Mariner 135 OPTIMAX Boat Outboard Motor Manuals

Manuals and User Guides for Mariner 135 OPTIMAX Boat Outboard Motor. We have 1 Mariner 135 OPTIMAX Boat Outboard Motor manual available for free PDF download: Service Manual

Mariner 135 OPTIMAX Service Manual

Mariner 135 OPTIMAX Service Manual (491 pages)

Brand: Mariner | Category: Outboard Motor | Size: 15 MB

Table of Contents

Cleanliness and Care of Outboard Motor
3
Page Numbering
3
Service Manual Outline
4
Important Information
5
Specifications
5
Master Specifications
5
Table of Contents
8
Maintenance
8
Gear Case Lubricant Capacity
8
Special Tools
9
Quicksilver Lubricant/Sealant
9
Inspection and Maintenance Schedule
11
Flushing Engine
12
- Flushing Cooling System - Using Cowl Flush Plug
  12
- Flushing Cooling System - Using Flushing Attachment 44357A2
  12
Fuel System
13
- Fuel Line Inspection
  13
- Water Separating Fuel Filter
  13
- Corrosion Control Anode
  14
- Spark Plug Inspection
  14
- Battery Inspection
  15
- Fuse Replacement
  15
- Compressor Air Intake Filter
  16
- Lubrication Points
  16
  - Removal
    16
  - Installation
    16
- Checking Power Trim Fluid
  18
- Gear Case Lubrication
  19
- Storage Preparation
  20
  - General Information
    22
  - Serial Number Location
    22
- Conditions Affecting Performance
  23
- Weather
  23
- Boat
  24
- Trim
  25
- Engine Compression
  27
- Following Complete Submersion
  28
- Salt Water Submersion
  28
- Submerged While Running
  28
- Model 135/150 DFI Powerhead Front View
  30
- Model 135/150 DFI Powerhead Starboard View 1C-10
  31
- Model 135/150 DFI Powerhead Port View
  32
- Model 135/150 DFI Powerhead Top View
  33
- Model 135/150 DFI Powerhead Aft View
  34
- Painting Procedures
  35
- Cleaning & Painting Aluminum Propellers & Gear Housings
  35
- Decal Application
  36
- Decal Removal
  36
- Instructions for "Wet" Application
  36
  - Outboard Motor Installation
    38
  - Installation Specifications
    38
  - Lifting Outboard
    38
- Installing Outboard to Boat Transom
  39
- Determining Recommended Outboard Mounting Height
  39
- Installing Outboard
  40
- Drilling Outboard Mounting Holes
  40
- Steering Cable
  41
- Securing Outboard to Boat Transom
  41
- Steering Link Rod
  42
- Electrical, Hoses and Control Cables
  43
- Installation Note
  43
- Remote Wiring Harness
  43
- Warning Gauge Harness
  44
- Battery Cables
  45
- Single Outboard
  45
- Dual Outboard
  45
- Shift Cable
  46
- Counter Rotation Outboards
  46
- Installation
  47
- Throttle Cable
  49
- Installation
  49
- Front Clamp Reassembly
  50
- Filling Fuel System
  51
- Oil Injection Set-Up
  51
- Priming the Oil Injection Pump
  52
- Purging Air from the Engine Oil Tank
  53
- Trim "In" Angle Adjustment
  53
- Trim Tab Adjustment
  54
- Models Without Power Steering
  54
- Models with Power Steering
  54
  - Electrical
    55
  - Ignition
    55
- Special Tools
  56
- Electrical Components
  58
- Theory of Operation
  60
- Ignition Component Description
  60
- Electronic Control Module (ECM)
  60
- Flywheel
  61
- Ignition Coils
  61
- Throttle Position Sensor (TPS)
  61
- Charging System Alternator
  61
- Crank Position Sensor
  61
- Temperature Sensor
  62
- Manifold Absolute Pressure (MAP) Sensor
  63
- Air Temperature Sensor
  63
- Direct Injectors
  63
- Disconnecting Harness Connectors from Ignition Coils And/Or Injectors
  63
- Fuel Injectors
  63
- Troubleshooting
  63
- Troubleshooting Without Digital Diagnostic Terminal
  64
- Troubleshooting with the Digital Diagnostic Terminal
  65
- Notes
  66
- DDT Functions – Optimax Models Software Version 4.0 and 4.1
  67
- DFI Troubleshooting Guide
  68
- Ignition Components Removal and Installation
  71
- Flywheel Cover Removal and Installation
  71
- Electronic Control Module (ECM)
  72
- Ignition Module (Coil)
  73
- Crank Position Sensor
  74
- Throttle Position Sensors (TPS)
  74
