Mercury 135 Verado FourStroke Operation And Maintenance Manual Download Page 80

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2. Install the upper half of the flywheel cover subassembly to the lower

flywheel cover subassembly. Ensure the upper flywheel cover latch

opening is properly secured to the lower flywheel cover.

a -

Upper flywheel cover latch

opening

b -

Lower flywheel cover latch

3. Push the two subassemblies together and install three screws. Tighten

the three screws to the specified torque.

14309

Description

lb‑in.

lb‑ft

Screw

–

4. Install the flywheel cover onto the resonator and the front mounting post.
5. Align the flywheel cover rear bolt holes with the rear mounting posts.

14314

MAINTENANCE

eng

Summary of Contents for 135 Verado FourStroke

Page 1: ...Operation and Maintenance Manual 2016 Mercury Marine 135 150 175 200 Verado FourStroke 8M0125711 1216 eng...

Page 2: ...eng...

Page 3: ...nual Thoroughly IMPORTANT If you do not understand any portion of this manual contact your dealer Your dealer can also provide a demonstration of actual starting and operating procedures Notice Throug...

Page 4: ...ne whose policies are based on continuous improvement reserves the right to discontinue models at any time or to change specifications or designs without notice and without incurring obligation Warran...

Page 5: ...le information Outboard Engine Model and Horsepower Engine Serial Number Gear Ratio Propeller Number Pitch Diameter Hull Identification Number HIN Purchase Date Boat Manufacturer Boat Model Length Exh...

Page 6: ...eng iv...

Page 7: ...ns 9 Selecting Accessories for Your Outboard 11 Safe Boating Recommendations 11 Recording Serial Number 14 135 150 175 200 Verado FourStroke Specifications 14 Component Identification 16 Propeller Sel...

Page 8: ...ng System 46 Power Trim and Tilt 48 Operation Important Daily Inspection Before Each Use 52 Prestarting Check List 52 Operating in Freezing Temperatures 53 Operating in Saltwater or Polluted Water 53...

Page 9: ...teners 82 DTS Wiring System 83 Accessory Drive Belt Inspection 83 Lubrication Points 83 Checking Power Trim Fluid 86 Checking Power Steering Fluid 87 Changing Engine Oil 88 Gearcase Lubrication 91 Sto...

Page 10: ...ervice Assistance 98 Ordering Literature 100 Installation Information Mercury Marine Validated Engine Mounting Hardware 102 Accessories Mounted to the Transom Clamp Bracket 102 Fastening the Outboard...

Page 11: ...g with using good common sense can help prevent personal injury and product damage This manual as well as safety labels posted on the outboard use the following safety alerts to draw your attention to...

Page 12: ...ination For additional information obtain a copy of our Hi Performance Boat Operation booklet from your dealer distributor or Mercury Marine Outboard Remote Control Models The outboard must be equippe...

Page 13: ...d stop switch is to stop the engine when the operator moves far enough away from the operator s position to activate the switch This would occur if the operator accidentally falls overboard or moves w...

Page 14: ...the operator s station without first disconnecting the stop switch lanyard from the operator Accidental or unintended activation of the switch during normal operation is also a possibility This could...

Page 15: ...Stop the engine immediately whenever anyone in the water is near your boat Shift the outboard into neutral and shut off the engine before allowing people to swim or be in the water near your boat Pass...

Page 16: ...jury or death Stay back from the front end of deck boats or raised platforms and remain seated while the boat is in motion BOATS WITH FRONT MOUNTED RAISED PEDESTAL FISHING SEATS Elevated fishing seats...

Page 17: ...er less common hazardous result from allowing your boat to launch off a wave or wake If the bow of your boat pitches down far enough while airborne upon water contact it may penetrate under the water...

Page 18: ...g pipes bridge supports wing dams trees stumps and rocks Striking a floating or underwater object could result in any of an infinite number of situations Some of these situations could yield the follo...

Page 19: ...exhaust fumes of all internal combustion engines including the engines that propel boats and the generators that power boat accessories By itself CO is odorless colorless and tasteless but if you can...

