Mercury Optimax 115, Optimax 135, Optimax 150, Optimax 175 Service Manual
115/135/150/175
OptiMax
Direct Fuel Injection
Starting Model Year 2000
Starting Serial Number OG960500
Starting Model Year 2000
Starting S/N OG960500
115/135/150/175 OptiMax
Notice
Throughout this publication, “Dangers”, “Warnings” and “Cautions” (accompanied by the International HAZARD Symbol
cerning a particular service or operation that may be hazardous if performed incorrectly or
carelessly. OBSERVE THEM CAREFULLY!
These “Safe t y A l e rts” alone cannot eliminate the hazards that they signal. Strict compliance
to these special instructions when performing the service, plus “Common Sense” operation,
are major accident prevention measures.
) are used to alert the mechanic to special instructions con-
DANGER
DANGER - Immediate hazards which WILL result in severe personal injury or death.
WARNING
WARNING - Hazards or unsafe practices which COULD result in severe personal injury or death.
CAUTION
Hazards or unsafe practices which could result in minor personal injury or product
or property damage.
Notice to Users of This Manual
This service manual has been written and published by the Service Department of Mercury
Marine to aid our dealers’ mechanics and company service personnel when servicing the
products described herein.
It is assumed that these personnel are familiar with the servicing procedures of these products, or like or similar products manufactured and marketed by Mercury Marine, that they
have been trained in the recommended servicing procedures of these products which includes the use of mechanics’ common hand tools and the special Mercury Marine or recommended tools from other suppliers.
We could not possibly know of and advise the service trade of all conceivable procedures
by which a service might be performed and of the possible hazards and/or results of each
method. We have not undertaken any such wide evaluation. Therefore, anyone who uses
a service procedure and/or tool, which is not recommended by the manufacturer, first must
completely satisfy himself that neither his nor the products safety will be endangered by the
service procedure selected.
All information, illustrations and specifications contained in this manual are based on the
latest product information available at the time of publication. As required, revisions to this
manual will be sent to all dealers contracted by us to sell and/or service these products.
It should be kept in mind, while working on the product, that the electrical system and ignition
system are capable of violent and damaging short circuits or severe electrical shocks. When
performing any work where electrical terminals could possibly be grounded or touched by
the mechanic, the battery cables should be disconnected at the battery.
Any time the intake or exhaust openings are exposed during service they should be covered
to protect against accidental entrance of foreign material which could enter the cylinders and
cause extensive internal damage when the engine is started.
90-859494R1 JUNE 2000 Page i
It is important to note, during any maintenance procedure replacement fasteners must have
the same measurements and strength as those removed. Numbers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial
lines for this purpose, while most American nuts do not have strength markings. Mismatched or incorrect fasteners can result in damage or malfunction, or possibly personal
injury. Therefore, fasteners removed should be saved for reuse in the same locations whenever possible. Where the fasteners are not satisfactory for re-use, care should be taken to
select a replacement that matches the original.
Cleanliness and Care of Outboard Motor
A marine power product is a combination of many machined, honed, polished and lapped
surfaces with tolerances that are measured in the ten thousands of an inch/mm. When any
product component is serviced, care and cleanliness are important. Throughout this manual, it should be understood that proper cleaning, and protection of machined surfaces and
friction areas is a part of the repair procedure. This is considered standard shop practice
even if not specifically stated.
Whenever components are removed for service, they should be retained in order. At the
time of installation, they should be installed in the same locations and with the same mating
surfaces as when removed.
Personnel should not work on or under an outboard which is suspended. Outboards should
be attached to work stands, or lowered to ground as soon as possible.
We reserve the right to make changes to this manual without prior notification.
Refer to dealer service bulletins for other pertinent information concerning the products de-
scribed in this manual.
Page Numbering
Two number groups appear at the bottom of each page. The example below is self-explanatory.
90-859494 R1 MAY 2000
EXAMPLE:
LOWER UNIT - 6A-7
Revision No. 1
Month of Printing
Year of Printing
Page ii 90-859494R1 JUNE 2000
Section Description
Section Number
Part of Section Letter
Page Number
Service Manual Outline
Section 1 - General Information & Specifications
A - Specifications
B - Maintenance
C - General Information
D - Outboard Installation
Section 2 - Electrical
A - Ignition
B - Charging & Starting System
C - Timing, Synchronizing & Adjusting
D - Wiring Diagrams
Section 3 - Fuel System
A - Fuel Pump
B - Direct Fuel Injection
C - Oil Injection
D - Emissions
Section 4 - Powerhead
A - Powerhead
B - Cooling
Section 5 - Mid-Section
A - Clamp/Swivel Brackets & Drive Shaft Housing
B - Power Trim – Design I (Showa)
C - Power Trim – Design II (Oildyne)
Section 6 - Gear Housing
A - Right Hand (Standard) Rotation Non-Ratcheting
B - Left Hand (Counter) Rotattion Non-Ratcheting
Section 7 - Attachments/Control Linkage
Section 8 - Color Diagrams
General Information
& Specifications
Ignition System
Fuel System
Powerhead
Mid-Section
Gear Housing
Attachment/Control Linkage
Color Diagrams
1
2
3
4
5
6
7
8
90-859494R1 JUNE 2000 Page iii
SPECIFICATIONS
IMPORTANT INFORMATION
Section 1A - Specifications
Table of Contents
Master Specifications 1A-1. . . . . . . . . . . . . . . . . . . . . . . . .