- Charging & Starting System
  75
- Battery Cable Size
  76
- Replacement Parts
  76
- Recommended Battery
  76
- Battery
  77
- Precautions
  77
- Special Tools
  77
- Charging a Discharged Battery
  78
- Winter Storage of Batteries
  78
- Flywheel Removal and Installation
  79
- Installation
  80
- Flywheel/Alternator
  82
- System Components
  84
- Precautions
  84
- Alternator Description
  85
- Diagnosis of Alternator System on Engine
  85
- Alternator Assembly
  86
- Alternator System Circuitry Test
  87
- Output Circuit
  87
- Sensing Circuit
  87
- Voltage Output
  88
- Current Output
  89
- Repair
  89
- Removal
  89
- Disassembly and Test
  90
- Rotor Test
  92
- Stator Test
  93
- Reassembly
  94
- Pulley
  95
- Alternator Belt Tension Adjustment
  96
- Installation
  96
- Starter Motor Amperes Draw
  97
- Starter System Components
  97
- Description
  97
- Starter Motor
  98
- Troubleshooting the Starter Circuit
  99
- Starter Circuit Troubleshooting Flow Chart
  100
- Starter Removal and Installation
  101
- Installation
  102
- Disassembly
  102
- Starter Cleaning, Inspection and Testing
  104
- Cleaning and Inspection
  104
- Starter Reassembly
  106
- Starter Solenoid Test
  108
- Commander 2000 Key Switch Test
  109
- Timing, Synchronizing & Adjusting
  110
- Special Tools
  111
- Crank Position Sensor
  113
- Throttle Cam Adjustment
  114
- Maximum Throttle
  114
- Idle Speed
  115
  - Throttle Position Sensor (TPS) Adjustment
    115
  - Throttle Plate Screw
    115
  - Wiring Diagrams
    116
- Power Trim Wiring Diagram
  117
- Instrument Wiring Connections
  118
- Commander 3000 Classic Panel Remote Control 2D-4
  119
- Commander 3000 Panel Remote Control
  120
- Instrument/Lanyard Stop Switch Wiring Diagram
  121
- Oil Level Gauge Wiring Diagram
  122
- Instrument/Lanyard Stop Switch Wiring Diagram (Dual Outboard)
  123
- QSI Gauge Wiring Diagrams
  125
- Tachometer Wiring Diagram
  125
- Water Temperature Gauge
  126
- Oil Level Gauge Wiring
  127
- Engine Synchronizer Wiring Diagram
  129
- Maintenance
  130
- Multi-Function Gauge
  131
- Dip Switch Setting/Testing
  131
- Outboard Multi-Function Gauge Setting
  132
- Warning System
  132
- Warning System Signals
  133
- Warning System Operation
  134
- Panel Mount Remote Control Wiring Installation 2D-22
  137
  - 1998 Model 135/150 DFI Wiring Diagram
    138
  - 1999 Model 135/150 DFI Wiring Diagram
    139
  - Fuel System
    140
  - Pulse Crankcase Driven Fuel Pump
    140
  - Fuel Pump
    141
  - Fuel Pump Description/Operation
    142
  - Checking for Restricted Fuel Flow Caused by Anti-Siphon Valves
    143
  - Testing Fuel Pump
    144
  - Fuel Pump Removal/Disassembly
    145
  - Cleaning/Inspection
    146
  - Reassembly/Lnstallation
    146
  - Direct Fuel Injection
    149
- Specifications
  150
- Special Tools
  151
- Notes
  153
- Air Handler
  154
- Air Handler Components
  156
- Vapor Separator Components
  158
- Fuel Rails/Air Compressor Hose Routing
  160
- Fuel Rails
  162
- Air Compressor Components
  164
- DFI Operation
  166
- Air Induction through Crankcase
  166
- Air Compressor System
  166
- Fuel
  166
- Oil
  167
- Electrical
  167
- Operation
  167
- Testing Electric Fuel Pump Pressure Output
  168
- Low Pressure Electric Fuel Pump
  168
- High Pressure Electric Fuel Pump
  169
- Fuel Management Assembly Removal
  170
- Reed Block Assembly Removal
  173
- Reed Block Assembly Installation
  173
- Air Temperature Sensor Removal
  173
- Air Temperature Sensor Installation
  174
- Throttle Plate Assembly Removal
  174
- Throttle Plate Assembly Installation
  174
- Vapor Separator Disassembly
  174
- Vapor Separator Reassembly
  176
- Air Plenum Installation
  177
- Low Pressure Electric Fuel Pump Installation
  177
- Vapor Separator Installation
  179
- Fuel Rail Removal
  181
- Fuel Rail Disassembly
  182
- Fuel Pressure Regulator
  185
- Air Pressure Regulator
