Mercury 135 Optimax Operation And Maintenance Manual
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Mercury 135 Optimax Operation And Maintenance Manual

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See also: Service Manual , Operation & Maintenance Manual
Welcome Aboard!
Proper care and maintenance is an important part in keeping your Mercury Product operating at peak
efficiency for maximum performance and economy. The enclosed Owner's Registration Card is your key
to trouble-free family fun. Refer to your Operation and Maintenance Manual for full details of your warranty
coverage.
Details of your nearest dealer can be found on www.marinepower.com where country maps and full
contact information are displayed.
Is your engine properly registered for warranty purpose? Please check on www.marinepower.com. If
necessary, please contact your local dealer.
If the outboard motor's serial number plate contains the CE mark in the lower left-hand corner, the
following statement applies:
This outboard motor manufactured by Mercury Marine, Fond du Lac, WI, USA or Marine Power Europe
Inc. Park Industrel, de Petit-Rechain, Belgium complies with the requirements of the following directives
and standards, as amended:
Recreational Craft Directive: 94/25/EC; std. ISO 8665, ISO 11547
Machinery Directive:
EMC Directive:
Patrick C. Mackey
President, Mercury Marine, Fond du Lac, WI USA
European Regulations Contact:
Product Environmental Engineering Department, Mercury Marine, Fond du Lac, WI USA
98/37/EC,
89/336/EC; std. EN50081-1, SAE J551 (CISPR Pub. 12),
EN 50082-1, IEC 61000 PT4-2, IEC 61000 PT4-3
i

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Questions and answers

gary
April 3, 2025

im thinking i put wrong oil in i have not run motor yet i used quicksilver premium plus 2- stroke synthethetic blend tcw3 oil is this ok im think it should of been dfi oil im i ok

0
1 comments:
Mr. Anderson
April 3, 2025

Quicksilver Premium Plus 2-Stroke Synthetic Blend TCW3 oil can be used if Optimax/DFI 2-Cycle Engine Oil is not available. However, Mercury or Quicksilver Optimax/DFI 2-Cycle Engine Oil is the recommended oil for the Mercury 135 Optimax motor. Using inferior oil may cause severe engine damage.

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Summary of Contents for Mercury 135 Optimax

  • Page 1 Welcome Aboard! Proper care and maintenance is an important part in keeping your Mercury Product operating at peak efficiency for maximum performance and economy. The enclosed Owner's Registration Card is your key to trouble-free family fun. Refer to your Operation and Maintenance Manual for full details of your warranty coverage.

  • Page 2: Table Of Contents

    Warranty Registration Outside The United States And Canada................1 Mercury Marine Two Years Limited Warranty (Europe)..................2 Mercury Marine One Year Limited Warranty (Confederation of Independent States, Middle-East, Africa).... 3 3 Year Limited Warranty Against Corrosion......................5 Warranty Coverage And Exclusions........................6 General Information Boater's Responsibilities............................
  • Page 3 TABLE OF CONTENTS Features and Controls Remote Control Features............................. 24 Warning System..............................24 Power Trim And Tilt.............................. 26 Operation Pre-Starting Check List............................30 Operating In Freezing Temperatures........................30 Operating In Salt Water Or Polluted Water......................30 Operating at High Elevations..........................30 Setting Trim Angle While Running Engine at Idle Speed..................
  • Page 4 Engine Will Not Start............................53 Engine Runs Erratically............................53 Performance Loss..............................54 Battery Will Not Hold Charge..........................54 OWNER SERVICE ASSISTANCE Local Repair Service............................55 Service Away From Home............................ 55 Parts And Accessories Inquiries........................... 55 Service Assistance............................... 55 Mercury Marine Service Offices........................... 55...

  • Page 5: Warranty Information

    Warranty Registration United States And Canada You may change your address at any time, including at time of warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and engine serial number to Mercury Marine’s warranty registration department.

  • Page 6: Mercury Marine Two Years Limited Warranty (Europe)

    Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time. If the service provided is not covered by this warranty, purchaser shall pay for all related labor and material, and any other expenses associated with that service.

  • Page 7: Mercury Marine One Year Limited Warranty (Confederation Of Independent States, Middle-East, Africa)

    No individual or entity, including Mercury Marine authorized dealers, has been given authority by Mercury Marine to make any affirmation, representation or warranty regarding the product, other than those contained in this limited warranty, and if made, shall not be enforceable against Mercury Marine.
  • Page 8 Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time. If the service provided is not covered by this warranty, purchaser shall pay for all related laborand material, and any other expenses associated with that service.