Master Specifications
Model 135/150 DFI
HORSEPOWER
(KW)
OUTBOARD
WEIGHT
Model 135
Model 150
Full Throttle RPM (135/150)
Idle RPM (In Gear) (135/150)
RPM Limiter
1998 Model 135/150
1999 Model 135
1999 Model 150
Model 135/150
– 20 in. (50.8cm) Shaft
– 25 in. (63.5cm) Shaft
1
A
135 (100.7 kw)
150 (111.8 kw)
5000 - 5600
550 ± 25
5750
5750
5950
440.0 lbs. (200.0 kg)
452.0 lbs. (206.0 kg)
CYLINDER
BLOCK
STROKE Length (All Models) 2.65 in. (67.3 mm)
CYLINDER
BORE
CRANKSHAFT Maximum Runout 0.006 in. (0.152 mm)
PISTON Piston Type
PISTON
DIAMETER
Type
Displacement
Diameter (Std)
Diameter 0.015 in. Oversize
Taper/Out of Round/Wear Maximum
Bore Type
Diameter Standard
Diameter 0.015 in. Oversize
Dimension
“A” at Right
Angle (90
to Piston
Pin
°)
.700
17.78mm
V-6 Cylinder, Two Cycle, Direct Injected
153 cu. in. (2508 cc) 60° Vee
3.501 in. (88.925 mm)
3.516 in. (89.306 mm)
0.003 in. (0.076 mm)
Cast Iron
Aluminum
3.4925 in. ± .0005 in. (88.7095 mm ±
0.0127 mm)
3.5075 in. ± 0.0005 in.
(89.0905 mm ± 0.0127 mm)
3.4925 in. ± .0005 in.
(88.7095 mm ± .0127 mm)
Using a micrometer, measure dimension
“A” at location shown. Dimension “A”
should be 3.4925 in. ± .0005 for a STAN-
DARD size piston (new) Dimension “A”
will be 0.001 – 0.0015 less if coating is
worn off piston (used)
REEDS Reed Stand 0pen (Max.) 0.020 in. (0.50 mm)
90-855347R1 JANUARY 1999 Page 1A-1
SPECIFICATIONS
Model 135/150 DFI
MID
SECTION
GEAR
HOUSING
Power Trim (Total Tilt Range)
Power Trim (Tilt Range)
Steering Pivot Range
Tilt Pin Adjustment Positions
Allowable Transom Thickness
Gear Ratio
Standard Ratio – 135
Standard Ratio – 150
Optional High Altitude Ratio
– 135
– 150
Gearcase Capacity
Pinion Height
Forward Gear Backlash
– 1.87:1
– 2.00:1
– 2.30:1
Reverse Gear Backlash
– Standard/Counter Rotation
Water Pressure @ RPM
73°
19°
60°
4
2-3/8 in. (6.03 cm)
2.00:1 12/24 Teeth
1.87:1 15/28 Teeth
2.30:1 13/30 Teeth
2.00:1 12/24 Teeth
22.5 fl. oz. (665.4 ml)
0.025 in. (0.635 mm)
.
0.017 in. – 0.028 in.
(0.431 mm – 0.711 mm)
0.015 in. – 0.022 in.
(0.381 mm – 0.558 mm)
0.018 in. – 0.023 in.
(0.460 mm – 0.584 mm)
0.030 in. to 0.050 in.
(0.076 mm to 0.127 mm)
12 PSI Minimum @ 5500 RPM
DIRECT
INJECTION
Injectors
– Quantity
– Injectors are Crank Angle Driven
by ECM
– #2 Cylinder
– #4 Cylinder
– #6 Cylinder
– #1 Cylinder
– #3 Cylinder
– #5 Cylinder
Fuel Line Pressure @ Injectors
Air Pressure
High Pressure Electric Fuel Pump
Amperage Draw
Low Pressure Electric Fuel Pump
Amperage Draw
Low Pressure Electric Fuel Pump
Output
Fuel Injector Ohm Resistance
Direct Injector Ohm Resistance
Fuel/Air Differential
6
WHT/RED + RED/WHT Leads
WHT/YEL + YEL/WHT Leads
WHT/PPL + PPL/WHT Leads
WHT/BRN + BRN/WHT Leads
WHT/ORG + ORG/WHT Leads
WHT/DRK BLU + DRK BLU/WHT
Leads
89 ± 2 psi (613.5 ± 13.8 kPa)
79 ± 2 psi (544.0 ± 13.8 kPa)
5 – 9 Amperes
1 – 2 Amperes
6 – 9 psi (41.37 – 62.04 kPa)
1.8 ± 0.1 Ω
1.3 ± 0.3 Ω
10 psi (68.5 kPa)
Page 1A-2 90-855347R1 JANUARY 1999
Master Specifications
SPECIFICATIONS
Model 135/150 DFI
FUEL
SYSTEM
STARTING
SYSTEM
IGNITION
SYSTEM
Fuel
Recommended Gasoline
Recommended Oil
Gasoline/Oil Ratio
– @ Idle
– @ WOT
Fuel Pressure
Crankcase Pump
– @ Idle
– @ WOT
Electric Start – All Models
Starter Draw (Under Load)
Starter Draw (No Load)
Minimum Brush Length
Battery Rating
Type
Spark Plug Type
Spark Plug Gap
Maximum Timing
Idle Timing
Throttle Position Sensor 1 (Inner
TPS)
@ Idle
@ W.O.T
Throttle Position Sensor 2 (Outer
TPS)
@ Idle
@ W.O.T
Crank Position Sensor
Air Gap
Gasoline w/Oil Injection
Unleaded 87 Octane Minimum
Quicksilver TC-W3 Premium Plus 2
Cycle Outboard Oil
300 – 400:1
60:1
2 psi (13.8 kPa)
8 psi (55.2 kPa)
165 Amperes
30 Amperes
0.25 in. (65.4 mm)
1000 (Minimum) Marine Cranking Amps
(MCA)
750 (Minimum) Cold Cranking Amps
(CCA)
Digital Inductive
NGK PZFR5F-11
NGK ZFR5F-11 or
Champion RC12MC4
0.040 in. (1.0 mm)
Not Adjustable; Controlled by ECM
Not Adjustable; Controlled by ECM
3.70 – 4.90 VDC
0.30 – 1.80 VDC
0.10 – 1.50 VDC
3.20 – 4.90 VDC
0.025 in. – 0.040 in.