Page 20: ...ide curtains or forward hatches to remove fumes Example of desired air flow through the boat 21622 POOR VENTILATION Under certain running and or wind conditions permanently enclosed or canvas enclosed...

Page 21: ...tboard Installation Accessories Mounted to the Transom Clamp Bracket for important information on mounting accessories to the transom clamp bracket Safe Boating Recommendations To safely enjoy the wat...

Page 22: ...unit into neutral is not sufficient Use personal flotation devices Federal law requires that there be a U S Coast Guard approved life jacket personal flotation device correctly sized and readily acce...

Page 23: ...block the operator s view when the boat is above idle or planing transition speed Watch out for others the water and your wake Never drive your boat directly behind a water skier Your boat traveling a...

Page 24: ...99 3 110 129 147 Full throttle RPM range 5200 6400 5800 6400 Idle speed in neutral gear1 650 RPM Number of cylinders 4 Piston displacement 1 731 cc 105 6 cid Cylinder bore 82 mm 3 23 in Stroke 82 mm...

Page 25: ...replacement 6 0 liter 6 3 US qt Required battery type 12 volt AGM absorbed glass mat battery Required USA SAE starting battery rating 800 minimum marine cranking amps MCA with a minimum reserve capaci...

Page 26: ...ne flush b Auxiliary tilt switch c Top cowl d Bottom cowl e Engine oil drain f Anti ventilation plate g Gearcase h Cooling water intake holes i Transom brackets j Tilt lock level a b c d e f g h i 148...

Page 27: ...in the specified full throttle operating range When operating the boat at full throttle under normal load conditions the engine RPM should be in the upper half of the recommended full throttle RPM ran...

Page 28: ...ller Adding 1 inch of pitch will reduce the full throttle RPM by 150 to 200 Subtracting 1 inch of pitch will increase full throttle RPM by 150 to 200 Upgrading from a 3 blade propeller to a 4 blade pr...

Page 29: ...al dealer for recommendations Additional clearance may be required for railroad crossings driveways and trailer bouncing 14825 IMPORTANT Do not rely on the power trim tilt system or tilt support lever...

Page 30: ...ntly in use in the USA is alcohol ethanol methanol or butanol GASOLINE CONTAINING ALCOHOL Bu16 Butanol Fuel Blends Fuel blends of up to 16 1 butanol Bu16 that meet the published Mercury Marine fuel ra...

Page 31: ...ine it is recommended to add Mercury or Quicksilver Quickstor fuel stabilizer additive to the engine s fuel at each tank fill throughout the boating season Use additive as directed on container Low Pe...

Page 32: ...rtain portable outboard models SPECIAL FEATURES OF THE PORTABLE FUEL TANK The fuel tank has a two way valve which allows air to enter the tank as the fuel is drawn to the engine and also opens to vent...

Page 33: ...for operation and cap removal Close the manual vent screw for transportation 3 For fuel hoses that have quick disconnects disconnect the fuel line from the engine or fuel tank when not in use 4 Follow...

Page 34: ...MMA FC W certified oil synthetic oils low quality oils or oils that contain solid additives are not recommended C 100 80 60 40 20 0 38 120 49 27 16 4 7 18 F MERCURY VERADO ENGINE OIL SAE 25W 40 54654...

Page 35: ...ve the oil filler cap and add approximately 500 ml 16 oz of specified outboard motor oil Allow a few minutes for the added oil to drain to the oil sump and check the dipstick Repeat the process until...

Page 36: ...7 Push the dipstick back in all the way 8 Install the oil fill cap hand tight 9 Install the top cowl FUEL AND OIL 26 eng...

Page 37: ...ward to increase speed Pull the control handle back from neutral to the first detent for reverse gear Continue pulling back to increase speed F N R 3413 2 Shift lock Pressing the shift lock allows the...

Page 38: ...tle to increase engine RPM To disengage return the control handle to the neutral position Engine RPM is limited to prevent engine damage 3416 5 Stop start button Allows the boat operator to start or s...

Page 39: ...ositions cover must be removed Turning the screw clockwise will increase tension Adjust to tension desired a Detent tension adjustment screw b Control handle tension adjustment screw Slim Binnacle Con...