  • Page 9: Year Limited Warranty Against Corrosion

    Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time. If the service provided is not covered by this warranty, purchaser shall pay for all related labor and material, and any other expenses associated with that service.

  • Page 10: Warranty Coverage And Exclusions

    Mercury Precision Parts or Quicksilver MerCathode system and/or Galvanic Isolator. Corrosion damage caused by improper application of copper base anti-fouling paints is also not covered by this limited warranty.
  • Page 11 Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. Oils, lubricants or fluids changed as a matter of normal maintenance is customer's responsibility unless loss or contamination of same is caused by product failure that would be eligible for warranty consideration.

  • Page 12: General Information

    GENERAL INFORMATION Boater's Responsibilities The operator (driver) is responsible for the correct and safe operation of the boat and safety of its occupants and general public. It is strongly recommended that each operator (driver) read and understand this entire manual before operating the outboard.

  • Page 13: High-Speed And High-Performance Boat Operation

    For additional information, obtain a copy of our Hi-Performance Boat Operation booklet (part number 90-849250--1) from your dealer, distributor, or Mercury Marine. ob00307 Outboard Remote Control Models The remote control connected to your outboard must be equipped with a start in neutral only protection device.

  • Page 14: Lanyard Stop Switch

    GENERAL INFORMATION WARNING Disengagement of a steering link rod can result in the boat taking a full, sudden, sharp turn. This potentially violent action can cause occupants to be thrown overboard exposing them to serious injury or death. ob00655 Self-locking nuts Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves far enough away from the operator's position (as in accidental ejection from the operator's position) to activate the switch.

  • Page 15: Protecting People In The Water

    GENERAL INFORMATION While activation of the lanyard stop switch will stop the engine immediately, a boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut down. However, the boat will not complete a full circle.

  • Page 16: Passenger Safety Message - Pontoon Boats And Deck Boats

    GENERAL INFORMATION Passenger Safety Message - Pontoon Boats And Deck Boats Whenever the boat is in motion, observe the location of all passengers. Do not allow any passengers to stand or use seats other than those designated for traveling faster than idle speed. A sudden reduction in boat speed, such as plunging into a large wave or wake, a sudden throttle reduction, or a sharp change of boat direction, could throw them over the front of boat.

  • Page 17: Impact With Underwater Hazards

    GENERAL INFORMATION ob00314 The primary concern is the boat changing direction while in the midst of the jump. In such case the landing may cause the boat to veer violently in a new direction. Such a sharp change in direction can cause occupants to be thrown out of their seats, or out of the boat.

  • Page 18: Exhaust Emissions

    GENERAL INFORMATION • A rapid reduction in speed. This will cause occupants to be thrown forward, or even out of the boat. • Impact damage to the outboard and/or boat. Keep in mind, the most important thing you can do to help reduce injury or impact damage during an impact is control the boat speed.

  • Page 19: Selecting Accessories For Your Outboard

    Some accessories not manufactured or sold by Mercury Marine are not designed to be safely used with your outboard or outboard operating system. Acquire and read the installation, operation, and maintenance manuals for all your selected accessories.

  • Page 20: Recording Serial Number

    GENERAL INFORMATION Know and obey all nautical rules and laws of the waterways. Boat operators should complete a boating safety course. Courses are offered in the U.S.A. by 1) The U.S. Coast Guard Auxiliary, 2) The Power Squadron, 3) The Red Cross and 4) your state boating law enforcement agency.
  • Page 21 GENERAL INFORMATION Models Kilowatts 100.7 111.9 130.5 Full Throttle RPM Speed 5000-5500 RPM 5250-5750 RPM Idle Speed in Forward Gear 550 ± 25 RPM Number of Cylinders Piston Displacement 2508 cc (153 cu. in.) Cylinder Bore 88.4 mm (3.500 in.) Piston Stroke 67.3 mm (2.650 in.) Recommended Spark Plug...

  • Page 22: Component Identification

    GENERAL INFORMATION Component Identification 3403 Top cowl Auxiliary tilt switch Bottom cowl Transom brackets Water pump indicator hole Gearcase Driveshaft housing Cooling water intake holes Anti-ventilation plate...