(0.635 mm – 1.01 mm)
CHARGING
SYSTEM
*Amperage listed is when battery is in a discharged state. If battery is fully charged, amperage readings will
be less.
90-855347R1 JANUARY 1999 Page 1A-3
Alternator Output (Regulated)
Brush Length
Voltage Output
Regulator Current Draw
32 - 38 Amperes @ 2000 RPM
@ Battery*
52 - 60 Amperes @ 2000 RPM
@ Alternator
Std Exposed Length:
0.413 in. (10.5 mm)
Min. Exposed Length:
0.059 in. (1.5 mm)
13.5 to 15.1 Volts
0.15 mA (Ign. Switch Off)
30.0 mA (Ign. Switch On)
MAINTENANCE
IMPORTANT INFORMATION
Section 1B - Maintenance
Table of Contents
Specifications 1B-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Case Lubricant Capacity 1B-1. . . . . . . . . . . . . .
Special Tools 1B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Quicksilver Lubricant/Sealant 1B-2. . . . . . . . . . . . . . . . . .
Inspection and Maintenance Schedule 1B-4. . . . . . . . . .
Before Each Use 1B-4. . . . . . . . . . . . . . . . . . . . . . . . . .
After Each Use 1B-4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Every 100 Hours of Use or Once yearly,
Whichever occurs first 1B-4. . . . . . . . . . . . . . . . . . . . .
Flushing Engine 1B-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing Cooling System – Using Cowl
Flush Plug 1B-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing Cooling System – Using Flushing
Attachment 44357A2 1B-5. . . . . . . . . . . . . . . . . . . . . .
Specifications
1
B
Fuel System 1B-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Line Inspection 1B-6. . . . . . . . . . . . . . . . . . . . . . .
Water Separating Fuel Filter 1B-6. . . . . . . . . . . . . . . .
Corrosion Control Anode 1B-7. . . . . . . . . . . . . . . . . . . . . .
Spark Plug Inspection 1B-7. . . . . . . . . . . . . . . . . . . . . . . . .
Battery Inspection 1B-8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse Replacement 1B-8. . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Air intake Filter 1B-9. . . . . . . . . . . . . . . . . . .
Removal 1B-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1B-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication Points 1B-9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Power Trim Fluid 1B-11. . . . . . . . . . . . . . . . . . .
Gear Case Lubrication 1B-12. . . . . . . . . . . . . . . . . . . . . . .
Storage Preparation 1B-13. . . . . . . . . . . . . . . . . . . . . . . . .
Gear Case Lubricant Capacity
Gear Case Ratio Capacity
1.87:1
2.00:1
2.30:1
22.5 fl. oz. (665ml)
22.5 fl. oz. (665ml)
22.5 fl. oz. (665ml)
90-855347R1 JANUARY 1999 Page 1B-1
MAINTENANCE
Special Tools
1. Grease Gun 91-37299A1
2. Flushing Attachment 44357A2
Quicksilver Lubricant/Sealant
1. Gear Lubricant - Premium Blend 92-19007A24
Page 1B-2 90-855347R1 JANUARY 1999
2. Anti-Corrosion Grease 92-78376A6
3. 2-4-C Marine Lubricant with Teflon 92-825407A12
MAINTENANCE
4. SAE 30W Motor Oil (Obtain Locally)
5. Quicksilver Power Trim and Steering Fluid 91-90100A12)
90-855347R1 JANUARY 1999 Page 1B-3
MAINTENANCE
Inspection and Maintenance Schedule
Before Each Use
1. Check that lanyard stop switch stops the engine.
2. Visually inspect the fuel system for deterioration or leaks.
3. Check outboard for tightness on transom.
4. Check steering system for binding or loose components.
5. Visually check steering link rod fasteners for proper tightness.
6. Check propeller blades for damage.
After Each Use
1. Flush out the outboard cooling system if operating in salt or polluted water.
2. Wash off all salt deposits and flush out the exhaust outlet of the propeller and gear
case with fresh water if operating in salt water.
Every 100 Hours of Use or Once yearly, Whichever occurs first
1. Lubricate all lubrication points. Lubricate more frequently when used in salt water.
2. Inspect and clean spark plugs.
3. Replace water separating fuel filter
4. Replace compressor air intake filter.
5. Check corrosion control anodes. Check more frequently when used in salt water.
6. Drain and replace gear case lubricant.
7. Lubricate splines on the drive shaft.
8. Check power trim fluid.
9. Inspect battery.
10. Check control cable adjustments.
11. Remove engine deposits with Quicksilver Power Tune Engine Cleaner.
12. Check tightness of bolts, nuts, and other fasteners.
13. Replace water pump impeller (more often if overheating occurs or reduced water
pressure is noted).
