Name: Mariner Mercury 135 JET
Brand: Mariner Mercury
Rating: 4 (1 reviews)

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5A-2 - MID-SECTION 90-824052R3 JUNE 2002

Swivel Bracket and Steering Arm

2-4-C With Teflon (92-825407A12)

Loctite 271 (92-809820)

Important 1 B15
- Page Numbering3
- Important Information5
- Table of Contents15
- Specifications16
- Inspection and Maintenance Schedule16
  - Before each Use16
  - After each Use16
- Lubrication Points17
- Checking Power Trim Fluid19
- Gear Case Lubrication20
- Propeller Replacement21
  - Removal21
  - Installation21
- Corrosion Control Anode22
- Flushing Engine23
  - Flushing Cooling System with Engine NOT Running (Using Cowl Flush Plug)23
  - Flushing Cooling System with Engine Running (Using Flushing Attachment 44357A2)23
- Storage24
Important 1 C26
- Conditions Affecting Performance27
- Serial Number Location27
- Following Complete Submersion30
- Painting Procedures31
  - Cleaning & Painting Aluminum Propellers & Gear Housings31
- Propeller Selection31
- Decal Application32
  - Decal Removal32
  - Instructions for "Wet" Application32
Important 1 D35
- Boat Horsepower Capacity36
- Notice to Installer and Owner36
- Outboard Remote Control36
- Selecting Accessories for the Outboard36
- Selecting Steering Cables and Remote Control Cables36
- Determining Recommended Outboard Mounting Height37
- Locating Centerline of Boat Transom38
  - Drilling Outboard Mounting Holes38
  - Applying Counter Rotation Decals38
- Installing Outboard to Boat Transom39
- Lifting Outboard39
- Single Steering Cable and Steering Link Rod Installation40
  - Installing Ride Guide Cable to Outboard Tilt Tube40
  - Steering Link Rod Installation40
- Remote Control Installation41
  - Counter (Left Hand) Rotation Outboards41
- Routing Location for Wiring and Hoses Thru Clamp in Bottom Cowl41
- Required Side Mount Remote Control or Ignition Key Switch Assembly42
  - Boats Equipped with Side Mount Remote Control42
  - Boats Equipped with Panel or Console Mount Remote Control42
- Shift and Throttle Cable Installation to the Outboard42
  - Shift Cable Installation42
  - Throttle Cable Installation43
- Battery Connections44
- Remote Wiring Connections44
- Fuel Connections45
  - Connecting Fuel Hose to Engine45
  - Portable Fuel Tank45
  - Permanent Fuel Tank45
  - Fuel Line45
- Set up Instructions for Oil Injection System 1D-1045
  - Installing Remote Oil Tank45
  - Installing Oil Hoses to Engine46
  - Filling the Oil Injection System46
  - Bleeding Air from Oil Injection Pump and Oil Injection Outlet Hose47
  - Adjusting Oil Injection Pump47
- Propeller Installation47
- Propeller Selection47
- Power Trim System48
  - General Information48
  - Power Trim Operation48
  - Trim "IN" Angle Adjustment49
  - Checking Trim System Fluid Level49
- Trim Tab Adjustment49
Electrical 251
- 40 Ampere Stator52
- DVA Specifications52
- Ignition Coil52
- Ignition Specifications52
- Trigger52
- Special Tools53
- Flywheel/Starter Motor55
- Ignition Coil/Voltage Regulator57
- Wiring Harness/Starter Solenoid59
- Theory of Operation61
  - Description61
- Ignition Test Procedures62
- Ignition Troubleshooting64
- Ignition System67
- Idle Stabilizer Modules71
- Ignition Components Removal and Installation73
Electrical 281
- Battery Cable Size82
- Special Tools82
- Specifications82
- Battery83
  - Precautions83
- Specific Gravity Readings83
  - Specific Gravity Cell Comparison Test84
- Charging a Discharged Battery84
- Electrolyte Level84
- Battery Charging System Description85
- Winter Storage of Batteries85
- Battery Charging System Troubleshooting86
  - General Troubleshooting86
    - 40 Ampere Alternator System86