  187
- Tracker Valve
  189
- Fuel Rail Cleaning
  191
- Direct Injector Removal
  191
- Fuel Rail and Direct Injector Installation
  193
- Air Compressor
  194
- Air Compressor Disassembly/Reassembly
  197
- Air Compressor Flow Diagram
  198
- Air Compressor Pressure Test
  199
  - Fuel Pressure and Air Pressure Troubleshooting Chart
    200
  - Oil Injection
    201
  - Oil System Operation
    201
  - Oil Pump Output
    201
- Oil System
  202
- Oil Hose Check Valve Installation on 1998 Model 135/150 DFI Outboards SN 0G886266 and below
  203
- Oil Injection Hose Installation
  209
- Oil Pump Removal and Installation
  210
- Engine Oil Reservoir Removal and Installation
  211
- Priming the Oil Pump
  212
- Priming Procedure - Method 1
  213
- Remote Oil Hose Connections
  214
- Filling the Oil Tanks
  214
- Purging Air from the Engine Oil Reservoir and Remote Oil Hose
  215
- Oil Warning Systems
  215
- Oil System Troubleshooting
  216
- Low Oil Warning System Is Activated
  216
  - Emissions
    217
  - Exhaust Emissions Standards
    217
  - What Are Emissions?
    217
  - Hydrocarbons – HC
    217
- Oxides of Nitrogen - Nox
  218
- Controlling Emissions
  218
- Stoichiometric (14.7:1) Air/Fuel Ratio
  218
- Outboard Hydrocarbon Emissions Reductions
  218
- Stratified Vs Homogenized Charge
  219
- Homogenized Charge
  219
- Stratified Charge
  220
- Emissions Information
  220
- Manufacturer's Responsibility
  220
- Dealer Responsibility
  221
- Owner Responsibility
  221
- EPA Emission Regulations
  221
- Decal Location
  222
- Emission Control Information
  222
- Replacement of Certification Label
  223
- Date Code Identification
  223
- Removal
  223
- Installation
  223
  - Powerhead
    224
  - Powerhead Specifications
    224
  - Powerhead Repair Stand
    226
  - Cylinder Block and End Caps
    227
  - Exhaust Manifold and Exhaust Plate
    229
  - Cylinder Head
    231
  - Crankshaft, Pistons and Connecting Rods
    233
  - Torque Sequence
    234
  - Powerhead Removal from Driveshaft Housing
    236
  - General Information
    236
  - Powerhead Disassembly
    240
  - Water Pressure Relief Valve Components
    248
  - Cylinder Block and Crankcase Cover
    249
  - Special Service Information
    249
  - Cylinder Bores
    250
  - Pistons and Piston Rings
    251
  - Cylinder Heads and Exhaust Divider Plate
    253
  - Crankshaft
    253
  - Crankshaft (and End Cap) Bearings
    254
  - Reed Block Assembly
    255
  - End Bearing Bleed System
    256
  - Connecting Rods
    256
  - Thermostats
    258
  - Powerhead Reassembly and Installation
    259
  - Crankshaft Installation
    263
  - Piston and Connecting Rod Reassembly
    265
  - Piston and Piston Ring Combinations
    266
  - Piston Installation
    267
  - Crankcase Cover Installation
    269
  - Assembly of Reed Blocks to Intake Manifold
    271
  - Assembly of Exhaust Divider Plate to Block
    271
  - Reinstalling Engine Components
    274
  - Throttle Lever and Shift Shaft
    275
  - Powerhead Installation on Driveshaft Housing
    277
  - Break-Ln Procedure
    281
  - Cooling
    282
  - Water Pressure
    282
  - Thermostat
    282
- Water Pressure
  283
- Special Tools
  283
- 2.5 Liter Optimax/Dfi Water Flow
  284
- Temperature Sensor
  284
- Description
  284
- 1998/1999 Water Flow Diagram
  286
- 1999 1/2 Water Flow Diagram
  287
- Thermostat Test
  288
- Troubleshooting
  288
- Water Pressure Check
  289
- Water Pump Cleaning and Inspection
  290
- Problem Diagnosis
  291
  - MID-Section
    292
  - Clamp/Swivel Brackets & Drive Shaft Housing
    292
- Swivel Bracket and Steering Arm
  293
- Transom Brackets
  295
- Drive Shaft Housing and Exhaust Tube
  297
- Drive Shaft Housing and Dyna-Float Suspension
  299
- Removal and Disassembly
  299
- Reassembly and Installation
  302
  - Power Trim
    306
  - Power Trim Specifications
    306
- Special Tools
