Mercury 135 Pro XS OptiMax User manual

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Thank You
for your purchase of one of the finest outboards available.
You have made a sound investment in boating pleasure.
Your outboard has been manufactured by Mercury Marine, a
world leader in marine technology and outboard
manufacturing since 1939. These years of experience have
been committed to the goal of producing the finest quality
products. This led to Mercury Marine's reputation for strict
quality control, excellence, durability, lasting performance,
and being the best at providing after the sale support.
Please read this manual carefully before operating your
outboard. This manual has been prepared to assist you in
the operation, safe use, and care of your outboard.
All of us at Mercury Marine took pride in building your
outboard and wish you many years of happy and safe
boating.
Again, thank you for your confidence in Mercury Marine.
EPA Emissions Regulations
Outboards sold by Mercury Marine in the United States are
certified to the United States Environmental Protection
Agency as conforming to the requirements of the regulations
for the control of air pollution from new outboard motors.
This certification is contingent on certain adjustments being
set to factory standards. For this reason, the factory
procedure for servicing the product must be strictly followed
and, wherever practicable, returned to the original intent of
the design. Maintenance, replacement, or repair of the
emission control devices and systems may be
performed by any marine engine repair establishment or
individual.
Engines are labeled with an Emission Control Information
decal as permanent evidence of EPA certification.
! WARNING
The engine exhaust from this product contains chemicals
known to the state of California to cause cancer, birth
defects or other reproductive harm.
© 2012 Mercury Marine 135/150/175/150-175 Pro XS OptiMax 90-8M0055670 311

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Warranty Message
The product you have purchased comes with a limited warranty
from Mercury Marine, the terms of the warranty are set forth in
the Warranty Information section of this manual. The warranty
statement contains a description of what is covered, what is not
covered, the duration of coverage, how to best obtain warranty
coverage, important disclaimers and limitations of damages,
and other related information. Please review this important
information.
The description and specifications contained herein were in
effect at the time this manual was approved for printing. Mercury
Marine, whose policy is one of continued improvement, reserves
the right to discontinue models at any time, to change
specifications, designs, methods, or procedures without notice
and without incurring obligation.
Mercury Marine, Fond du Lac, Wisconsin U.S.A.
Litho in U.S.A.
© 2010, Mercury Marine
Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser,
Mercury Racing, Mercury Precision Parts, Mercury Propellers,
Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Pro Max,
OptiMax, Sport‑Jet, K‑Planes, MerCathode, RideGuide,
SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves
logo, and SmartCraft logo are all registered trademarks of
Brunswick Corporation. Mercury Product Protection logo is a
registered service mark of Brunswick Corporation.
Mercury Premier Service
Mercury evaluates the service performance of its dealers and
assigns its highest rating of "Mercury Premier" to those
demonstrating an exceptional commitment to service.
Earning a Mercury Premier Service rating means a dealer:
• Achieves a high 12 month service CSI (Customer
Satisfaction Index) score for warranty service.
• Possesses all necessary service tools, test equipment,
manuals, and parts books.
• Employs at least one Certified or Master technician.

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• Provides timely service for all Mercury Marine customers.
• Offers extended service hours and mobile service, when
appropriate.
• Uses, displays, and stocks adequate inventory of genuine
Mercury Precision Parts.
• Offers a clean, neat shop with well organized tools and
service literature.
Declaration of Conformity OptiMax ‑ For Recreational Craft
Propulsion Engines with the Requirements of Directive
94/25/EC as amended by 2003/44/EC
Name of engine manufacturer: Mercury Marine
Address: W6250 Pioneer Road P.O. Box 1939
Town: Fond du Lac, WI Post Code: 54936‑1939 Country: USA
Name of Authorized Representative: Brunswick Marine in EMEA Inc.
Address: Parc Industriel de Petit‑Rechain
Town: Verviers Post Code: 4800 Country: Belgium
Name of Notified Body for exhaust emission assessment: Det Norske
Veritas AS
Address: Veritasveien 1
Town: Hovik Post Code:
1322
Country:
Norway ID Number: 0575
Name of Notified Body for noise emission assessment: Det Norske
Veritas AS
Address: Veritasveien 1
Town: Hovik Post Code:
1322
Country:
Norway ID Number: 0575
Conformity assessment
module used for exhaust
emissions:
☐ B+C ☐ B+D ☐ B+E ☐ B+F ☐ G☒ H
Conformity assessment
module used for noise
emissions:
☐ A☐ Aa ☐ G☒ H
Other Community Directives applied: Safety of Machinery Directive
98/37/EC; Electromagnetic Compatibility Directive 2004/108/EC