    - Amp Stator Test (Alternator Coils Only)86
- Troubleshooting 40 Amp Alternator System86
- System Wired for Split Output90
  - 20 Amperes to Auxiliary Battery90
  - 20 Amperes to Cranking Battery90
- System Wired for 40 Ampere Output to Isolator91
- Starter System92
- Starter Circuit Troubleshooting Flow Chart93
- Starter Removal and Installation94
- Starter Cleaning, Inspection and Testing96
Electrical 2102
- Timing/Synchronizing/Adjusting103
  - Specifications103
    - Carbureted Models103
    - Electronic Fuel Injection Models104
- Special Tools104
- Adjustments105
  - Carburetor Models105
- Adjustments109
- Electronic Fuel Injection Models109
- Timing Pointer Adjustment109
- Throttle Cam Adjustment110
- Static Idle Timing Adjustment (Cranking Engine with Starter)111
- Maximum Throttle112
- Maximum Timing Adjustment for 225 Pro Max/Super Magnum112
- Static Maximum Timing Adjustment (Cranking Engine with Starter)112
- Throttle Position Sensor (TPS) Adjustment113
- Idle Adjustment114
- Idle Timing (Engine Running)114
- Throttle Cable Installation115
- Throttle Valve/Oil Pump Synchronization115
- Detonation Control (200 Model)116
- Maximum Timing Adjustment (Engine Running)116
Electrical 2118
- Wiring Diagram 135/150119
- Wiring Diagram XR6/MAG III/175120
- Wiring Diagram 200121
- Wiring Diagram 200 Carb Serial # 0D077248 Thru Serial # 0D122746122
- Wiring Diagram 150/175 EFI123
- Wiring Diagram 200 EFI124
- Wiring Diagram 200 Pro Max/Super Magnum (Early Model with Detonation Module)125
- Wiring Diagram 150/200/225 Pro Max/Super Magnum126
- Wiring Diagram105/140 Jet127
- Power Trim Wiring Diagram with Relays129
- Instrument Wiring Connections130
- Commander 3000 Classic Panel Remote Control131
- Commander 3000 Panel Remote Control132
- Commander Side Mount Remote Control (Power Trim/Tilt Electric Start with Warning Horn) Wiring Diagram136
- Commander 2000 Side Mount Remote Control (Power Trim/Tilt Electric Start with Warning Horn) Wiring Diagram137
- Oil Level Gauge Wiring Diagram138
- Visual Warning Wiring Diagram139
- Instrument/Lanyard Stop Switch Wiring Diagram140
- Instrument/Lanyard Stop Switch Wiring Diagram (Dual Outboard)140
- QSI Gauge Wiring Diagrams143
  - Tachometer Wiring Diagram143
  - Water Temperature Gauge143
  - Oil Level Gauge Wiring144
  - Engine Synchronizer Wiring Diagram145
- Maintenance145
- Multi-Function Gauge146
- Panel Mount Remote Control Wiring Installation147
- Side Mount Remote Control Wiring Installation148
  - Fuel Systems149
Fuel Systems150
- Special Tools151
- Specifications151
  - Fuel Pump Pressure @ W.O.T151
  - Fuel Pump Pressure @ Idle151
- Fuel Pump152
  - General Information154
    - Checking for Restricted Fuel Flow Caused by Anti-Siphon Valves154
    - Fuel Pump Description/Operation154
  - Testing Fuel Pump155
- Checking Fuel Pump Lift (Vacuum)155
Fuel Systems160
- Notes161
- WMH 1,2,3,4,5,6,7,8,9,10,11 Carburetor Assembly162
- WMH 1,2,3,4,5,6,7,8,9,10,11 Carburetor Specifications164
- WMH 12,13,14,15,16,27 Carburetor Assembly166
- WMH 12,13,14,15,16,27 Carburetor Specifications168
- WMH 21,22,23,25,26,28 Carburetor Assembly170
- WMH 21,22,23,25,26,28 Carburetor Specifications172
- WMH 30,31,32,33,34,39 Carburetor Assembly174
- WMH 30,31,32,33,34,39 Carburetor Specifications176
- Wmv 1/1A, 2/2A, 3/3A, 4/4A, 5/5A178
- WMV 1,2,3,4,5 Carburetor Front View182
- WMV 1,2,3,4,5 Carburetor Specifications182
- Fuel System - Troubleshooting183
  - General Information183
- Reed Valve Leak Test185
  - Tools Needed for Test185
  - Thermal Air Valve Circuit Description186
- WMH Carburetor Fuel Circuit Description186
- WMV Carburetor Fuel Circuit Description189
- Carburetor Disassembly197
- Removing Carburetor(S) from Engine197