  307
- Power Trim Components
  309
- Power Trim Motor
  311
- Power Trim - General Information
  312
- Trimming Characteristics
  312
- Description
  312
- Trailering Outboard
  313
- Tilting Outboard Manually
  313
- Striker Plate Replacement
  314
- Trim "In" Angle Adjustment
  314
- Anode Plate
  315
- Trim Indicator Gauge
  315
- Check, Fill and Purge - Power Trim System
  315
- Troubleshooting
  317
- Power Trim System with Relays and 2 Wire Trim Motor
  319
- Electrical System Troubleshooting
  320
- Troubleshooting the "Down Circuit
  320
- General Checks
  320
- Troubleshooting the "Up" Circuit
  321
- Troubleshooting the "Down" and "Up" Circuits (All Circuits Inoperative)
  322
- Power Trim Assembly Removal and Installation
  323
- Installation
  326
- Testing Power Trim System with Test Gauge Kit (91-52915A6)
  328
  - "UP" Pressure Check
    328
  - “DOWN” Pressure Check
    331
- Hydraulic Repair
  333
- Trim Rod End Cap Seal
  334
- Tilt Ram
  335
- Disassembly
  336
- Scraper Seal Replacement
  339
- Motor and Electrical Tests/Repair
  343
- Trim Pump Motor Test
  343
- Motor Disassembly
  343
- Armature Tests
  344
- Motor Repair
  345
- Reassembly
  349
- Reassembly - Motor and Pump
  351
- Priming Power Trim System
  352
- Trim Sender Test
  352
- Trim Indicator Gauge Needle Adjustment
  353
- Trim Indicator Wiring Diagrams
  354
  - Lower Unit
    355
  - Right Hand Non-Ratcheting
    355
  - Gear Housing Specifications (Standard Rotation)
    355
  - Gear Housing (Drive Shaft)(Standard Rotation)
    360
  - Gear Housing (Prop Shaft)(Standard Rotation)
    362
  - General Service Recommendations
    364
  - Removal, Disassembly, Cleaning and Inspection – Standard Rotation
    365
  - Draining and Inspecting Gear Housing Lubricant
    366
  - Water Pump
    367
  - Bearing Carrier and Propeller Shaft Removal
    370
  - Shift Shaft
    372
  - Propeller Shaft
    374
  - Clutch Actuator Rod
    376
  - Pinion Gear and Driveshaft
    376
- Forward Gear
  379
  - Gear Housing
    380
  - Reassembly and Installation Standard Rotation
    380
  - Driveshaft Needle Bearing
    380
  - Bearing Carrier
    381
  - Forward Gear Bearing Race
    385
  - Driveshaft and Pinion Gear
    386
  - Pinion Gear Depth/Forward Gear Backlash/Reverse Gear Backlash
    388
  - Shift Shaft Bushing
    392
  - Gear Lubricant Filling Instructions
    399
  - Installing Gear Housing to Driveshaft Housing
    399
  - Propeller Installation
    400
  - Left Hand Non-Ratcheting
    402
  - Gear Housing Specifications (Counter Rotation)
    402
- In. (0.635 MM) with Tool 91-12349A2 Using Disc #2 and Flat #7
  402
- Flat #7
  402
- Mark #1
  402
- In. (0.635 MM) with Tool 91-12349A2 Using Disc #2 and Flat #7 #2
  402
- 0.018 In. to 0.027 in
  402
- 0.015 In. to 0.022 in
  402
- Attachments / Control Linkage
  460
- Ride Guide Steering Cable/Attaching Kit Installation (92876A3)
  461
- Dual Cable - Single Outboard
  461
- Super Ride-Guide Steering Kit Installation
  462
- Steering Cable Mounting Tube Installation
  463
- Installing Steering Cables
  464
- Coupler Installation
  465
- Installing Link Rod
  465
- Maintenance Instructions
  467
- Ride Guide Steering Cable/Attaching Kit Installation (92876A6)
  468
- Dual Cable - Dual Outboard
  468
- Installation Requirements
  468
- Parallel Routed Steering Cables and Attaching Kit Installation
  469
- Opposite Side Routed Steering Cables and Attaching Kit Installation
  476
- Trim Tab Adjustment
  483
- Ride Guide Steering Attachment Extension Couplers
  483
- Maintenance Instructions
  484
- Transom Mounted Ride Guide Attaching Kit Installation (73770A1)
  486
- Attaching Kit Installation
  486
- Maintenance Instructions
  489
- Clevis Attaching Kit Installation (A-70599A2)
  490
- Installation Instructions
  490
- Maintenance Instructions
  490

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