These items should be serviced by an authorized dealer.
∗
∗
∗
∗
Page 1B-4 90-855347R1 JANUARY 1999
Flushing Engine
Flushing Cooling System – Using Cowl Flush Plug
Flush the internal water passages of the outboard with fresh water after each use in salt,
polluted or muddy water. This will help prevent a buildup of deposits from clogging the
internal water passages.
NOTE: Engine can be stopped or running at idle speed when flushing the cooling system.
Do not flush engine using a water system that exceeds 45 psi.
1. Remove the plug from fitting in the bottom cowl.
MAINTENANCE
2. Attach a water hose to the fitting. Turn water on and flush for 3 to 5 minutes.
Flushing Cooling System – Using Flushing Attachment 44357A2
WARNING
When flushing, verify that area in vicinity of propeller is clear and that no person
is standing nearby – to avoid possible injury . It is recommended to remove propeller as a precautionary measure.
1. Install Quicksilver Flushing Attachment 44357A2 (or equivalent tool) on the gear
housing from the FRONT side, positioning the rubber cups over the water intake
openings.
2. Connect hose [1/2 in. (12.7mm) I.D. or larger] between flushing attachment and water
tap.
IMPORTANT: To prevent water pump damage, do not start or run engine unless
cooling water is flowing.
3. With the outboard in the normal operating position (vertical), partially open water tap
(IT IS NOT NECESSARY to use full water pressure) and adjust water flow so that
there is a significant water loss around the rubber cups.
4. Start engine and idle in NEUTRAL. Increase engine speed, not to exceed 2500 RPM.
5. Flush or service engine as required. Verify adequate cooling water is provided.
a. Water must be discharged thru “tell tale.”
IMPORT ANT: Prevent engine overheating. If water flow is insufficient, stop engine
and determine cause before continuing.
b. Flush until discharge water is clear. In salt-water areas, run outboard 3 to 5 min-
utes.
c. Stop engine before turning off water.
6. Stop engine, turn water off and remove flushing attachment from gear housing.
90-855347R1 JANUARY 1999 Page 1B-5
MAINTENANCE
IMPORTANT: While and after flushing, keep outboard in upright position until all
water has drained from drive shaft housing to prevent water from entering the powerhead via drive shaft housing and exhaust ports.
Fuel System
Avoid serious injury or death from gasoline fire or explosion. Carefully follow all
fuel system service instructions. Always stop the engine and DO NOT smoke or
allow open flames or sparks in the area while servicing any part of the fuel system.
Before servicing any part of the fuel system, stop engine and disconnect the battery . Drain
the fuel system completely . Use an approved container to collect and store fuel. Wipe up
any spillage immediately . Material used to contain spillage must be disposed of in an approved receptacle. Any fuel system service must be performed in a well ventilated area.
Inspect any completed service work for sign of fuel leakage.
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 is found, the fuel line or primer
bulb must be replaced.
WARNING
Water Separating Fuel Filter
NOTE: The warning system will turn on when water in the fuel filter reaches the full level.
1. This filter removes moisture and also debris from the fuel. If the filter becomes filled
with water, the water can be removed. If the filter becomes plugged with debris, the
filter must be replaced with a new filter.
Remove and replace filter as follows:
a. Turn ignition key switch to OFF position.
b. Disconnect wire at bottom of filter.
c. Remove filter by turning the filter in the direction of the arrow (clockwise). Tip the
filter to drain fluid in a suitable container.
d. Lubricate the sealing ring on the filter with oil. Thread on the filter and tighten se-
curely by hand. Reconnect the wire to the filter.
IMPORT ANT : Visually inspect for fuel leakage from the filter by squeezing the primer bulb until firm, forcing fuel into the filter.
Page 1B-6 90-855347R1 JANUARY 1999
Corrosion Control Anode
The gear case has two corrosion control anodes (a). Another anode (b) is installed on the
bottom of the transom bracket assembly. An anode helps protect the outboard against
galvanic corrosion by sacrificing its metal to be slowly eroded instead of the outboard
metals.
a
Each anode requires periodic inspection especially in salt water which will accelerate the
erosion. T o maintain this corrosion protection, always replace the anode before it is completely eroded. Never paint or apply a protective coating on the anode as this will reduce
effectiveness of the anode.
MAINTENANCE
b
Spark Plug Inspection
Inspect spark plugs at the recommended intervals.
1. Remove the spark plug leads by twisting the rubber boots slightly and pull off. Inspect
spark plug boots and replace if cracked.
2. Remove the spark plugs to inspect and clean. Replace spark plug if electrode is worn
or the insulator is rough, cracked, broken, blistered or fouled.
3. Set the spark plug gap. See Specification Chart in General Information Section.
4. Before reinstalling spark plugs, clean away dirt on the spark plug seats. Install plugs
finger tight, and tighten 1/4 turn or torque to 20 lb. ft. (27 N·m).
90-855347R1 JANUARY 1999 Page 1B-7
MAINTENANCE
Battery Inspection
The battery should be inspected at periodic intervals to ensure proper engine starting
capability.
IMPORTANT: Read the safety and maintenance instructions which accompany
your battery.
