models The remote control connected to your outboard must be equipped with a start in neutral only protection device.

  • Page 14: Lanyard Stop Switch

    GENERAL INFORMATION WARNING Disengagement of a steering link rod can result in the boat taking a full, sudden, sharp turn. This potentially violent action can cause occupants to be thrown overboard exposing them to serious injury or death. ob00655 Self‑locking nuts Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves far enough away from the operator's position (as in accidental ejection from the operator's position) to activate the switch.

  • Page 15: Protecting People In The Water

    GENERAL INFORMATION While activation of the lanyard stop switch will stop the engine immediately, a boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut down. However, the boat will not complete a full circle.

  • Page 16: Passenger Safety Message - Pontoon Boats And Deck Boats

    GENERAL INFORMATION Shift outboard into neutral and shut off the engine before allowing people to swim or be in the water near your boat. 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.

  • Page 17: Impact With Underwater Hazards

    GENERAL INFORMATION ob00314 The primary concern is the boat changing direction while in the midst of the jump. In such case the landing may cause the boat to veer violently in a new direction. Such a sharp change in direction can cause occupants to be thrown out of their seats, or out of the boat.

  • Page 18: Exhaust Emissions

    GENERAL INFORMATION • The boat could move suddenly in a new direction. Such a sharp change in direction can cause occupants to be thrown out of their seats or out of the boat. • A rapid reduction in speed. This will cause occupants to be thrown forward, or even out of the boat. •...

  • Page 19: Selecting Accessories For Your Outboard

    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 20: Recording Serial Number

    GENERAL INFORMATION Know and obey all nautical rules and laws of the waterways. Boat operators should complete a boating safety course. Courses are offered in the U.S.A. by 1) The U.S. Coast Guard Auxiliary, 2) The Power Squadron, 3) The Red Cross and 4) your state boating law enforcement agency.
  • Page 21 GENERAL INFORMATION Models Kilowatts 100.7 111.9 130.5 Full Throttle RPM Speed 5000‑5500 RPM 5250‑5750 RPM Idle Speed in Forward 550 ± 25 RPM Gear Number of Cylinders Piston Displacement 2508 cc (153 cu. in.) Cylinder Bore 88.4 mm (3.500 in.) Piston Stroke 67.3 mm (2.650 in.) Recommended Spark...

  • Page 22: Component Identification

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

  • Page 23: Installation

    INSTALLATION Installing Outboard WARNING Before operation, the outboard must be correctly installed with the required mounting hardware as shown. Failure to correctly fasten outboard could result in outboard ejecting off boat transom causing serious injury, death, or property damage. We strongly recommend that your dealer install your outboard and related accessories to ensure proper installation and good performance.
  • Page 24 INSTALLATION ob00323 If changing conditions cause the RPM to drop below the recommended range, such as warmer, more humid weather, operation at higher elevations, increased boat load, or a dirty boat bottom/gearcase, a propeller change or cleaning may be required to maintain performance and ensure the outboards durability. Check full‑throttle RPM, using an accurate tachometer, with the engine trimmed out to a balanced‑steering condition (steering effort equal in both directions) without causing the propeller to break loose.

  • Page 25: Transporting

    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 26: 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 27: Fuel Additives

    Mercury Optimax/DFI or Quicksilver DFI 2‑Cycle Engine Oil is recommended for your engine. If Mercury Optimax/ DFI or Quicksilver DFI 2‑Cycle engine oil is not available, we recommend using Mercury or Quicksilver TC‑W3 Premium Plus 2‑Cycle Oil. Severe engine damage may result from use of an inferior oil.

  • Page 28: Filling Fuel Tank

    FUEL AND OIL Filling Fuel Tank WARNING Avoid serious injury or death from a gasoline fire or explosion. Always stop the engine and do not smoke or allow open flames or sparks in the area while filling fuel tanks. Fill fuel tanks outdoors away from heat, sparks, and open flames. Remove portable fuel tanks from boat to refill them.

  • Page 29: 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. ob00329 Control handle ‑...
  • Page 30 FEATURES AND CONTROLS The warning horn will emit either a continuous beep or intermittent short beeps. This will alert the operator and help identify the following listed situations. For visual display of the specific engine functions and for additional engine data, refer to SmartCraft Product information, following. Warning Horn Function Sound...