Page 40: ...dle out of detent positions Turning screw clockwise will increase tension Adjust to tension desired 4 Control handle tension adjustment screw This screw can be adjusted to increase or decrease the ten...

Page 41: ...h must be in the run position for the start stop switch to function c Transfer Allows boat control to be transferred to a different helm d Throttle only Allows the boat operator to increase engine RPM...

Page 42: ...rs at the helms are moved to neutral and transfer is requested again Some fault codes may appear on VesselView if other control or navigation functions are attempted after the helm transfer procedure...

Page 43: ...3 When the helm transfer is complete another beep sounds and the transfer button light turns off NOTE If the helm transfer is not completed in 10 seconds the request is automatically cancelled a doubl...

Page 44: ...gage throttle only mode 1 Place the ERC lever into neutral Throttle only will not disengage unless the ERC lever is in neutral 2 Press the Throttle Only button The button light will turn off 3 The neu...

Page 45: ...neutral to the first detent for reverse gear Continue pulling the handle back to increase speed in reverse a Forward b Neutral c Reverse The amount of force needed to move the handles and to move the...

Page 46: ...eeds adjustment 2 Turn the adjustment screw clockwise to increase tension on the control handle and counterclockwise to decrease tension 3 Adjust to the tension desired a Detent tension adjustment scr...

Page 47: ...ate when the drive is in the neutral gear position The lights flash when the engine is in throttle only mode c TRANSFER Allows boat control to be transferred to a different helm Refer to Helm Transfer...

Page 48: ...control of engine power in close quarter situations 51854 DOCK button Throttle Only NOTE Throttle only mode should be used if the captain is not in command at the helm Placing the ERC in throttle onl...

Page 49: ...ess the ERC levers are in neutral 2 Press the THROTTLE ONLY button The button light will turn off 3 The neutral lights stop flashing and remain illuminated 1 Lever This feature commands both engines w...

Page 50: ...ngines are at a minimum speed The indicator light on the SYNC button is on when both engines are on The light is yellow at idle and 95 of throttle and when the engines are not synchronized The light t...

Page 51: ...ansfer should only be performed while engine is in neutral The helm transfer function allows the boat operator to select which helm is in control of the vessel Before a transfer can be initiated the E...

Page 52: ...ERC levers in neutral press the TRANSFER button one time After the TRANSFER button is pressed the transfer button light turns on and one beep will sound confirming the impending transfer 51858 TRANSF...

Page 53: ...rt and starboard engines Center engine shift neutral unless both engines are in the same gear Running Running Off Port and center engine throttle and shift controlled by port control handle Off Runnin...

Page 54: ...engine throttle speed and gear shift positions of all four engines The throttle and shift function is dependent on what engines are running The following table represents the most common quad engine v...

Page 55: ...d on Running Running Off ignition key switch turned on Port inner engine throttle and shift controlled by port control handle Starboard inner engine throttle and shift controlled by starboard control...

Page 56: ...ting power You should return to port immediately and contact your servicing dealer 2 Intermittent short beeps for six seconds Indicates a noncritical engine condition This condition does not require i...

Page 57: ...n RPM greater than the operating range In the event that the engine is operated at an RPM greater than or equal to the overspeed limit the PCM does not allow the engine to maintain the power requested...

Page 58: ...be tilted out of the water At low idle speed the outboard can also be tilted up past the trim range to permit for example shallow water operation a Trim switch b Trim range c Tilt range POWER TRIM OP...

Page 59: ...speeds with the outboard trimmed too far under can create excessive bow steer resulting in the operator losing control of the boat Install the trim limit pin in a position that prevents excessive tri...

Page 60: ...the OFF position and both remote control handles are in the wide open throttle reverse WOTR position TILTING TO FULL UP POSITION Tilt at Helm NOTE The trim tilt switch will remain active for 15 minut...

Page 61: ...TE This model allows the auxiliary tilt switch to be mounted on either the port side shown or on the starboard side This switch can be used to tilt the outboard up or down using the power trim system...