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Description of Engines and Essential Requirements
Engine Type Fuel Type Combustion Cycle
☒ Outboard engine ☒ Petrol ☒ 2 stroke
Identification of Engines Covered by This Declaration of
Conformity
Name of engine family
Unique engine
identification number:
starting serial number
EC Module H
certificate
number
1.5L OptiMax 75, 80, 90, 115,
125 hp 1B227000 RCD‑H‑2
2.5L OptiMax 135, 150, 175 hp 1B227000 RCD‑H‑2
3.0L OptiMax 200, 225 hp 1B227000 RCD‑H‑2
Essential
requirements standards
other
normative
document/
method
technical
file
Please specify in
more detail
(* = mandatory
standard)
Annex 1.B—Exhaust Emissions
B.1 engine
identification ☐ ☐ ☒
B.2 exhaust
emission
requirements
☒* ☐ ☐ * EN ISO
8178‑1:1996
B.3 durability ☐ ☐ ☒
B.4 owner's
manual ☒ ☐ ☐ ISO 8665: 1995
Annex 1.C—Noise Emissions
C.1 Noise emission
levels ☒* ☐ ☐ EN ISO 14509
C.2 Owner's
manual ☐ ☒ ☐ Owner's manual
This declaration of conformity is issued under the sole responsibility of the
manufacturer. I declare on behalf of the engine manufacturer that the engines
mentioned preceding complies with all applicable essential requirements in
the way specified.

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Name / function:
Mark D. Schwabero, President, Mercury
Outboard
Date and place of issue:July 24, 2008
Fond du Lac, Wisconsin, USA

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eng vii
WARRANTY INFORMATION
Warranty Registration.................................................................. 1
Transfer of Warranty.................................................................... 2
Transfer of Mercury Product Protection (Extended Service
Coverage) Plan United States and Canada.................................2
Outboard Limited Warranty..........................................................3
3 Year Limited Warranty Against Corrosion................................ 7
Warranty Coverage and Exclusions.......................................... 11
U.S. EPA Emissions Limited Warranty...................................... 13
Emission Control System Components..................................... 13
California Emissions Limited Warranty...................................... 14
California Air Resources Board Explanation of Your California
Emission Control Warranty Statement.......................................18
Emission Certification Star Label............................................... 19
General Information
Boater's Responsibilities............................................................ 21
Before Operating Your Outboard............................................... 21
Boat Horsepower Capacity........................................................ 22
High‑Speed and High‑Performance Boat Operation................. 22
Propeller Selection.....................................................................23
Outboard Remote Control Models ............................................ 26
Remote Steering Notice.............................................................26
Lanyard Stop Switch.................................................................. 27
Protecting People in the Water.................................................. 31
Passenger Safety Message ‑ Pontoon Boats and Deck Boats
................................................................................................... 32
Wave and Wake Jumping.......................................................... 33
Impact with Underwater Hazards...............................................34
Exhaust Emissions.................................................................... 35
Selecting Accessories for Your Outboard.................................. 37
Safe Boating Suggestions......................................................... 38
Recording Serial Number.......................................................... 40
Specifications.............................................................................40
Component Identification........................................................... 42

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Transporting
Trailering Boat/Outboard .......................................................... 43
Fuel and Oil
Fuel Recommendations............................................................. 44
Oil Recommendation ‑ 135/150/175 (Standard) Models........... 46
Oil Recommendation ‑ 150–175 Pro XS Models....................... 46
Fuel Additives............................................................................ 46
Fuel Requirements.................................................................... 47
Avoiding Fuel Flow Restriction.................................................. 47
Low Permeation Fuel Hose Requirement ................................. 47
EPA Pressurized Portable Fuel Tank Requirements................. 47
Fuel Demand Valve (FDV) Requirement................................... 48
Mercury Marine's Pressurized Portable Fuel Tank.................... 48
Filling Remote Oil Tank............................................................. 49
Filling Engine‑Mounted Oil Reservoir Tank............................... 50
Filling Fuel Tank........................................................................ 51
Features and Controls
Remote Control Features.......................................................... 52
Warning System........................................................................ 53
Power Trim and Tilt....................................................................55