1. Turn off the engine before servicing the battery.
2. Add water as necessary to keep the battery full.
3. Make sure the battery is secure against movement.
4. Battery cable terminals should be clean, tight, and correctly installed. Positive to positive and negative to negative.
5. Make sure the battery is equipped with a nonconductive shield to prevent accidental
shorting of battery terminals.
Fuse Replacement
IMPORTANT: Always carry spare SFE 20 AMP fuses.
The electrical wiring circuits on the outboard are protected from overload by fuses in the
wiring. If a fuse is blown, try to locate and correct the cause of the overload. If the cause
is not found, the fuse may blow again.
1. Open the fuse holder and look at the silver colored band inside the fuse. If band is
broken, replace the fuse. Replace fuse with a new fuse with the same rating.
2. The fuses and circuits are identified as follows:
a. Electric Fuel Pump Circuit – SFE 20 AMP Fuse.
b. Fuel/Air Injector Circuits – SFE 20 AMP Fuse.
c. Starting Circuit – SFE 20 AMP Fuse.
d. Ignition Coil/Oil Pump Circuit – SFE 20 AMP Fuse.
a
b
c
d
Page 1B-8 90-855347R1 JANUARY 1999
Compressor Air intake Filter
The filter should be changed every 100 hours of operation, or once a season. Never run
the engine without the air filter.
Removal
1. Remove flywheel cover from the engine. Snap out the retainer (a) and remove filter
(b).
MAINTENANCE
a
b
Installation
Install filter (b) into the cover. Secure filter into cover with retainer (a).
Lubrication Points
Lubricate Point 1 with Quicksilver Special Lubricant 101.
1. Trim Rod Ball Ends – Turn the ball ends to work the lubricant into the ball sockets.
1
90-855347R1 JANUARY 1999 Page 1B-9
MAINTENANCE
Lubricate Point 2 with Quicksilver Anti-Corrosion Grease or 2-4-C Marine Lubricant with Teflon.
2. 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.
2
Lubricate Points 3 thru 6 with Quicksilver 2-4-C Marine Lubricant with Teflon or Special
Lubricate 101.
3. Swivel Bracket – Lubricate through fitting.
4. Tilt Support Lever – Lubricate through fitting.
5. Tilt Tube – Lubricate through fitting.
5
3
4
Page 1B-10 90-855347R1 JANUARY 1999
6. Steering Cable Grease Fitting (If Equipped) – Rotate steering wheel to fully retract the
steering cable end (a) into the outboard tilt tube. Lubricate through fitting (b).
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. An hydraulically
locked steering cable will cause loss of steering control, possibly resulting in serious injury or death.
Lubricate Points 7 With Light Weight Oil.
7. Steering Link Rod Pivot Points – Lubricate pivot points.
MAINTENANCE
WARNING
6-b
Checking Power Trim Fluid
8. Tilt outboard to the full up position and engage the tilt support lock.
6-a
7
8
9. Remove fill cap and check fluid level. The fluid level should be even with the bottom
of the fill hole. Add Quicksilver Power Trim & Steering Fluid. If not available, use automotive (ATF) automatic transmission fluid.
90-855347R1 JANUARY 1999 Page 1B-1 1
9
MAINTENANCE
Gear Case Lubrication
When adding or changing gear case lubricant, visually check for the presence of water
in the lubricant. If water is present, it may have settled to the bottom and will drain out prior
to the lubricant, or it may be mixed with the lubricant, giving it a milky colored appearance.
If water is noticed, have the gear case checked by your dealer.W ater in the lubricant may
result in premature bearing failure or, in freezing temperatures, will turn to ice and damage
the gear case.
Whenever you remove the fill/drain plug, examine the magnetic end for metal particles.
A small amount of metal filings or fine metal particles indicates normal gear wear. An excessive amount of metal filings or larger particles (chips) may indicate abnormal gear
wear and should be checked by an authorized dealer.
DRAINING GEAR CASE
NOTE: Some models may have the vent and fill/drain plugs on the opposite side.
1. Place outboard in a vertical operating position.
2. Place drain pan below outboard.
3. Remove vent plug and fill/drain plug and drain lubricant.
3
2
GEAR CASE LUBRICANT CAPACITY
Gear case lubricant capacity is approximately 22.5 fl. oz. (666 ml).
1
Page 1B-12 90-855347R1 JANUARY 1999
CHECKING GEAR CASE LUBRICANT LEVEL AND REFILLING GEAR CASE
NOTE: Some models may have the vent and fill/drain plugs on the opposite side.
1. Place outboard in a vertical operating position.
2. Remove vent plug (a).
3. Place lubricant tube (b) into the fill hole and add lubricant until it appears at the vent
hole (c).
IMPORTANT: Replace sealing washers if damaged.
4. Stop adding lubricant. Install the vent plug and sealing washer (a) before removing
the lubricant tube.
5. Remove lubricant tube and reinstall cleaned fill/drain plug and sealing washer (d).
a
MAINTENANCE
c
1-5
b
STORAGE PREPARATION
The major consideration in preparing your outboard for storage is to protect it from rust,
corrosion, and damage caused by freezing of trapped water.
The following storage procedures should be followed to prepare your outboard for out of
season storage or prolonged storage (two months or longer).
Never start or run your outboard (even momentarily) without water circulating
through all the cooling water intake holes in the gear case to prevent damage to
the water pump (running dry) or overheating of the engine.
