Mercury 135 HP Outboard 1999–2004 Service Repair Manual – PDF Download

🛠️ Mercury 135 HP Outboard 1999–2004 Service Repair Manual – PDF Download

🧰 OEM Factory Workshop Manual – Covers Mercury 135 HP V6 2-Stroke Outboard Engines (U.S. Serial No. 0G960500 and up)
📲 Instant PDF Download – Works on Windows, macOS, iOS, Android, and Linux
🔧 Trusted by certified marine mechanics, boat owners, and Mercury service professionals

🔍 Model Background

The Mercury 135 HP outboard (1999–2004) was part of Mercury’s long-running 2.0L and 2.5L V6 2-stroke lineup, offering a balance between power and affordability for recreational anglers and family boaters. Positioned just below the 150 HP models, the 135 delivered reliable performance with fewer emissions and slightly lower fuel consumption, making it a popular choice for mid-sized boats and freshwater applications.

This engine featured a carbureted fuel system, oil injection (Precision Blend), and CDM ignition, which allowed for easy maintenance and solid cold starts. Known for its lightweight design and mechanical simplicity, the 135 was a frequent sight on bass boats, bowriders, and pontoons throughout the early 2000s.

Though eventually phased out in favor of cleaner EFI and FourStroke models, the 135 HP 2-stroke remains widely respected for its durability, strong midrange power, and excellent parts availability. Many are still in service today, especially in freshwater regions where low weight and fast throttle response are preferred.

📆 Model Years Covered:

• Mercury 135 HP – 1999
• Mercury 135 HP – 2000
• Mercury 135 HP – 2001
• Mercury 135 HP – 2002
• Mercury 135 HP – 2003
• Mercury 135 HP – 2004

📘 Manual Details:

• Model: 135 HP V6 2-Stroke
• Serial Numbers: 0G960500 and above
• Document Type: OEM Service & Repair Manual (Factory Shop Manual)
• Language: English
• Publisher: Mercury Marine
• Pages: 600+ with diagrams, testing procedures, and illustrations

📚 Manual Sections Include:

• General Information & Specifications
• Ignition & Charging System
• Switch boxes, stators, timing adjustment
• Fuel System
• Carburetors, fuel pump, primer bulb, link & sync
• Powerhead
• Cylinder block, pistons, crankshaft, gaskets
• Cooling System
• Thermostat, impeller, water passages
• Midsection & Power Trim
• Tilt system, mounts, bushings
• Gearcase Assembly
• Propshaft, seals, shimming, water pickup
• Control Linkage & Adjustment
• Shift/throttle linkage, idle stop
• Wiring Diagrams
• Full schematics with color and component references

💾 Format & Compatibility:

• File Format: PDF
• Searchable & Bookmarked: ✅ Yes
• Printable: ✅ Yes – Entire manual or selected sections
• Compatible With: Windows, macOS, iOS, Android, Linux
• Delivery: 📩 Instant Digital Download

🔍 Keywords:

Mercury 135 HP outboard service manual PDF, 1999–2004 Mercury repair guide, V6 2-stroke, powerhead rebuild, fuel system, ignition, wiring diagrams, OEM shop manual

❓ Mini FAQ:

Q: Is this the official OEM Mercury manual?
A: Yes – this is the complete factory-issued repair manual used by certified Mercury service centers.

Q: Does it include electrical and fuel system schematics?
A: Absolutely – includes detailed wiring diagrams and step-by-step carburetor tuning procedures.

Q: Can I use this manual on my smartphone or tablet?
A: Yes – it's fully optimized for all digital devices and easy to navigate.

🧭 Helpful Resources for Mercury Outboard Owners

• Why Every Mercury Mariner Owner Needs a Service Manual for At-Home Repairs – Learn how a digital service manual can save you time and money on common DIY maintenance tasks.
• Outboard Engine Troubleshooter – Not sure what’s wrong with your engine? Our free troubleshooting guide covers common issues across Mercury Outboards and more.

🔧 Browse More Mercury Manuals

Note: While our manuals are designed for DIY use, they do not replace professional mechanical training. If you're unsure about a repair or your engine shows serious issues, we strongly recommend visiting a certified marine mechanic. These guides are best suited for owners with basic to moderate mechanical experience.