- Fuel Line and Primer Bulb Assembly204
  - Fuel Line Clamp Removal and Installation205
Fuel Systems207
- Special Tools208
- Specifications208
- Electronic Control Module (ECM) Assembly209
- Fuel Management System211
- Fuel Pump and Fuel Filter215
- Electronic Fuel Injection (Efl) System217
- Outboard Powerhead View217
- Preliminary Steps219
- Fuel Flow Diagram221
  - Fuel Flow Components222
- EFI Electrical Diagram223
  - EFI Electrical Components224
- EFI Fuel Management (Low Pressure Fuel Route)226
- EFI Fuel Management (High Pressure Fuel Route)227
- Fuel Rail Electrical/Fuel Determination228
- EFI System Test Procedures229
- EFI Induction Manifold Removal247
- EFI Induction Manifold Disassembly255
- EFI System Cleaning and Inspection260
  - Cleaning260
  - Inspection260
- Induction Manifold Assembly261
- EFI Induction Manifold Installation265
Fuel Systems273
- Special Tools274
- Specifications274
- Detonation Controller/Air Temperature Sensor/Throttle Position Sensor276
- Electronic Control Module (ECM) Assembly277
- Fuel Management System279
- Fuel Pump283
- Electronic Fuel Injection (Efl) System285
  - Introduction285
  - Using the Test Procedures285
  - EFI System Tests286
  - Safety Precautions286
  - Fuel Injection System Function286
- Outboard Powerhead View285
- Preliminary Checks287
- Fuel Flow Diagram289
- Fuel Flow Component Description290
  - Fuel Injectors290
  - EFI Electrical Components (from Electrical Component Diagram)294
- EFI Fuel Management (Low Pressure Fuel Route)296
- EFI Fuel Management (High Pressure Fuel Route)297
- Fuel Rail Electrical/Fuel Determination298
- EFI System Test Procedures299
  - Fuel Gauge Connection/Pressure Test299
  - Vapor Separator Fuel Delivery Test300
  - Vapor Separator Float Test301
  - Water Separating Filter Flow Test301
  - Pulse Fuel Pump Delivery Test302
  - Final Filter Check and De-Pressurizing EFI System Procedures302
  - Pressure Regulator Test304
  - Electric Fuel Pump Voltage Test305
  - Voltage Test Chart306
  - Injector Electrical Harness Test307
  - ECM Injector Driver Test307
  - Injector Fuel Delivery Test307
  - Injector Operation Test308
  - Induction Manifold Leak Check309
  - Air Temperature Sensor Test310
  - Engine Head Temperature Sensor Test310
  - Detonation Control System Test (200 Models Only)311
  - Detonation Sensor Check311
  - Detonation Control Module Check312
  - Throttle Position Sensor Test312
  - Map Sensor Test313
  - Problem Diagnosis314
- EFI Induction Manifold Removal317
  - Water Separating Filter Assembly Removal318
  - Water Separating Filter Assembly Installation319
  - Throttle Position Sensor and Temperature Sensor Fuel Injector Harness Disconnections319
  - Oil Reservoir Removal320
  - Fuel Pressure Regulator Removal320
  - Fuel Pressure Regulator Disassembly321
  - Fuel Pressure Regulator Reassembly321
  - Vapor Separator Removal321
  - Vapor Separator Disassembly322
  - Vapor Separator Reassembly324
  - Installing Vapor Separator Assembly to Induction Manifold326
  - Manifold Removal327
- EFI Induction Manifold Disassembly328
  - Air Temperature Sensor Removal328
  - Throttle Position Sensor Removal329
  - Fuel Rail Removal329
  - Fuel Rail Disassembly330
  - Fuel Injector Removal and Disassembly331
  - Injector Harness Removal332
  - Throttle Linkage Removed332
- EFI System Cleaning and Inspection333
  - Cleaning333
  - Inspection333
- Induction Manifold Assembly334
  - Injector Harness Installation334
  - Fuel Injector Assembly and Installation335
  - Fuel Rail Assembly335
  - Fuel Rail Installation336
  - Throttle Position Sensor Installation337
  - Air Temperature Sensor Installation337
- EFI Induction Manifold Installation338