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Operation
Pre‑Starting Check List.............................................................. 60
Operating in Freezing Temperatures......................................... 60
Operating in Saltwater or Polluted Water.................................. 61
Operating at High Elevations..................................................... 61
Setting Trim Angle While Running Engine at Idle Speed.......... 62
Engine Break‑In Procedure....................................................... 62
Starting the Engine.................................................................... 63
Gear Shifting.............................................................................. 66
Stopping the Engine.................................................................. 67
Maintenance
Outboard Care........................................................................... 68
EPA Emissions Regulations...................................................... 68
Inspection and Maintenance Schedule...................................... 69
Flushing the Cooling System..................................................... 72
Top Cowl Removal and Installation........................................... 72
Cleaning Care for Top Cowl...................................................... 73
Flywheel Cover Removal and Installation..................................73
Fuel System............................................................................... 74
Steering Link Rod Fasteners..................................................... 76
Fuse Replacement.....................................................................77
Corrosion Control Anode........................................................... 78
Battery Inspection ..................................................................... 79
Battery Information.................................................................... 79
Propeller Replacement.............................................................. 81
Spark Plug Inspection and Replacement...................................84
Compressor Air Intake Filter...................................................... 85
Alternator Belt Inspection...........................................................86
Lubrication Points...................................................................... 86
Checking Power Trim Fluid........................................................89
Gearcase Lubrication.................................................................90
Submerged Outboard................................................................ 92

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Storage
Storage Preparation...................................................................93
Protecting Internal Engine Components.................................... 94
Protecting External Outboard Components............................... 95
Gearcase................................................................................... 95
Positioning Outboard for Storage.............................................. 95
Battery Storage.......................................................................... 95
Troubleshooting
Starter Motor Will Not Crank the Engine....................................96
Engine Will Not Start..................................................................96
Engine Runs Erratically............................................................. 97
Performance Loss......................................................................97
Battery Will Not Hold Charge..................................................... 97
OWNER SERVICE ASSISTANCE
Local Repair Service..................................................................98
Service Away from Home.......................................................... 98
Parts and Accessories Inquiries................................................ 98
Service Assistance.................................................................... 98
Mercury Marine Service Offices.................................................99

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OUTBOARD INSTALLATION
Important Information...............................................................101
Boat Horsepower Capacity...................................................... 102
Start in Gear Protection........................................................... 102
Selecting Accessories for Your Outboard................................ 102
Fuel System............................................................................. 103
Installation Specifications........................................................ 105
Lifting the Outboard................................................................. 105
Steering Cable ‑ Starboard Side Routed Cable....................... 106
Steering Link Rod Fasteners................................................... 107
Determining Recommended Outboard Mounting Height......... 110
Drilling Outboard Mounting Holes............................................ 110
Fastening the Outboard to the Transom.................................. 112
Electrical, Hoses, and Control Cables..................................... 115
Shift and Throttle Cable........................................................... 120
Front Clamp Reassembly........................................................ 127
Oil Injection Set‑Up.................................................................. 128
Propeller Installation................................................................ 131
Trim In Pin............................................................................... 132
MAINTENANCE LOG
Maintenance Log..................................................................... 134

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WARRANTY INFORMATION
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Warranty Registration
UNITED STATES AND CANADA
To be eligible for warranty coverage, the product must be
registered with Mercury Marine.
At the time of sale, the selling dealer should complete the
warranty registration and immediately submit it to Mercury
Marine via MercNET, e‑mail, or mail. Upon receipt of this
warranty registration, Mercury Marine will record the registration.
A copy of the warranty registration should be provided to you by
your selling dealer.
NOTE: Registration lists must be maintained by Mercury Marine
and any dealer on marine products sold in the United States,
should a safety recall notification under the Federal Safety Act
be required.
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.
Your dealer can also process this change of information.
Mercury Marine
Attn: Warranty Registration Department
W6250 W. Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939
920-929-5054
Fax [phone]
OUTSIDE UNITED STATES AND CANADA
For products purchased outside the United States and Canada,
contact the distributor in your country, or the Marine Power
Service Center closest to you.