FUEL SYSTEM
IMPORTANT: Gasoline containing alcohol (ethanol or methanol) can cause a formation of acid during storage and can damage the fuel system. If the gasoline being used contains alcohol, it is advisable to drain as much of the remaining gasoline as possible from the fuel tank, remote fuel line, and engine fuel system.
d
CAUTION
Fill the fuel system (tank, hoses, fuel pumps, and fuel injection systems) with treated (stabilized) fuel to help prevent formation of varnish and gum. Proceed with following instructions.
1. Portable Fuel T ank – Pour the required amount of Quicksilver Gasoline Stabilizer (follow instructions on container) into fuel tank. Tip fuel tank back and forth to mix stabilizer with the fuel.
2. Permanently Installed Fuel Tank – Pour the required amount of Quicksilver Gasoline
Stabilizer (follow instructions on container) into a separate container and mix with approximately one quart (one liter) of gasoline. Pour this mixture into fuel tank.
90-855347R1 JANUARY 1999 Page 1B-13
MAINTENANCE
3. Place the outboard in water or connect flushing attachment for circulating cooling
water. Run the engine at 2000 rpm for 25 minutes to allow treated fuel to fill the fuel
system.
PROTECTING INTERNAL ENGINE COMPONENTS
NOTE: Make sure the fuel system has been prepared for storage.
1. Remove the spark plugs and add approximately one ounce (30ml) of engine oil into
each spark plug hole. Rotate the flywheel manually several times to distribute the oil
in the cylinders. Reinstall spark plugs.
2. Remove the water separating fuel filter and empty contents into a suitable container.
Refer to Maintenance Section for removal and installation of filter. Replace fuel filter
annually , or every 100 Hours of operation, or if large amount of fuel contamination is
present.
PROTECTING EXTERNAL OUTBOARD COMPONENTS
1. Lubricate all outboard components listed in the Inspection and Maintenance
Schedule.
2. Touch up any paint nicks. See your dealer for touch-up paint.
3. Spray Quicksilver Corrosion Guard on external metal surfaces (except corrosion control anodes).
GEAR CASE
Drain and refill the gear case lubricant (refer to maintenance procedure).
POSITIONING OUTBOARD FOR STORAGE
Store outboard in an upright (vertical) position to allow water to drain out of outboard.
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 gear case
could freeze and cause damage to the outboard.
BATTERY STORAGE
1. Follow the battery manufacturers instructions for storage and recharging.
2. Remove the battery from the boat and check water level. Recharge if necessary.
3. Store the battery in a cool, dry place.
4. Periodically check the water level and recharge the battery during storage.
CAUTION
Page 1B-14 90-855347R1 JANUARY 1999
GENERAL INFORMATION
IMPORTANT INFORMATION
Section 1C - General Information
Table of Contents
Serial Number Location 1C-1. . . . . . . . . . . . . . . . . . . . . . .
Conditions Affecting Performance 1C-2. . . . . . . . . . . . . .
Weather 1C-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boat 1C-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trim 1C-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine 1C-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Compression 1C-6. . . . . . . . . . . . . . . . . . . . . . .
Following Complete Submersion 1C-7. . . . . . . . . . . . . . .
Salt Water Submersion 1C-7. . . . . . . . . . . . . . . . . . . . .
Submerged While Running 1C-7. . . . . . . . . . . . . . . . .
Serial Number Location
The engine serial number is located on the lower starboard side of the engine block. A
serial number is also located on the starboard side of the swivel bracket.
1
C
Model 135/150 DFI Powerhead Front View 1C-9. . . . . .
Model 135/150 DFI Powerhead Starboard View 1C-10
Model 135/150 DFI Powerhead Port View 1C-11. . . . . .
Model 135/150 DFI Powerhead Top View 1C-12. . . . . .
Model 135/150 DFI Powerhead Aft View 1C-13. . . . . .
Painting Procedures 1C-14. . . . . . . . . . . . . . . . . . . . . . . .
Cleaning & Painting Aluminum Propellers & Gear
Housings 1C-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Decal Application 1C-15. . . . . . . . . . . . . . . . . . . . . . . . . . .
Decal Removal 1C-15. . . . . . . . . . . . . . . . . . . . . . . . . .
Instructions for “Wet” Application 1C-15. . . . . . . . . .
a-Serial Number
b-Model Year
c-Model Description
d-Year Manufactured
e-Certified Europe Insignia
a
OGXXXXXX
19XX
XXXX
b
c
e
XX
d
90-855347R1 JANUARY 1999 Page 1C-1
GENERAL INFORMATION
Conditions Affecting Performance
Weather
Weather conditions exert a profound effect on power output of internal combustion engines. Established horsepower ratings refer to the power that the engine will produce at
its rated RPM under a specific combination of weather conditions.
Corporations internationally have settled on adoption of I.S.O. (International Standards
Organization) engine test standards, as set forth in I.S.O. 3046 standardizing the computation of horsepower from data obtained on the dynamometer, correcting all values to the
power that the engine will produce at sea level, at 30% relative humidity at 77° F (25°C)
temperature and a barometric pressure of 29.61 inches of mercury.
Summer conditions of high temperature, low barometric pressure and high humidity all
combine to reduce engine power. This is reflected in decreased boat speeds – as much
as 2 or 3 mph. Nothing will regain this speed for the boater but the coming of cool, dry
weather.
In pointing out the consequences of weather effects, an engine – running on a hot, humid
summer day – may lose as much as 14% of the horsepower it would produce on a dry,
brisk spring or fall day. The horsepower that any internal combustion engine produces
depends upon the density of the air that it consumes and this density is dependent upon
the temperature of the air, its barometric pressure and water vapor (or humidity) content.