  - Oil Reservoir Installation339
  - Vapor Separator Installation340
  - Throttle Position Sensor, Air Temperature Sensor and Fuel Injector Harness Connections341
  - ECM Installation342
  - Engine Head Temperature Sensor Installation343
Fuel Systems345
- Operation of the Oil Injection System346
- Oil Injection Components347
- Oil Injection Flow System348
- Pump Drive Assembly349
- Pump Drive System349
  - Set up Instructions for Oil Injection System350
- Oil Injection Pump353
  - Oil Pump Removal353
- Worm Bushing354
- Motion Sensor355
  - Oil Injection System Troubleshooting Chart356
- Oil Pump Volume (Flow) Test360
Table of Contents363
- Exhaust Emissions Standards364
- Outboard Hydrocarbon Emissions Reductions365
- Stratified Vs Homogenized Charge366
  - Homogenized Charge366
  - Stratified Charge366
- Emissions Information367
Powerhead371
- Powerhead Specifications372
- Special Tools373
  - Powerhead Repair Stand374
- Cylinder Block and End Caps375
- Exhaust Manifold and Exhaust Plate377
- Reed Block and Cylinder Head379
- Crankshaft, Pistons and Connecting Rods381
- Torque Sequence383
- General Information384
- Powerhead Removal from Driveshaft Housing384
  - Removing Engine Components388
- Powerhead Disassembly389
  - Water Pressure Relief Valve Components395
  - Torque Specifications395
- Cleaning and Inspection396
- Powerhead Reassembly and Installation404
- Bleed Line Routing (Carbureted Models)416
- Bleed Line Routing (Fuel Injected Models)416
  - Port Side View417
  - Starboard Side View417
- Reinstalling Engine Components417
- Notes418
- Throttle Lever and Shift Shaft419
- Powerhead Installation on Driveshaft Housing423
- Break-Ln Procedure428
  - Break-In Fuel Mixture428
    - Engine Break-In Procedure (All Models)428
    - Gasoline/Oil Mixing Ratio Chart428
Powerhead430
- Special Tools431
- Specifications431
  - Thermostat431
  - Water Pressure431
- Water Flow433
MID-Section442
- Notes443
- Swivel Bracket and Steering Arm444
- Transom Brackets (S/N-0G590000446
- Drive Shaft Housing and Exhaust Tube450
- Drive Shaft Housing and Dyna-Float Suspension452
MID-Section458
- Power Trim Specifications459
- Special Tools459
- Power Trim Components460
- Power Trim Motor462
- Power Trim - General Information463
- Electrical System Troubleshooting469
  - General Checks469
- Troubleshooting the "Down Circuit469
- Troubleshooting the "Up" Circuit470
- Troubleshooting the "Down" and "Up" Circuits (All Circuits Inoperative)471
- Power Trim Assembly Removal and Installation472
- Motor and Electrical Tests/Repair485
- Trim Indicator Wiring Diagrams494
  - Lower Unit495
Lower Unit496
- Forward Gear Backlash497
- Lubricant Capacity497
- Pinion Depth497
- Reverse Gear Backlash497
- (S/N-0G437999 & Below)504
- Gear Housing (Prop Shaft)(Standard Rotation) (S/N-0G437999 & BELOW)504
- Gear Housing (Drive Shaft) (CLE) (Standard Rotation) (Pro Max/Super Magnum Models)506
- Gear Housing (Prop Shaft) (CLE) (Standard Rotation) (Pro Max/Super Magnum Models)508
- Gear Housing (Drive Shaft) (Standard Rotation) (Torque Master)(Pro Max/Super Magnum Models)510
- Gear Housing (Prop Shaft) (Standard Rotation) (Torque Master) (Pro Max/Super Magnum Models)512
- Gear Housing (Driveshaft) (Standard Rotation) (Sportmaster)514
- Gear Housing (Prop Shaft) (Standard Rotation) (Sportmaster)518
- General Service Recommendations520
- Removal, Disassembly, Cleaning and Inspection - Standard Rotation521
  - Removal521
  - Draining and Inspecting Gear Housing Lubricant522
  - Water Pump523
    - Cleaning and Inspection523
    - Removal and Disassembly523
  - Bearing Carrier and Propeller Shaft Removal524
  - Shift Shaft526
  - Propeller Shaft528
    - Inspection528