WARRANTY INFORMATION
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Transfer of Warranty
UNITED STATES AND CANADA
The limited warranty is transferable to a subsequent purchaser,
but only for the remainder of the unused portion of the limited
warranty. This will not apply to products used for commercial
applications.
To transfer the warranty to the subsequent owner, send or fax a
copy of the bill of sale or purchase agreement, new owner’s
name, address, and engine serial number to Mercury Marine’s
warranty registration department. In the United States and
Canada, mail to:
Mercury Marine
Attn: Warranty Registration Department
W6250 W. Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939
920-929-5054
Fax [phone]
Upon processing the transfer of warranty, Mercury Marine will
record the new owner's information.
There is no charge for this service.
OUTSIDE THE UNITED STATES AND CANADA
For products purchased outside the United States and Canada,
contact the distributor in your country, or the Marine Power
Service Center closest to you.
Transfer of Mercury Product Protection (Extended
Service Coverage) Plan United States and Canada
The remaining coverage period of the Product Protection Plan is
transferable to the subsequent purchaser of the engine within
thirty (30) days from the date of sale. Contracts not transferred
within thirty (30) days of the subsequent purchase will no longer
be valid and the product will no longer be eligible for coverage
under the terms of the contract.

WARRANTY INFORMATION
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To transfer the plan to the subsequent owner, contact Mercury
Product Protection or an authorized dealer to receive a Request
for Transfer form. Submit to Mercury Product Protection a
receipt/bill of sale, a completed Request of Transfer form, and a
check payable to Mercury Marine in the amount of $50.00 (per
engine) to cover the transfer fee.
Plan coverage is not transferable from one product to another
product or for non‑eligible applications.
The Certified Pre‑Owned engine plans are not transferable.
For help or assistance, contact Mercury Product Protection
Department at 1‑888‑427‑5373 from 7:30 a.m. to 4:30 p.m. CST,
Monday–Friday or email [email protected].
Outboard Limited Warranty
UNITED STATES, CANADA, EUROPE, MIDDLE EAST,
AFICA, AND THE CONFEDERATION OF INDEPENDENT
STATES
WHAT IS COVERED: Mercury Marine warrants its new products
to be free of defects in material and workmanship during the
period described below.

WARRANTY INFORMATION
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DURATION OF COVERAGE: This Limited Warranty provides
coverage for three (3) years from the date the product is first sold
to a recreational use retail purchaser, or the date on which the
product is first put into service, whichever occurs first.
Commercial users of these products receive warranty coverage
of one (1) year from the date of first retail sale, or one (1) year
from the date on which the product was first put into service,
whichever occurs first. Commercial use is defined as any work or
employment related use of the product, or any use of the product
which generates income, for any part of the warranty period,
even if the product is only occasionally used for such purposes.
The repair or replacement of parts, or the performance of service
under this warranty, does not extend the life of this warranty
beyond its original expiration date. Unexpired warranty coverage
can be transferred from one recreational use customer to a
subsequent recreational use customer upon proper reregistration
of the product. Unexpired warranty coverage cannot be
transferred either to or from a commercial use customer.
Warranty coverage may be terminated for used repossessed
product; or product purchased at auction, from a salvage yard, or
from an insurance company.
CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN
WARRANTY COVERAGE: Warranty coverage is available only
to retail customers that purchase from a Dealer authorized by
Mercury Marine to distribute the product in the country in which
the sale occurred, and then only after the Mercury Marine
specified predelivery inspection process is completed and
documented. Warranty coverage becomes available upon proper
registration of the product by the authorized dealer. Inaccurate
warranty registration information regarding recreational use, or
subsequent change of use from recreational to commercial
(unless properly reregistered) may void the warranty at the sole
discretion of Mercury Marine. Routine maintenance outlined in
the Operation and Maintenance Manual must be timely
performed in order to maintain warranty coverage. Mercury
Marine reserves the right to make warranty coverage contingent
upon proof of proper maintenance.

WARRANTY INFORMATION
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WHAT MERCURY WILL DO: Mercury's sole and exclusive
obligation under this warranty is limited to, at our option,
repairing a defective part, replacing such part or parts with new
or Mercury Marine certified remanufactured parts, or refunding
the purchase price of the Mercury product. Mercury reserves the
right to improve or modify products from time to time without
assuming an obligation to modify products previously
manufactured.
HOW TO OBTAIN WARRANTY COVERAGE: The customer
must provide Mercury with a reasonable opportunity to repair,
and reasonable access to the product for warranty service.
Warranty claims shall be made by delivering the product for
inspection to a 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. Purchaser shall not, unless
requested by Mercury, ship the product or parts of the product
directly to Mercury. Proof of registered ownership must be
presented to the dealer at the time warranty service is requested
in order to obtain coverage.

