Name: Mercury 135 Pro XS OptiMax
Brand: Mercury
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OUTBOARD INSTALLATION

eng 115

Description Nm lb‑in. lb‑ft

Outboard mounting locknuts and

bolts ‑ metal lift plates and setback

brackets

122 90

Electrical, Hoses, and Control Cables

FRONT CLAMP DISASSEMBLY

Remove screws and open the front clamp assembly.

a - Screw (2)

b - Front clamp

7644

Table of Contents7
Warranty Registration13
Warranty Information13
Transfer of Warranty14
Transfer of Mercury Product Protection (Extended Service Coverage) Plan United States and Canada14
Outboard Limited Warranty15
Year Limited Warranty against Corrosion19
Warranty Coverage and Exclusions23
U.S. EPA Emissions Limited Warranty25
Emission Control System Components25
California Emissions Limited Warranty26
California Air Resources Board Explanation of Your California Emission Control Warranty Statement30
Emission Certification Star Label31
Boater's Responsibilities33
Before Operating Your Outboard33
General Information33
Boat Horsepower Capacity34
High-Speed and High-Performance Boat Operation34
Propeller Selection35
Outboard Remote Control Models38
Remote Steering Notice38
Lanyard Stop Switch39
Protecting People in the Water43
Passenger Safety Message - Pontoon Boats and Deck Boats44
Wave and Wake Jumping45
Impact with Underwater Hazards46
Exhaust Emissions47
Selecting Accessories for Your Outboard49
Safe Boating Suggestions50
Recording Serial Number52
Specifications52
Component Identification54
Trailering Boat/Outboard55
Fuel Recommendations56
Fuel and Oil56
Oil Recommendation - 135/150/175 (Standard) Models58
Oil Recommendation - 150-175 Pro XS Models58
Fuel Additives58
Fuel Requirements59
Avoiding Fuel Flow Restriction59
Low Permeation Fuel Hose Requirement59
EPA Pressurized Portable Fuel Tank Requirements59
Fuel Demand Valve (FDV) Requirement60
Mercury Marine's Pressurized Portable Fuel Tank60
Filling Remote Oil Tank61
Filling Engine-Mounted Oil Reservoir Tank62
Filling Fuel Tank63
Remote Control Features64
Features and Controls64
Warning System65
Power Trim and Tilt67
Pre-Starting Check List72
Operating in Freezing Temperatures72
Operating in Saltwater or Polluted Water73
Operating at High Elevations73
Setting Trim Angle While Running Engine at Idle Speed74
Engine Break-In Procedure74
Starting the Engine75
Gear Shifting78
Stopping the Engine79
Outboard Care80
EPA Emissions Regulations80
Maintenance80
Inspection and Maintenance Schedule81
Flushing the Cooling System84
Top Cowl Removal and Installation84
Cleaning Care for Top Cowl85
Flywheel Cover Removal and Installation85
Fuel System86
Steering Link Rod Fasteners88
Fuse Replacement89
Corrosion Control Anode90
Battery Inspection91
Battery Information91
Propeller Replacement93
Spark Plug Inspection and Replacement96
Compressor Air Intake Filter97
Alternator Belt Inspection98
Lubrication Points98
Checking Power Trim Fluid101
Gearcase Lubrication102
Submerged Outboard104
Storage Preparation105
Protecting Internal Engine Components106
Protecting External Outboard Components107
Gearcase107
Positioning Outboard for Storage107
Battery Storage107
Starter Motor will Not Crank the Engine108
Engine will Not Start108
Troubleshooting108
Engine Runs Erratically109
Performance Loss109
Battery will Not Hold Charge109
Local Repair Service110
Service Away from Home110
Parts and Accessories Inquiries110
Service Assistance110
Owner Service Assistance110
Mercury Marine Service Offices111
Important Information113
Outboard Installation113
Boat Horsepower Capacity114
Start in Gear Protection114
Selecting Accessories for Your Outboard114
Fuel System115
Installation Specifications117
Lifting the Outboard117
Steering Cable - Starboard Side Routed Cable118
Steering Link Rod Fasteners119
Determining Recommended Outboard Mounting Height122
Drilling Outboard Mounting Holes122
Fastening the Outboard to the Transom124
Electrical, Hoses, and Control Cables127
Single Outboard129
Shift and Throttle Cable132
Front Clamp Reassembly139
Oil Injection Set-Up140
Propeller Installation143
Trim in Pin144
Maintenance Log146

Mercury 135 Pro XS OptiMax User Manual

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Mercury 135 Pro XS OptiMax Specifications

Related product manuals

Brand	Mercury
Model	135 Pro XS OptiMax
Category	Outboard Motor
Language	English