  - Disassembly (Std. Gear Cases)530
- Pinion Gear and Drive Shaft531
  - Removal531
- Forward Gear533
  - Removal and Disassembly533
- Gear Housing534
- Bearing Carrier535
  - Reassembly535
- Driveshaft Needle Bearing535
  - Reassembly/Installation535
- Reassembly and Installation Standard Rotation535
- Forward Gear537
  - Reassembly537
- Forward Gear Bearing Race537
  - Installation537
- Driveshaft and Pinion Gear538
  - Reassembly/Installation538
  - Play (Sport Master)543
  - Drive Shaft End Play543
- Clutch Actuator Rod545
  - (Std. Gear Case)545
  - Reassembly/Shimming (High-Performance Gear Cases)546
- Propeller Shaft546
- Shift Shaft Bushing546
  - Reassembly546
- Water Pump549
- Gear Lubricant Filling Instructions551
- Installing Gear Housing to Drive Shaft Housing552
- Propeller Installation553
Lower Unit556
- Gear Housing (Prop Shaft)(Counter Rotation) (S/N-0G437999 & BELOW)564
- Gear Housing (Driveshaft)(Counter Rotation) (Sportmaster)568
- Gear Housing (Prop Shaft)(Counter Rotation) (Sportmaster)572
- General Service Recommendations576
- Removal, Disassembly, Cleaning and Inspection of Counter Rotation (Left Hand) Gear Housing577
  - Removal577
  - Draining and Inspecting Gear Housing Lubricant578
  - Water Pump579
    - Cleaning and Inspection579
    - Removal and Disassembly579
  - Bearing Carrier and Propeller Shaft Removal580
  - Shift Shaft583
  - Propeller Shaft584
    - Disassembly584
    - Inspection584
  - Clutch Actuator Rod586
    - Cleaning and Inspection586
    - Disassembly586
  - Forward Gear and Bearing Adapter587
    - Disassembly/Cleaning/Inspection587
  - Pinion Gear and Driveshaft588
    - Removal588
  - Reverse Gear591
    - Cleaning and Inspection591
    - Removal and Disassembly591
  - Gear Housing592
    - Cleaning and Inspection592
- Driveshaft Needle Bearing592
  - Reassembly/Installation592
- Reassembly and Installation of Counter Rotation Gear Housing592
- Bearing Carrier, Forward Gear and Bearing Adaptor593
  - Reassembly593
  - Propeller Shaft Needle Roller Bearing and Oil Seal Installation593
  - Reverse Gear and Bearing Cup Adaptor Reassembly594
- Driveshaft and Pinion Gear595
  - Reassembly/Installation595
- Pinion Gear Depth597
  - Determining Pinion Gear Depth597
  - Setting/Checking Driveshaft End Play (Sport Master Only)598
- Reverse Gear600
  - Determining Reverse Gear Backlash600
- Forward Gear601
- Propeller Shaft/Forward Gear Bearing Adapter/Bearing Carrier603
  - Reassembly603
- Clutch Actuator Rod606
  - Reassembly/Shimming606
- Propeller Shaft607
- Shift Shaft Bushing607
  - Reassembly607
- Water Pump611
- Gear Lubricant Filling Instructions613
- Installing Gear Housing to Driveshaft Housing613
- Propeller Installation614
Lower Unit617
- Gear Housing Specifications (1.78:1 Ratio)618
- Special Tools618
  - 1.78:1 Ratio618
- Gear Housing (Prop Shaft) - Xr6/Magnum III - 1.78:1 Ratio623
- General Service Recommendations625
- Removal, Disassembly, Cleaning and Inspection626
- Driveshaft Needle Bearing637
- Reassembly and Installation637
- Driveshaft Needle Bearing638
  - Installation - Late Model638
  - Late Model638
- Lower Shift Shaft and Bushing639
  - Reassembly and Installation639
- Bearing Carrier640
  - Reassembly640
- Forward Gear and Race640
- Driveshaft and Pinion Gear642
  - Reassembly/Installation642
- Determining Pinion Gear Depth643
- Propeller Shaft644
  - Reassembly644
- Determining Forward Gear Backlash645
- Water Pump647
  - Reassembly/Installation647
- Filling Gear Housing with Lubricant648
- Installing Gear Housing to Driveshaft Housing648
- Propeller Installation650
Lower Unit652
- Gear Housing Specifications (Standard Rotation)653
- Special Tools653