Accompanying this weather-inspired loss of power is a second but more subtle loss. At
rigging time in early spring, the engine was equipped with a propeller that allowed the
engine to run within its recommended RPM range at full throttle. With the coming of the
summer weather and the consequent drop in available horsepower, this propeller will, in
effect, become too large. Consequently, the engine operates at less than its recommended RPM.
Due to the horsepower/RPM characteristics of an engine, this will result in further loss of
horsepower at the propeller with another decrease in boat speed. This secondary loss
can be regained by switching to a smaller pitch propeller that allows the engine to run
again at recommended RPM.
Page 1C-2 90-855347R1 JANUARY 1999
To obtain optimum engine performance under changing weather conditions, the engine
MUST be propped to allow it to operate at or near the top end of the recommended maximum RPM range at wide-open-throttle with a normal boat load.
This will allow the engine to develop full power while operating in an RPM range that discourages damaging detonation.
Boat
WEIGHT DISTRIBUTION
1. Proper positioning of the weight inside the boat (persons and gear) has a significant
effect on the boat’s performance, for example:
a. Shifting weight to the rear (stern)
b. Shifting weight to the front (bow)
GENERAL INFORMATION
(1.)Generally increases top speed.
(2.)If in excess, can cause the boat to porpoise.
(3.)Can make the bow bounce excessively in choppy water.
(4.)Will increase the danger of the following wave splashing into the boat when
coming off plane.
(1.)Improves ease of planing off.
BOTTOM
(2.)Generally improves rough water ride.
(3.)If excessive, can make the boat veer back-and-forth (bow steer).
1. Boat Bottom: For maximum speed, a boat bottom should be nearly a flat plane where
it contacts the water and particularly straight and smooth in fore-and-aft direction.
a. Hook: Exists when bottom is concave in fore-and -aft direction when viewed from
the side. When boat is planing, “hook” causes more lift on bottom near transom
and allows bow to drop, thus greatly increasing wetted surface and reducing boat
speed. “Hook” frequently is caused by supporting boat too far ahead of transom
while hauling on a trailer or during storage.
b. Rocker: The reverse of hook and much less common. “Rocker” exists if bottom
is convex in fore-and-aft direction when viewed from the side, and boat has strong
tendency to porpoise.
c. Surface Roughness: Moss, barnacles, etc., on boat or corrosion of motor’s gear
housing increase skin friction and cause speed loss. Clean surfaces when necessary .
d. Gear Housing: If unit is left in the water, marine vegetation may accumulate over
a period of time. This growth MUST be removed from unit before operation, as it
may clog the water inlet holes in the gear housing and cause the engine to overheat.
90-855347R1 JANUARY 1999 Page 1C-3
GENERAL INFORMATION
Trim
TRIMMING OUTBOARD “OUT” (“UP”)
Excessive trim “out” also may reduce the stability of some high speed hulls. T o
correct instability at high speed, reduce the power GRADUALL Y and trim the outboard “in” slightly before resuming high speed operation. (Rapid reduction in
power will cause a sudden change of steering torque and may cause additional
momentary boat instability.)
1. Will lift bow of boat, generally increasing top speed.
2. Transfers steering torque harder to left on single outboard installations below 23 in.
(584mm) transom height.
3. Increases clearance over submerged objects.
4. In excess, can cause porpoising and/or ventilation.
5. If trimmed out beyond the water pickup, reduced water supply can cause overheating
resulting in engine damage.
WARNING
Page 1C-4 90-855347R1 JANUARY 1999
TRIMMING OUTBOARD “IN” (“DOWN”) CHARACTERISTICS
WARNING
Excessive speed at minimum trim “in” may cause undesirable and/or unsafe
steering conditions. Each boat should be tested for handling characteristics after
any adjustment is made to the angle (trim adjustment bolt relocation.)
1. Will help planing off, particularly with a heavy load.
2. Usually improves ride in choppy water.
3. In excess, can cause boat to veer to the left or right (bow steer).
4. Transfers steering torque harder to right (or less to the left) on single outboard installations.
5. Improves planing speed acceleration (by moving trim adjustment bolt one hole closer
to transom).
WATER ABSORPTION
It is imperative that all through hull fasteners be coated with a quality marine sealer at time
of installation. Water intrusion into the transom core and/or inner hull will result in additional boat weight (reduced boat performance), hull decay and eventual structural failure.
CAVITATION
GENERAL INFORMATION
VENTILATION
Cavitation is caused by water vapor bubbles forming either from a sharp edge or angle
on the gear case or from an irregularity in the propeller blade itself. These vapor bubbles
flow back and collapse when striking the surface of the propeller blade resulting in the erosion of the propeller blade surface. If allowed to continue, eventual blade failure (breakage) will occur.
Ventilation occurs when air is drawn from the water’s surface (excessive trim out angle)
or from the engine exhaust flow (wrong propeller/propeller hardware installed or gear
case labyrinth seal worn) into the propeller blades. These air bubbles strike the propeller
blade surface and cause erosion of the blade surface. If allowed to continue, eventual
blade failure (breakage) will occur.
90-855347R1 JANUARY 1999 Page 1C-5
GENERAL INFORMATION
Engine
DETONATION
Detonation in a 2-cycle engine resembles the “pinging” heard in an automobile engine.
It can be otherwise described as a tin-like “rattling” or “plinking” sound.