  • Page 23: Installation

    INSTALLATION Installing Outboard WARNING Before operation, the outboard must be correctly installed with the required mounting hardware as shown. Failure to correctly fasten outboard could result in outboard ejecting off boat transom causing serious injury, death, or property damage. We strongly recommend that your dealer install your outboard and related accessories to ensure proper installation and good performance.

  • Page 24: Propeller Selection

    INSTALLATION Propeller Selection For best all around performance from your outboard/boat combination, select a propeller that allows the engine to operate in the upper half of the recommended full throttle RPM range with the boat normally loaded (refer to General Information - Specifications).

  • Page 25: Transporting

    TRANSPORTING Trailering Boat/Outboard Trailer your boat with the outboard tilted down in a vertical operating position. If additional ground clearance is required, the outboard should be tilted up using an accessory outboard support device. Refer to your local dealer for recommendations. Additional clearance may be required for railroad crossings, driveways and trailer bouncing.

  • Page 26: Fuel And Oil

    Mercury or Quicksilver Optimax/DFI 2-Cycle Engine Oil is recommended for your engine. If Optimax/DFI 2-Cycle engine oil is not available, we recommend using Mercury or Quicksilver TC-W3 Premium Plus 2-Cycle Oil. Severe engine damage may result from use of an inferior oil.

  • Page 27: Avoiding Fuel Flow Restriction

    FUEL AND OIL Avoiding Fuel Flow Restriction IMPORTANT: Adding components to the fuel supply system (filters, valves, fittings, etc.) may restrict the fuel flow. This may cause engine stalling at low speed, and/or a lean fuel condition at high RPM that could cause engine damage.

  • Page 28: Features And Controls

    FEATURES AND CONTROLS Remote Control Features Your boat may be equipped with one of the Mercury Precision or Quicksilver remote controls shown. If not, consult your dealer for a description of the functions and operations of the remote control. ob00329 Control handle - forward, neutral, reverse.
  • Page 29 FEATURES AND CONTROLS The warning horn will emit either a continuous beep or intermittent short beeps. This will alert the operator and help identify the following listed situations. For visual display of the specific engine functions and for additional engine data, refer to SmartCraft Product information, following. Warning Horn Function Sound...

  • Page 30: Power Trim And Tilt

    Consult your dealer for assistance. SMARTCRAFT PRODUCT A Mercury SmartCraft System instrument package can be purchased for this outboard. A few of the functions the instrument package will display are engine RPM, coolant temperature, battery voltage, fuel consumption and engine operating hours.

  • Page 31: Power Trim Operation

    FEATURES AND CONTROLS ob00663 Trim switch Trim range of travel Tilt range of travel POWER TRIM OPERATION With most boats, operating around the middle of the trim range will give satisfactory results. However, to take full advantage of the trimming capability there may be times when you choose to trim your outboard all the way in or out.
  • Page 32 FEATURES AND CONTROLS WARNING Avoid possible serious injury or death. Adjust outboard to an intermediate trim position as soon as boat is on plane to avoid possible ejection due to boat spin out. Do not attempt to turn boat when on plane if outboard is trimmed extremely in or down and there is a pull on the steering wheel or tiller handle.

  • Page 33: Shallow Water Operation

    FEATURES AND CONTROLS ob00665 SHALLOW WATER OPERATION When operating your boat in shallow water, you can tilt the outboard beyond the maximum trim range to prevent hitting bottom. Reduce engine speed below 2000 RPM. Tilt outboard up. Make sure all the water intake holes stay submerged at all times. Operate the engine at slow speed only.

  • Page 34: Operation

    Wash the outboard exterior and flush out the exhaust outlet of the propeller and gearcase with fresh water after each use. Each month, spray Mercury Precision or Quicksilver Corrosion Guard on external metal surfaces. Do not spray on corrosion control anodes as this will reduce the effectiveness of the anodes.

  • Page 35: Engine Break-In Procedure

    OPERATION ob01079 Engine Break-in Procedure CAUTION Severe damage to the engine can result by not complying with the Engine Break-in Procedure. GASOLINE/OIL BREAK-IN MIXTURE NOTE: Do not use pre-mixed gas and oil during break-in. Use straight gasoline during engine break-in and after engine break-in.
  • Page 36 OPERATION 3405 Open fuel tank vent screw (in filler cap) on manual venting type fuel tanks. ob00348 Squeeze the fuel line primer bulb several times until it feels firm. ob00349 Set the lanyard stop switch to "RUN" position. Refer to General Information - Lanyard Stop Switch. ob00350 Shift outboard to neutral (N) position.

