2003 Optimax 135 Spark Plugs

Tom Z

Recruit
Joined
Sep 19, 2004
Messages
3
Has anyone experienced a good way to change the spark plugs in a 2003 135 Merc Optimax. I just winterized this engine for the first time (the dlr supposedly performed this operation last year) and could not believe how difficult it is to access the spark plugs, especially on the port side. I removed the coil plate (which was a mistake because this was difficult to put back on due to one of the bolts is almost impossible to access. Even if one can remove and install the plugs, how can you use a torque wrench in this limited space?? I am not sure if there is a special socket ( I used a swivel spark plug socket and tried different length extensions)or if you have to remove the lower cowling or other components to provide easier access to the plugs. I am amazed at how inaccessable the plugs are on this 2 stroke engine.
 

hondon

Lieutenant Commander
Joined
Jun 11, 2001
Messages
1,922
Re: 2003 Optimax 135 Spark Plugs

Welcome to my world.Is'nt it fun?You will in the long run be better off removeing at least the port half of the lower cowl before you cross up the treads trying to start that # 6 plug.Also it is helpful if you shove the plug into a piece of flexible hose ,like a piece of fuel line,and start the plugs by hand that way.That way if you are crossed up at all the plug will turn in the hose before doing any damage and you can tell when things are going in straight. Just take your time and keep your cool.
 

Tom Z

Recruit
Joined
Sep 19, 2004
Messages
3
Re: 2003 Optimax 135 Spark Plugs

How difficult is it to remove the lower cowl? It appears that there are some bolts that join the 2 halves but I wasn't sure how many and they didn't look real fun to access either. Once the bolts are loose to remove the lower cowl is there anything else that needs to be disconnected?
 

MMTech1

Cadet
Joined
Sep 13, 2004
Messages
10
Re: 2003 Optimax 135 Spark Plugs

There is four I think. The front part of the cowl trim so you can pull the wiring and cables up to help remove the port side. And like "hondon" said use a hose to start the plugs back in with.
 

rodbolt

Supreme Mariner
Joined
Sep 1, 2003
Messages
20,066
Re: 2003 Optimax 135 Spark Plugs

hello<br /> I never remove the cowl. takes to long. remove the coil connectors to access #4 and # 6. remove the port water hose from the head. use a pice of rubber to reinstall them. job takes 20-30 min. I use a 3" extension and patience.<br /> good luck and keep posting
 

Mr. Grumpy

Recruit
Joined
Sep 29, 2004
Messages
2
Re: 2003 Optimax 135 Spark Plugs

The hose trick works great on spark plugs for any gas engine - and beats cross threading. To remove the bottom port side plug, Snap-On makes a 3/8 drive flex ratchet that's built in a 1/4 in. drive frame. It's about $50. but after your first change without it, that $$ doesn't seem nearly as unreasonable. ;) BTW - I found my wifes' small fingers really come in handy for the out and in - she gets to help, and I don't have hand cramps.<br />After 30 years of fixing diesels stuffed into all kinds of ridiculous places, an outboard is a piece of cake (Don't have to crawl under or into / doesn't drip on you / don't need a torque multiplier!)
 
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