  • Page 31: Power Trim And Tilt

    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 32: Operation

    FEATURES AND CONTROLS ob00663 Trim switch Trim range of travel Tilt range of travel 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.

  • Page 33: Operation

    FEATURES AND CONTROLS WARNING Avoid possible serious injury or death. Adjust outboard to an intermediate trim position as soon as boat is on plane to avoid possible ejection due to boat spin out. Do not attempt to turn boat when on plane if outboard is trimmed extremely in or down and there is a pull on the steering wheel or tiller handle.

  • Page 34: Operation

    FEATURES AND CONTROLS ob00665 SHALLOW WATER OPERATION When operating your boat in shallow water, you can tilt the outboard beyond the maximum trim range to prevent hitting bottom. Reduce engine speed below 2000 RPM. Tilt outboard up. Make sure all the water intake holes stay submerged at all times. Operate the engine at slow speed only.

  • Page 35: Operation

    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 36: Engine Break-In Procedure

    OPERATION ob01079 Engine Break‑in Procedure CAUTION Severe damage to the engine can result by not complying with the Engine Break‑in Procedure. GASOLINE/OIL BREAK-IN MIXTURE NOTE: Do not use pre‑mixed gas and oil during break‑in. Use straight gasoline during engine break‑in and after engine break‑in.
  • Page 37 OPERATION 3405 Open fuel tank vent screw (in filler cap) on manual venting type fuel tanks. ob00348 Squeeze the fuel line primer bulb several times until it feels firm. ob00349 Set the lanyard stop switch to "RUN" position. Refer to General Information ‑ Lanyard Stop Switch. ob00350 Shift outboard to neutral (N) position.

  • Page 38: Gear Shifting

    OPERATION Do not advance the neutral fast idle speed feature on the remote control for starting. ob00560 Turn the ignition key to "START" position. Release the key when engine starts. If engine fails to start in 10 seconds, return the key to "OFF" position, wait one second and try again. ob00354 NOTE: The electronic starting system will automatically prime (choke) the engine and increase idle speed for starting.

  • Page 39: Stopping The Engine

    OPERATION ob00557 Stopping The Engine Reduce engine speed and shift outboard to neutral position. Turn ignition key to "OFF" position. ob00360...

  • Page 40: Maintenance

    SELECTING REPLACEMENT PARTS FOR YOUR OUTBOARD We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants. WARNING Using a replacement part that is inferior to the original part could result in personal injury, death, or product failure.

  • Page 41: Inspection And Maintenance Schedule

    MAINTENANCE Inspection And Maintenance Schedule BEFORE EACH USE • Check that lanyard stop switch stops the engine. • Visually inspect the fuel system for deterioration or leaks. • Check outboard for tightness on transom. • Check steering system for binding or loose components. •...

  • Page 42: Top Cowl Removal And Installation

    MAINTENANCE ob01084 Attach a water hose to the fitting. Turn on the water and flush for 3 to 5 minutes. ob01085 Top Cowl Removal And Installation REMOVAL Pull out the front cowl latch. ob00672 Lift up the rear cowl latch. Remove the top cowl. FOURSTROKE ob00673 INSTALLATION...

  • Page 43: Cleaning Care For Top Cowl

    MAINTENANCE Cleaning Care for Top Cowl IMPORTANT: Dry wiping (wiping the plastic surface when it is dry) will result in minor surface scratches. Always wet the surface before cleaning. Follow cleaning and waxing procedure. CLEANING AND WAXING PROCEDURE Before washing, rinse the top cowl with clean water to remove dirt and dust that may scratch the surface. Wash the top cowl with clean water and a mild non‑abrasive soap.

  • Page 44: Steering Link Rod Fasteners

    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 45: Fuse Replacement

    MAINTENANCE ob00676 Special washer head bolt (10‑849838) Nylon insert locknut (11‑826709113) Flat washer (2) Nylon insert locknut (11‑826709113) Description lb. in. lb. ft. Special washer head bolt Nylon insert locknut "d" Nylon insert locknut "c" Tighten until seats, then back off 1/4 turn Assemble steering link rod to steering cable with two flat washers and self‑locking nylon insert locknut.

  • Page 46: Corrosion Control Anode

    MAINTENANCE 3406 Good fuse Accessories ‑ 20 AMP fuse Blown fuse Ignition coil circuit ‑ 20 AMP fuse SmartCraft data bus circuit ‑ 5 AMP fuse Electric fuel pump/ECM driver power/oil pump circuit ‑ 20 AMP fuse Corrosion Control Anode Your outboard has corrosion control anodes at different locations.