  • Page 37: Gear Shifting

    OPERATION ob00560 Turn the ignition key to "START" position. Release the key when engine starts. If engine fails to start in 10 seconds, return the key to "OFF" position, wait one second and try again. ob00354 NOTE: The electronic starting system will automatically prime (choke) the engine and increase idle speed for starting.

  • Page 38: Stopping The Engine

    OPERATION ob00557 Stopping The Engine Reduce engine speed and shift outboard to neutral position. Turn ignition key to "OFF" position. ob00360...

  • Page 39: Maintenance

    SELECTING REPLACEMENT PARTS FOR YOUR OUTBOARD We recommend using original Mercury Precision or Quicksilver replacement parts and Genuine Lubricants. WARNING Using a replacement part that is inferior to the original part could result in personal injury, death, or product failure.

  • Page 40: Inspection And Maintenance Schedule

    MAINTENANCE Inspection And Maintenance Schedule BEFORE EACH USE • Check that lanyard stop switch stops the engine. • Visually inspect the fuel system for deterioration or leaks. • Check outboard for tightness on transom. • Check steering system for binding or loose components. •...

  • Page 41: Top Cowl Removal And Installation

    MAINTENANCE ob01084 Attach a water hose to the fitting. Turn on the water and flush for 3 to 5 minutes. ob01085 Top Cowl Removal And Installation REMOVAL Pull out the front cowl latch. ob00672 Lift up the rear cowl latch. Remove the top cowl. FOURSTROKE ob00673 INSTALLATION...

  • Page 42: Cleaning Care For Top Cowl

    MAINTENANCE Cleaning Care for Top Cowl IMPORTANT: Dry wiping (wiping the plastic surface when it is dry) will result in minor surface scratches. Always wet the surface before cleaning. Follow cleaning and waxing procedure. CLEANING AND WAXING PROCEDURE Before washing, rinse the top cowl with clean water to remove dirt and dust that may scratch the surface. Wash the top cowl with clean water and a mild non-abrasive soap.

  • Page 43: Steering Link Rod Fasteners

    MAINTENANCE FUEL LINE INSPECTION Visually inspect the fuel line and primer bulb for cracks, swelling, leaks, hardness, or other signs of deterioration or damage. If any of these conditions are found, the fuel line or primer bulb must be replaced. WATER SEPARATING FUEL FILTER NOTE: The warning system will turn on when water in the fuel filter reaches the full level.

  • Page 44: Fuse Replacement

    MAINTENANCE ob00676 Special washer head bolt (10-849838) Flat washer (2) Nylon insert locknut (11-826709113) Nylon insert locknut (11-826709113) Description lb. in. lb. ft. Special washer head bolt Nylon insert locknut "d" Nylon insert locknut "c" Tighten until seats, then back off 1/4 turn Assemble steering link rod to steering cable with two flat washers and self-locking nylon insert locknut.

  • Page 45: Corrosion Control Anode

    MAINTENANCE 3406 Good fuse Blown fuse SmartCraft data bus circuit - 5 AMP fuse Accessories - 20 AMP fuse Ignition coil circuit - 20 AMP fuse Electric fuel pump/ECM driver power/oil pump circuit - 20 AMP fuse Corrosion Control Anode Your outboard has corrosion control anodes at different locations.

  • Page 46: Battery Information

    MAINTENANCE IMPORTANT: Read the safety and maintenance instructions which accompany your battery. Turn off the engine before servicing the battery. Add water as necessary to keep the battery full. Make sure the battery is secure against movement. Battery cable terminals should be clean, tight, and correctly installed. Positive to positive and negative to negative.

  • Page 47: Propeller Replacement

    MAINTENANCE Propeller Replacement WARNING If the propeller shaft is rotated while the engine is in gear, there is the possibility that the engine will crank over and start. To prevent this type of accidental engine starting and possible serious injury caused from being struck by a rotating propeller, always shift outboard to neutral position and remove spark plug leads when you are servicing the propeller.
  • Page 48 MAINTENANCE Coat the propeller shaft with Quicksilver or Mercury Precision Lubricants Anti-Corrosion Grease or 2-4-C with Teflon. ob00378 IMPORTANT: To prevent the propeller hub from corroding and seizing to the propeller shaft (especially in salt water), always apply a coat of the recommended lubricant to the entire propeller shaft at the recommended maintenance intervals and also each time the propeller is removed.