Page 62: ...for each person aboard and readily accessible it is the law A ring type life buoy or buoyant cushion designed to be thrown to a person in the water Know your boats maximum load capacity Look at the bo...

Page 63: ...tilt the outboard so the gearcase is completely out of water except in freezing temperatures when not in use Wash the outboard exterior and flush out the exhaust outlet of the propeller and gearcase...

Page 64: ...ility of the engine Setting Trim Angle While Running Engine at Idle Speed The exhaust relief hole on the outboard can become submerged on some boats if the engine is trimmed full in while running at i...

Page 65: ...section NOTICE Without sufficient cooling water the engine the water pump and other components will overheat and suffer damage Provide a sufficient supply of water to the water inlets during operatio...

Page 66: ...he fuel lift pump Turn the ignition key switch back to the OFF position and then return the ignition key switch to the ON position again for an additional minute Turn the ignition key switch back to t...

Page 67: ...everse when the forward motion of the boat is greater than a no wake speed Shifting into reverse at higher boat speeds could cause the engine to stall and in some situations this could cause water to...

Page 68: ...idle Panel mount remote control requires the operator to always press shift lock while moving the control handle out of the neutral position 3428 Advance the control lever to further increase speed DT...

Page 69: ...ver to further increase speed Stopping the Engine IMPORTANT Turning key to the START position while the engine is running will result in engine shut down while leaving the DTS system active This will...

Page 70: ...lure Some caustic cleaning chemicals may cause or accelerate corrosion Exercise caution when using cleaning chemicals around the engine and follow the recommendations on the packaging of the cleaning...

Page 71: ...mild nonabrasive soap Use a soft clean cloth when washing 3 Dry thoroughly with a soft clean cloth 4 Wax the surface using a nonabrasive automotive polish polish designed for clear coat finishes Remo...

Page 72: ...CERTIFICATION LABEL An emission certification label showing emission levels and engine specifications directly related to emissions is placed on the engine at the time of manufacture a Idle speed b E...

Page 73: ...y ANNUALLY OR 100 HOURS Grease the engine if applicable Change the engine oil and filter if equipped Inspect the thermostat saltwater or brackish water only Add Quickleen to the fuel tank once per yea...

Page 74: ...nal water passages NOTE The outboard can be tilted or in the vertical operating position during flushing 1 With the engine turned off place the outboard in either the operating position vertical or in...

Page 75: ...lace Ensure the cowl is securely fastened by trying to pull up on the back of the cowl 29768 Battery Inspection The battery should be inspected at periodic intervals to ensure proper engine starting c...

Page 76: ...marine cranking amps with a minimum reserve capacity of 135 minutes RC25 rating International EN Verado Starting Battery Rating Required Verado starting battery 12 volt absorbed glass mat AGM battery...

Page 77: ...t Metric hex nuts are not supplied 54395 Place decal on or near battery box for future service reference Included with the engine rigging components are 5 16 and 3 8 hex nuts to be used for battery te...

Page 78: ...M vent hose c Crankcase ventilation hose 3 Lift the flywheel cover off the front mounting post and the intake resonator 4 Remove three screws holding the upper flywheel cover to the lower flywheel cov...

Page 79: ...wer flywheel cover assembly a Flywheel cover subassembly b Air filter AIR FILTER INSTALLATION 1 Install the air filter onto the flywheel cover subassembly a Flywheel cover subassembly b Air filter a b...

Page 80: ...pper flywheel cover latch opening b Lower flywheel cover latch 3 Push the two subassemblies together and install three screws Tighten the three screws to the specified torque 14309 Description Nm lb i...

Page 81: ...spark or open flame in the area while servicing Keep the work area well ventilated and avoid prolonged exposure to vapors Always check for leaks before attempting to start the engine and wipe up any s...

Page 82: ...ter can be removed If the filter becomes plugged with debris replace the filter Refer to the Inspection and Maintenance Schedule for the proper maintenance interval Filter Removal 1 Turn ignition key...

Page 83: ...re by pushing core of valve end in 13282 4 Unscrew the filter in a counterclockwise direction to remove 14762 Filter Draining 1 Slide filter holder up to release from bracket Hoses and wire harness ca...