  • Page 47: Battery Information

    MAINTENANCE Make sure the battery is secure against movement. Battery cable terminals should be clean, tight, and correctly installed. Positive to positive and negative to negative. Make sure the battery is equipped with a nonconductive shield to prevent accidental shorting of battery terminals.
  • Page 48 Pull propeller straight off shaft. If propeller is seized to the shaft and cannot be removed, have the propeller removed by an authorized dealer. Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with Teflon.
  • Page 49 MAINTENANCE ob00378 Tube Ref No. Description Where Used Part No. Anti-Corrosion Grease Propeller shaft 92-802867Q1 2-4-C with Teflon Propeller shaft 92-802859Q1 IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft (especially in salt water), 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.

  • Page 50: Spark Plug Inspection And Replacement

    MAINTENANCE Place a block of wood between gearcase and propeller and torque propeller nut to specifications. Description lb. in. lb. ft. Propeller nut 10. Secure propeller nut by bending three of the tabs into the thrust hub grooves. ob00422 Spark Plug Inspection And Replacement WARNING Avoid serious injury or death from fire or explosion caused by damaged spark plug boots.

  • Page 51: Compressor Air Intake Filter

    MAINTENANCE Spark Plug Spark plug gap 0.80 mm (0.031 in.) 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. Description lb. in. lb. ft. Spark plug Compressor Air Intake Filter The filter should be changed every 100 hours of operation, or once a season.

  • Page 52: Lubrication Points

    92-802865Q1 • Trim Rod Ball Ends ‑ Turn the ball ends to work the lubricant into the ball sockets. ob01093 Lubricate the following with Quicksilver or Mercury Precision Lubricants Anti‑Corrosion Grease or 2‑4‑C with Teflon. Tube Ref No. Description Where Used Part No.
  • Page 53 MAINTENANCE ob00378 Lubricate the following with Quicksilver or Mercury Precision Lubricants 2‑4‑C with Teflon or Special Lubricant 101. Tube Ref No. Description Where Used Part No. Alternator belt tensioner pivot shaft, swivel Special Lubricant 101 bracket, tilt support 92-802865Q1 lever, tilt tube, steering...

  • Page 54: Gearcase Lubrication

    MAINTENANCE ob00684 WARNING The end of the steering cable must be fully retracted into the outboard tilt tube before adding lubricant. Adding lubricant to steering cable when fully extended could cause steering cable to become hydraulically locked. A hydraulically locked steering cable will cause loss of steering control, possibly resulting in serious injury or death.
  • Page 55 Fill/drain plug 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 Place outboard in a vertical operating position. Remove vent plug.

  • Page 56: Submerged Outboard

    MAINTENANCE Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the water. This immediate attention by a servicing dealer is necessary once the engine is exposed to the atmosphere to minimize internal corrosion damage to the engine.

  • Page 57: Storage

    The most effective method for storage preparation is to add the recommended amount of Mercury Precision fuel Stabilizer and Mercury Precision Quickleen products as described on their containers to the fuel tank before the last operation of the boat.

  • Page 58: 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 Ref No. Description Where Used Part No.

  • Page 59: Starter Motor Will Not Crank The Engine

    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 60: Performance Loss

    TROUBLESHOOTING Performance Loss POSSIBLE CAUSES • Throttle not fully open. • Damaged propeller or improper propeller size. • Boat overloaded or load improperly distributed. • Excessive water in bilge. • Boat bottom is dirty or damaged. Battery Will Not Hold Charge POSSIBLE CAUSES •...

  • Page 61: Local Repair Service

    Your satisfaction with your outboard product is very important to your dealer and to us. If you ever have a problem, question or concern about your outboard product, contact your dealer or any authorized Mercury Marine dealership. If additional assistance is required, take these steps.
  • Page 62 Telephone (954) 744‑3513 Mercury Marine 11650 Interchange Circle North Miramar, FL 33025 (954) 744‑3535 U.S.A. Japan Telephone 81‑053‑423‑2500 Mercury Marine - Japan Anshin-cho 283-1 Hamamatsu 81‑053‑423‑2510 Shizuoka-ken, Japan 435-0005 Japan Asia, Singapore Telephone 5466160 Mercury Marine Singapore 72 Loyang Way...

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