WARRANTY INFORMATION
6 eng
WHAT IS NOT COVERED: This limited warranty does not cover
routine maintenance items, tune‑ups, adjustments, normal wear
and tear, damage caused by abuse, abnormal use, use of a
propeller or gear ratio that does not allow the engine to run in its
recommended wide‑open throttle RPM range (see the Operation
and Maintenance Manual), operation of the product in a manner
inconsistent with the recommended operation/duty cycle section
of the Operation and Maintenance Manual, neglect, accident,
submersion, improper installation (proper installation
specifications and techniques are set forth in the installation
instructions for the product), improper service, use of an
accessory or part not manufactured or sold by us, jet pump
impellers and liners, operation with fuels, oils or lubricants which
are not suitable for use with the product (see the Operation and
Maintenance Manual), alteration or removal of parts, water
entering the engine through the fuel intake, air intake or exhaust
system, or damage to the product from insufficient cooling water
caused by blockage of the cooling system by a foreign body,
running the engine out of water, mounting the engine too high on
the transom, or running the boat with the engine trimmed out too
far. Use of the product for racing or other competitive activity, or
operating with a racing type lower unit, at any point, even by a
prior owner of the product, voids the warranty.
Expenses related to haul‑out, launch, towing, storage, telephone,
rental, inconvenience, slip fees, insurance coverage, loan
payments, loss of time, loss of income, or any other type of
incidental or consequential damages are not covered by this
warranty. Also, expenses associated with the removal and/or
replacement of boat partitions or material caused by boat design
for access to the product are not covered by this warranty.
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.

WARRANTY INFORMATION
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For additional information regarding events and circumstances
covered by this warranty, and those that are not, see the
Warranty Coverage section of the Operation and Maintenance
Manual, incorporated by reference into this warranty.
DISCLAIMERS AND LIMITATIONS:
THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR
A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE
EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED
WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE
EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES
ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOME
STATES/COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS,
LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE, AS A RESULT,
THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU
SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL
RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO
COUNTRY.
3 Year Limited Warranty Against Corrosion
WHAT IS COVERED: Mercury Marine warrants that each new
Mercury, Mariner, Mercury Racing, Sport Jet, M2 Jet Drive,
Tracker by Mercury Marine Outboard, Mercury MerCruiser
Inboard or Sterndrive Engine (Product) will not be rendered
inoperative as a direct result of corrosion for the period of time
described below.
DURATION OF COVERAGE: This limited corrosion warranty
provides coverage for three (3) years from either the date the
product is first sold, or the date on which the product is first put
into service, whichever occurs first. The repair or replacement of
parts, or the performance of service under this warranty, does
not extend the life of this warranty beyond its original expiration
date. Unexpired warranty coverage can be transferred to
subsequent (noncommercial use) purchaser upon proper
reregistration of the product.

WARRANTY INFORMATION
8 eng
CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN
WARRANTY COVERAGE: Warranty coverage is available only
to retail customers that purchase from a Dealer authorized by
Mercury Marine to distribute the product in the country in which
the sale occurred, and then only after the Mercury Marine
specified predelivery inspection process is completed and
documented. Warranty coverage becomes available upon proper
registration of the product by the authorized dealer. Corrosion
prevention devices specified in the Operation and Maintenance
Manual must be in use on the boat, and routine maintenance
outlined in the Operation and Maintenance Manual must be
timely performed (including, without limitation, the replacement of
sacrificial anodes, use of specified lubricants, and touch‑up of
nicks and scratches) in order to maintain warranty coverage.
Mercury Marine reserves the right to make warranty coverage
contingent upon proof of proper maintenance.
WHAT MERCURY WILL DO: Mercury's sole and exclusive
obligation under this warranty is limited to, at our option,
repairing a corroded part, replacing such part or parts with new
or Mercury Marine certified remanufactured parts, or refunding
the purchase price of the Mercury product. Mercury reserves the
right to improve or modify products from time to time without
assuming an obligation to modify products previously
manufactured.