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Mercury Optimax 135 Service Manual

Mercury Optimax 135
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POWERHEAD
Page 4A-46 90-855347R1 JANUARY 1999
13. Rotate crankshaft several times (using powerhead stand) to assure free operation
(no binds and catching).
Connecting Rod Cap Alignment
Check each connecting rod cap for correct alignment. If not aligned, a ridge can be seen
or felt at the separating line as shown below. Correct any misalignment.
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Ä
Ä
Ä
Ä
Side View
Correct
End View
Correct
Side View
Incorrect-Cap
on Backwards
End View
Incorrect-Cap
on Backwards
ÄÄ
ÄÄ
ÄÄ
ÄÄ
End View
Incorrect-
Not Aligned
14. Verify that no piston rings were broken during installation by pressing in on each piston
ring thru exhaust port using a screwdriver. If no spring tension exists (ring fails to re-
turn to position), it’s likely ring is broken and must be replaced.
51852
a
a-Screwdriver
Crankcase Cover Installation
1. Thoroughly remove all oil from mating surfaces of crankcase cover and cylinder block
with Loctite 7649 Primer (92-809824).
2. Install gasket strips into grooves in crankcase cover. Trim end of each gasket strip
flush with edge of cover as shown.
51852
a
b
a-Gasket Strips
b-Edge of Cover

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Mercury Optimax 135 Specifications

General IconGeneral
Engine TypeV6
Horsepower135 HP
Fuel Induction System2-stage direct fuel injection
Full Throttle RPM Range5000-5750 RPM
Alternator Output60 amp / 756 watt
Starting SystemElectric
SteeringRemote
Dry Weight431 lbs
Shaft Length20", 25"

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