Detonation is an explosion of an unburned portion of the fuel/air charge after the spark
plug has fired. Detonation creates severe shock waves in the engine, and these shock
waves often find or create a weakness: The dome of a piston, cylinder head/gasket, piston
rings or piston ring lands, piston pin and roller bearings.
A few of the most common causes of detonation in a marine 2-cycle application are as
follows:
• Over-advanced ignition timing.
• Use of low octane gasoline.
• Propeller pitch too high (engine RPM below recommended maximum range).
• Lean fuel mixture at or near wide-open-throttle.
• Spark plugs (heat range too hot – incorrect reach – cross-firing).
• Inadequate engine cooling (deteriorated cooling system).
Detonation usually can be prevented if:
1. The engine is correctly set up.
2. Diligent maintenance is applied to combat the detonation causes.
Engine Compression
Engine compression should be checked with engine block warm, throttle shutter wide
open, all spark plugs removed and using a fully charged battery . Normal compression for
all cylinders should be 1 10 to 130 psi (758.5 to 896.4 kPa). Cylinders should not vary more
than 15 psi (103.4 kPa) between one another. A variance of more than 15 psi would indicate the need for a power head inspection/disassembly.
51115
Page 1C-6 90-855347R1 JANUARY 1999
Following Complete Submersion
Salt Water Submersion
Due to the corrosive effect of salt water on internal engine components, complete disassembly is necessary before any attempt is made to start the engine.
Submerged While Running
When an engine is submerged while running, the possibility of internal engine damage
is greatly increased. If, after engine is recovered and with spark plugs removed, engine
fails to turn over freely when turning flywheel, the possibility of internal damage (bent connecting rod and/or bent crankshaft) exists. If this is the case, the powerhead must be disassembled.
SUBMERGED ENGINE (FRESH WATER)
IMPORT ANT: Engine should be run within 2 hours after recovery, or serious internal damage may occur. If unable to start engine in this period, disassemble engine
and clean all parts. Apply oil as soon as possible.
NOTE: If sand has entered the air intake on the engine, do not attempt to the start the
engine. Sand will cause internal engine damage. disassembly is required to clean all internal engine components of sand.
GENERAL INFORMATION
1. Recover engine from water as quickly as possible.
2. Remove cowling.
3. Clean the exterior of the outboard with fresh water.
4. Dry all wiring and electrical components using compressed air.
5. Drain water from fuel system as follows:
a. Disconnect remote fuel hose from engine.
b. Remove drain plug from vapor separator and drain fuel/water. Reinstall plug after
draining.
c. Remove the fuel hose from bottom of port side fuel rail and drain fuel/water. Rein-
stall hose.
d. Remove the water separating fuel filter and empty contents.
6. Drain water from air compressor system as follows:
a. Dry or replace the air filter for the compressor.
b. Remove air outlet hose for the air compressor and drain water from compressor
and hose. Reinstall hose.
c. Remove the air hose from bottom of port side fuel rail and drain water. Reinstall
hose.
7. Drain water from engine as follows:
a. Remove air sensor from front of the air plenum. Tilt up the outboard and drain wa-
ter out of the air plenum through the air sensor mounting hole. Reinstall Sensor.
b. Remove spark plugs from engine.
c. Rotate flywheel manually to blow out any water from the cylinders.
d. Add approximately one ounce (30ml) of engine oil into each spark plug hole. Ro-
tate the flywheel manually several times to distribute the oil in the cylinders. Rein-
stall spark plugs.
90-855347R1 JANUARY 1999 Page 1C-7
GENERAL INFORMATION
8. Drain water from the oil injection system as follows:
a. Remove remote oil hose (black without blue stripe) from pulse fitting on starboard
side of engine.
b. Drain any water from hose and reconnect.
c. If water was present in hose, check for water in the remote oil tank. Drain tank if
water is present.
9. Disassemble the engine starter motor and dry components.
10. Prime the oil injection pump as follows:
a. Fill the engine fuel system with fuel. Connect fuel hose and squeeze primer bulb
until it feels firm.
b. Turn the ignition key switch to the “ON” position.
c. Within the first 10 seconds after the key switch has been turned on, move the re-
mote control handle from neutral into forward gear 3 to 5 times. This will automatically start the priming process.
N
F
NOTE: Audible click from the oil pump will tell you the pump is priming. It may take a few
minutes for the pump to complete the priming process.
1 1. Attempt to start engine, using a fresh fuel source.If engine starts, it should be run for
at least one hour to eliminate any water in engine.
12. If engine fails to start, determine cause (fuel, electrical or mechanical).
Page 1C-8 90-855347R1 JANUARY 1999
Model 135/150 DFI Powerhead Front View
12
11
GENERAL INFORMATION
10
13
1
9
7
6
2
8
5
4
1-High Pressure Electric Fuel Pump (Inside Vapor Separator)
2-Vapor Separator
3-Vapor Separator Drain Plug
4-Air Temperature Sensor
5-Fuel Hose Outlet from Low Pressure Electric Fuel Pump
6-Fuel Return Hose from Fuel Cooler
7-Electric Fuel Pump Harness Connection
8-Electric Oil Pump (Hidden)
9-Digital Diagnostic Terminal Harness Connection
10 - Crank Position Sensor Harness Connection
11 - Starter Motor
12 - Throttle Plate Assembly
13 - Fuel Hose Out to Fuel Rails (High Pressure)
90-855347R1 JANUARY 1999 Page 1C-9
3
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