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Mercury Optimax 135 Service Manual

Mercury Optimax 135
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RIGHT HAND NON-RATCHETING
Page 6A-42 90-855347R1 JANUARY 1999
19. Start cover nut a few turns by hand, then using Cover Nut Tool (91-61069) and torque
wrench, torque cover nut to 210 Ib. ft. (285 Nm).
51871
a
b
c
a-O-ring
b-Cover Nut Tool
c-Torque Wrench
20. Bend one lock tab of tab washer into cover nut (only one will align).
21. Bend remaining tabs of tab washer toward front of gear housing.
22. Use Shift Shaft Bushing Tool (91-31107) and torque shift shaft bushing to 30 Ib. ft.
(41 Nm).
Water Pump
REASSEMBLY/INSTALLATION
1. Install oil seals into water pump base, as follows:
a. Place water pump base on a press.
b. Just before installing each seal apply Loctite 271 on outside diameter of oil seal.
c. With a suitable mandrel, press the smaller diameter oil seal into pump base with
lip of oil seal toward impeller side of base.
d. With a suitable mandrel, press the larger diameter oil seal into pump base with lip
of oil seal toward gear housing side of base.
e. Wipe any excess Loctite from oil seals and water pump base.
2. Install O-ring into O-ring groove of water pump base. Lubricate O-ring and oil seals
with 2-4-C w/Teflon Marine Lubricant (92-90018A12).
51869
a
b
c
a-Mandrel
b-Oil Seal (Smaller OD)
c-O-ring Groove

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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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