Page 84: ...he filter and tighten securely by hand IMPORTANT Visually inspect for fuel leakage from the filter while turning the ignition key to the RUN position forcing fuel into the filter 14764 Corrosion Contr...

Page 85: ...n the anode as this will reduce effectiveness of the anode Two anodes are located on each side of the gearcase Another anode is installed on the bottom of the transom bracket assembly 14812 Propeller...

Page 86: ...rust hub replaceable drive sleeve propeller thrust hub propeller nut retainer and propeller nut onto the shaft a Propeller nut b Propeller nut retainer c Thrust hub d Propeller e Replaceable drive sle...

Page 87: ...AND REAR COVER REMOVAL 1 Remove the pivot screw and flat washer from the rear cowl latch 2 Pull out on the rear corner of the latch to clear the rear cover Remove the rear cowl latch a Rear cowl latch...

Page 88: ...Pry point arrow c Cowl lock SPARK PLUG REMOVAL AND INSPECTION 1 Disconnect the wiring harness connectors from the pencil coils 2 Remove the mounting bolts that are securing the pencil coils Pull the...

Page 89: ...us metal is not visible on the spark plug electrode IMPORTANT The color of the plug may not accurately reflect its condition To accurately diagnose a faulty plug inspect the precious metal on the plug...

Page 90: ...o close the gap gently tap the plug ground electrode on a hard surface 6 Saltwater use Apply a thin coating of Anti Seize Compound only on threads of spark plugs SPARK PLUG INSTALLATION 1 Before insta...

Page 91: ...e engine Remove the cover from the fuse holder Remove the suspected blown fuse and look at the silver band inside the fuse If the band is broken replace the fuse Replace the fuse with a new fuse with...

Page 92: ...rod This can cause a sudden unexpected loss of boat control resulting in serious injury or death due to occupants being thrown within or out of the boat Always use required components and follow inst...

Page 93: ...esses are not routed near sharp edges hot surfaces or moving parts Verify all unused connectors and receptacles are covered with a weather cap Verify the harnesses are fastened along the routing path...

Page 94: ...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 26902 3 Lubr...

Page 95: ...bricants 2 4 C with PTFE or Extreme Grease WARNING Incorrect cable lubrication can cause hydraulic lock leading to serious injury or death from loss of boat control Completely retract the end of the s...

Page 96: ...tube Lubricate through the fitting a Fitting b Cable end 5 Lubricate the following with lightweight oil Steering Link Rod Pivot Points Lubricate pivot points 29765 Checking Power Trim Fluid 1 Tilt th...

Page 97: ...No 114 Power Trim and Steering Fluid Power trim system 92 858074K01 Checking Power Steering Fluid WARNING Dirt or contaminants in the hydraulic steering system can damage the steering system s interna...

Page 98: ...y 6 0 liter 6 3 US qt PUMP METHOD IMPORTANT Tilt outboard out up past vertical for approximately one minute to allow trapped oil to drain back to the oil sump IMPORTANT To reduce or prevent oil spilla...

Page 99: ...ward 3 Remove the drain plug seal and drain the engine oil into an appropriate container 4 Lubricate seal washer on the drain plug with oil and reinstall 15613 CHANGING OIL FILTER IMPORTANT To reduce...

Page 100: ...ockwise 14772 Oil Filter Wrench 91 802653Q02 5221 Assists in removal of oil filter 4 Clean the oil filter mounting base 5 Apply a film of clean oil to filter gasket Do not use grease 6 Screw new filte...

Page 101: ...r 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 gearcas...

Page 102: ...s GEARCASE LUBRICANT RECOMMENDATION Mercury or Quicksilver High Performance Gear Lubricant CHECKING LUBRICANT LEVEL AND REFILLING GEARCASE 1 Place the outboard in a vertical operating position 2 Remov...

Page 103: ...top adding the lubricant Install the vent plug and sealing washer before removing the lubricant tube 5 Remove the lubricant tube and install cleaned fill drain plug and sealing washer MAINTENANCE eng...