  - (S/N-0G438000658
  - (S/N-0G438000660
- General Service Recommendations662
- Removal, Disassembly, Cleaning and Inspection - Standard Rotation663
  - Draining and Inspecting Gear Housing Lubricant664
- Reassembly and Installation Standard Rotation675
  - Reassembly/Installation675
- Bearing Carrier676
- Forward Gear677
- Forward Gear Bearing Race678
- Driveshaft and Pinion Gear679
  - Reassembly/Installation679
- Pinion Gear Depth/Forward Gear Backlash/Reverse Gear Backlash680
  - Determining Pinion Gear Depth680
  - Determining Forward Gear Backlash681
- Clutch Actuator Rod683
- Shift Shaft Bushing683
- Propeller Shaft684
- Water Pump686
- Gear Lubricant Filling Instructions688
- Installing Gear Housing to Driveshaft Housing688
- Propeller Installation689
Lower Unit692
- Gear Housing (Prop Shaft) (Counter Rotation) (S/N-0G438000 & UP)700
- General Service Recommendations704
- Removal, Disassembly, Cleaning and Inspection of Counter Rotation (Left Hand) Gear Housing705
- Driveshaft Needle Bearing719
  - Reassembly/Installation719
- Reassembly and Installation of Counter Rotation Gear Housing719
- Bearing Carrier, Forward Gear and Bearing Adaptor720
  - Propeller Shaft Needle Roller Bearing and Oil Seal Installation720
  - Reverse Gear and Bearing Cup Adaptor Reassembly721
- Driveshaft and Pinion Gear723
  - Reassembly/Installation723
- Pinion Gear Depth724
  - Determining Pinion Gear Depth724
- Forward Gear726
- Reverse Gear726
  - Determining Reverse Gear Backlash726
- Propeller Shaft/Forward Gear Bearing Adapter/Bearing Carrier729
- Water Pump735
  - Reassembly/Installation735
- Gear Lubricant Filling Instructions737
- Installing Gear Housing to Driveshaft Housing737
- Propeller Installation738
Jet Outboards741
- Jet Components745
- Engine Horsepower Selection746
- Selecting a Boat that Is Best Suited for Jet Power746
- Locate Centerline of the Outboard747
- Outboard Mounting Height747
- Transom Height of the Boat747
- Water Testing748
  - Checking for Cavitation748
- Shift Cable Installation Jet 105 and749
- Impeller Removal and Installation750
- Lubricating the Driveshaft Bearing750
- Flushing the Cooling System752
- Impeller Clearance Adjustment752
- Steering Pull Adjustment752
- Worn (Dull) Impeller752
- Jet Drive Removal and Installation753
- Liner Replacement753
- Bearing Carrier Disassembly755
- Bearing Carrier Reassembly755
Attachments/Control Linkage760
- Installing Production Outboards761
- Installing High Performance Outboards - Pro Max/Super Magnum Models762
  - Installing Outboard on Transom763
  - Lifting Outboard764
- Rideguide Steering Cable/Attaching Kit Installation (92876A1)766
- Rideguide Steering Cable/Attaching Kit Installation (92876A3)768
- Rideguide Steering Cable/Attaching Kit Installation (92876A6)773
- Transom Mounted Rideguide Attaching Kit Installation (73770A1)788
  - Attaching Kit Installation788
    - Steering Cable Installation789
  - Maintenance Instructions790
- Clevis Attaching Kit Installation (A-70599A2)790
  - Installation Instructions790
- Remote Control Installation791
- Required Side Mount Remote Control or Ignition Key Switch Assembly791
- Routing Location for Wiring and Hoses Thru Clamp in Bottom Cowl792
- Remote Control Installation793
- Shift Cable Adjustment and Installation to the Engine793
- Throttle Cable Adjustment and Installation to the Engine794
- Battery Connections795
- Fuel Connections796
  - Connecting Fuel Hose to Engine796

Mariner Mercury 135 JET User Manual

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Mariner Mercury 135 JET Specifications

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Brand	Mariner Mercury
Model	135 JET
Category	Engine
Language	English