  • Page 49: Spark Plug Inspection And Replacement

    MAINTENANCE ob00422 Spark Plug Inspection And Replacement WARNING Avoid serious injury or death from fire or explosion caused by damaged spark plug boots. Damaged spark plug boots can emit sparks. Sparks can ignite fuel vapors under the engine cowl. To avoid damaging spark plug boots, do not use any sharp object or metal tool such as pliers, screwdriver, etc.

  • Page 50: Compressor Air Intake Filter

    MAINTENANCE Description lb. in. lb. ft. Spark plug Compressor Air Intake Filter The filter should be changed every 100 hours of operation, or once a season. IMPORTANT: Never run the engine without the air filter. REMOVAL Remove flywheel cover from engine. Snap out the retainer and remove filter.

  • Page 51: Lubrication Points

    Propeller Shaft - Refer to Propeller Replacement for removal and installation of the propeller. Coat the entire propeller shaft with lubricant to prevent the propeller hub from corroding and seizing to the shaft. ob00378 Lubricate the following with Quicksilver or Mercury Precision Lubricants 2-4-C with Teflon or Special Lubricant 101. •...
  • Page 52 MAINTENANCE • Tilt Support Lever - Lubricate through fitting. ob00683 Swivel bracket Tilt support lever • Tilt Tube - Lubricate through fitting. ob00684 WARNING The end of the steering cable must be fully retracted into the outboard tilt tube before adding lubricant. Adding lubricant to steering cable when fully extended could cause steering cable to become hydraulically locked.

  • Page 53: Gearcase Lubrication

    GEARCASE LUBRICANT CAPACITY Gearcase lubricant capacity is approximately 666 ml (22.5 fl. oz.). GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver Premium or High Performance Gear Lubricant. CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE Place outboard in a vertical operating position. Remove vent plug.

  • Page 54: Submerged Outboard

    MAINTENANCE 3400 Vent plug Fill/drain plug Vent hole IMPORTANT: Replace sealing washers if damaged. Stop adding lubricant. Install the vent plug and sealing washer before removing the lubricant tube. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer. Submerged Outboard A submerged outboard will require service within a few hours by an authorized dealer once the outboard is recovered from the water.

  • Page 55: Storage

    The most effective method for storage preparation is to add the recommended amount of Mercury Precision fuel Stabilizer and Mercury Precision Quickleen products as described on their containers to the fuel tank before the last operation of the boat.

  • Page 56: Positioning Outboard For Storage

    STORAGE Positioning Outboard For Storage Store outboard in an upright (vertical) position to allow water to drain out of outboard. CAUTION If outboard is stored tilted up in freezing temperature, trapped cooling water or rain water that may have entered the propeller exhaust outlet in the gearcase could freeze and cause damage to the outboard.

  • Page 57: Starter Motor Will Not Crank The Engine

    TROUBLESHOOTING Starter Motor Will Not Crank the Engine POSSIBLE CAUSES • Blown 20 Amp fuse in the starting circuit. Refer to Maintenance. • Outboard is not shifted to neutral position. • Weak battery or battery connections are loose or corroded. •...

  • Page 58: Performance Loss

    TROUBLESHOOTING Performance Loss POSSIBLE CAUSES • Throttle not fully open. • Damaged propeller or improper propeller size. • Boat overloaded or load improperly distributed. • Excessive water in bilge. • Boat bottom is dirty or damaged. Battery Will Not Hold Charge POSSIBLE CAUSES •...

  • Page 59: Local Repair Service

    Your satisfaction with your outboard product is very important to your dealer and to us. If you ever have a problem, question or concern about your outboard product, contact your dealer or any authorized Mercury Marine dealership. If additional assistance is required, take these steps.

  • Page 60: Owner Service Assistance

    Telephone (954) 744-3513 Mercury Marine 11650 Interchange Circle North Miramar, FL 33025 (954) 744-3535 U.S.A. Japan Telephone 81-053-423-2500 Mercury Marine - Japan Anshin-cho 283-1 Hamamatsu 81-053-423-2510 Shizuoka-ken, Japan 435-0005 Japan Asia, Singapore Telephone 5466160 Mercury Marine Singapore 72 Loyang Way...

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