Mercury 135 Optimax

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iii

Patrick C. Mackey

President, Mercury Marine, Fond du Lac, WI USA on May 1, 2006.

European Regulations Contact:

Regulations and Product Safety Department, Mercury Marine,

Fond du Lac, WI USA

Main Page

Table of Contents5
Transfer of Warranty9
Warranty Registration United States and Canada9
Warranty Registration Outside the United States and Canada9
Warranty Information9
Optimax Outboard Limited Warranty United States, Canada, Europe, Confederation of Independent States, Middle-East and Africa10
Year Limited Warranty against Corrosion11
Warranty Coverage and Exclusions13
Boater's Responsibilities14
Before Operating Your Outboard14
Boat Horsepower Capacity14
General Information14
High-Speed and High-Performance Boat Operation15
Propeller Selection15
Outboard Remote Control Models17
Remote Steering Notice17
Lanyard Stop Switch17
Protecting People in the Water19
Passenger Safety Message - Pontoon Boats and Deck Boats19
Wave and Wake Jumping20
Impact with Underwater Hazards21
Exhaust Emissions21
Selecting Accessories for Your Outboard23
Safe Boating Suggestions23
Recording Serial Number24
135/150/175 Optimax Specifications24
Component Identification25
Trailering Boat/Outboard26
Transporting26
Fuel Recommendations27
Oil Recommendation27
Fuel and Oil27
Fuel Additives28
Fuel Requirements28
Avoiding Fuel Flow Restriction28
Filling Remote Oil Tank28
Filling Engine Mounted Oil Reservoir Tank28
Filling Fuel Tank29
Remote Control Features30
Warning System30
Features and Controls30
Power Trim and Tilt32
- Shallow Water Operation34
- Auxiliary Tilt Switch34
Pre-Starting Check List35
Operating in Freezing Temperatures35
Operating in Salt Water or Polluted Water35
Operating at High Elevations35
Operation35
Setting Trim Angle While Running Engine at Idle Speed36
Engine Break-In Procedure36
Starting the Engine36
Gear Shifting39
Stopping the Engine39
Outboard Care40
EPA Emissions40
Inspection and Maintenance Schedule40
Maintenance40
Maintenance41
Flushing the Cooling System41
Top Cowl Removal and Installation42
Cleaning Care for Top Cowl42
Flywheel Cover Removal and Installation43
Fuel System43
Steering Link Rod Fasteners44
Fuse Replacement45
Corrosion Control Anode46
Battery Inspection46
Battery Information47
Propeller Replacement48
Spark Plug Inspection and Replacement50
Compressor Air Intake Filter51
Alternator Belt Inspection52
Lubrication Points52
Gearcase Lubrication55
Submerged Outboard56
Storage Preparation57
Protecting Internal Engine Components57
Storage57
Protecting External Outboard Components58
Gearcase58
Positioning Outboard for Storage58
Battery Storage58
Starter Motor will Not Crank the Engine59
Engine will Not Start59
Engine Runs Erratically59
Troubleshooting59
Performance Loss60
Battery will Not Hold Charge60
Local Repair Service61
Service Away from Home61
Parts and Accessories Inquiries61
Service Assistance61
Mercury Marine Service Offices61
Owner Service Assistance61
Important Information63
Avoiding Fuel Flow Restriction63
Electric Fuel Pump63
Boat Horsepower Capacity63
Outboard Installation63
Start in Gear Protection64
Selecting Accessories for Your Outboard64
Fuel Tanks64
Installation Specifications65
Lifting the Outboard65
Steering Cable - Starboard Side Routed Cable66
Steering Link Rod Fasteners67
Determining Recommended Outboard Mounting Height69
Drilling Outboard Mounting Holes69
Fastening the Outboard to the Transom71
Electrical, Hoses, and Control Cables73
Single Outboard74
Shift and Throttle Cable77
Throttle Cable Installation80
Front Clamp Reassembly81
Filling the Fuel System82
Oil Injection Set-Up83
- Priming the Oil Injection Pump84
- Purging Air from the Engine Oil Tank84
Propeller Installation85
Trim in Pin86

Mercury 135 Optimax - Page 3

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