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The tilt operation seems to move smooth and easy under motor power, so I don't think anything is binding. And I put quite a bit a force (hydraulic floor jack) trying to move it with the manual valve...

It won't manually move down from the full up position, so the two trim rams are unattached at that point. That leaves only the main center ram, which doesn't appear to have any bends in it. And...

There are 3 o-rings - it looks just like the relief screws pictured on the internet. One additional observation I noticed is that the relief screw works to the extent that I can stop the trim unit...

Thanks for the suggestion, Don. I pulled the nylon screw out, but unfortunately it appears to be fully intact.

Tom

2003 Mercury Optimax 135XL 1135D83AC S/N OT674472

I'm having some intermittent issues with the power tilt / trim. It works most of the time, but occasionally its dead. As a backup I tried to...

Motor will go into limp-home mode at some point when it thinks oil reservoir is empty - don't want to idle back home. Without Smartcraft you can't tell when.

Common problem on Optimax. Oil reservoir tank sensor (magnetic) mechanism fails. Reservoir tank mounted on side of motor must be replaced.

I haven't had a chance to troubleshoot yet, but I did disconnect the battery terminal (no battery switch) to prevent any further issues. I was lucky in that it just ran the battery down and didn't...

Thanks Don. I'll try tapping the switches to see if I can cause the fault.

Optimax 135XL 1135D83AC S/N OT674472

Last week I left the motor stored in the up position as usual. Came back to boat a few days later with motor fully down and battery partially drained. Trim...

Thanks Joe. Yes, its a 2.5L, 135HP. Sounds like a better idea than removing the cowls. I got the plug out with a double wobble spark plug tool. I am having some difficulty getting it back in with...

2003 Optimax, S/N OT674472. I'm replacing the spark plugs and need to remove the lower cowling to access the bottom plug. I followed the online instructions, removing the back center bolt (by the...

Makes sense - nice and simple.

Thanks for the quick help Joe.

I have a 2003 Optimax 135, S/N OT674472. I am in process of changing the impeller and encountered a problem. How is the nylon sleeve (23-29804T) attached to the copper water tube? I am not sure...

Thanks again Don, that explains it all. I'll see what I find?

I pulled the sensor off the tank, but haven't been able to find the connections for the sensor - the wires run behind the tank and out of reach. Do you have to remove the tank to access the...

Thanks Don. I'll pull the sensor off and see if I can check the operation of the float.

I bled the reserve tank yesterday - tank appeared filled, didn't see any leaks. When I loosened the cap, oil began to seep out immediately, didn't see any bubbles. I guess the next thing to do is...

Thanks for the advice Martin. When I saw the word "reserve", I thought it would be the outside tanks. I will pull the cowling off tomorrow and check the oil tank. The "99% remaining" part of the...

I have a 2003 Optimax 135, S/N OT674472. I just started getting warning beeps with a "RESERVE OIL LOW, 99% Remaining" message on the Tachometer screen. The separate oil tanks have 2.4 gallons...