Page 104: ...engine s fuel system other than the fuel tank will remain stable during normal storage periods without the addition of fuel treatment stabilizers Fill the fuel tank and engine fuel system with treate...

Page 105: ...s and pencil coils Gearcase Drain and refill the gearcase lubricant refer to Gearcase Lubrication Positioning Outboard for Storage Store outboard in an upright vertical position to allow water to drai...

Page 106: ...ection Old or contaminated gasoline Fuel is not reaching the engine Fuel tank is empty Fuel tank vent not open or restricted Fuel line is disconnected or kinked Fuel filter is obstructed Refer to Main...

Page 107: ...r improper propeller size Low water pressure Low battery voltage Worn stretched or broken accessory belt Boat overloaded or load improperly distributed Excessive water in bilge Boat bottom is dirty or...

Page 108: ...t to your authorized dealer Only authorized dealers specialize in Mercury products and have factory trained mechanics special tools and equipment and genuine Quicksilver parts and accessories to prope...

Page 109: ...sories from the factory Mercury Marine does not sell to unauthorized dealers or retail customers When inquiring about parts and accessories the dealer requires the engine model and serial numbers to o...

Page 110: ...75 Australia Fax 61 3 9706 7228 Europe Middle East Africa Telephone 32 87 32 32 11 Brunswick Marine Europe Parc Industriel de Petit Rechain B 4800 Verviers Belgium Fax 32 87 31 19 65 Mexico Central Am...

Page 111: ...UTSIDE THE UNITED STATES AND CANADA Contact your nearest Mercury Marine authorized service center to order additional literature that is available for your particular power package Submit the followin...

Page 112: ...ilize the outboard mounting hardware will compromise the ability of that hardware to properly and safely secure the outboard to the transom Outboards that require validated mounting hardware will have...

Page 113: ...ORY MOUNTING TO THE TRANSOM CLAMP BRACKET After the engine is mounted to the transom or jack plate in accordance with the engine installation instructions it is acceptable to attach an accessory to th...

Page 114: ...bracket Refer to Figure 1 Figure 1 a Minimum clearance 3 175 mm 0 125 in b Edge of accessory bracket c Transom clamp bracket wall d Radius e Engine supplied mounting fasteners f Fasteners supplied by...

Page 115: ...ring the engine to the boat 1 Do not mount an accessory to the transom clamp bracket in an unsupported condition Refer to Figure 2 54625 Figure 2 2 Do not attach an accessory to the boat by use of the...

Page 116: ...n thread 826711 17 Nylon insert locknut 20 28421 Flat washer 1 50 in diameter 54012 Flat washer 0 875 in diameter Available Outboard Mounting Bolts Part Number Description 67755005 20 x 2 50 in long 1...

Page 117: ...e boat transom must be strengthened or the load carrying area increased a Transom yielding under bolt torque b Transom cracking under bolt torque Use a dial torque wrench to determine transom strength...

Page 118: ...flat within 3 17 mm 0 125 in No step in the transom mounting surface is allowed The inside transom mounting bolt washer surface must be flat within 3 17 mm 0 125 in a Step not allowed b Gap between t...

Page 119: ...sure proper clearance of the transom bracket relief radius area 51867 Installation 1 Apply marine sealer to the shanks of the bolts not to the threads 2 Fasten the outboard with the correct mounting h...

Page 120: ...in flat washer 4 c Nylon insert locknut 4 d 1 500 in flat washer 4 e Marine sealer apply to the shank of the bolts not the threads Description Nm lb in lb ft Outboard mounting locknuts and bolts stan...

Page 121: ...n property damage serious injury or death Before operation the outboard must be correctly installed with the required mounting hardware Have your dealer install your outboard and related accessories t...

Page 122: ...boat speed 22551 If changing conditions cause the RPM to drop below the recommended range such as warmer more humid weather operation at higher elevations increased boat load or a dirty boat bottom g...

Page 123: ...Maintenance Log Record all maintenance performed on your outboard here Be sure to save all work orders and receipts Date Maintenance Performed Engine Hours MAINTENANCE LOG eng 113...

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Mercury 135 Verado FourStroke, Operation And Maintenance Manual

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