Mercury 3.5HP (6202173 AND UP) Outboard Motor Parts Diagram & Catalog – Free PDF Download

by JLM Marine 22 Apr 2025 0 Comments

Mercury 3.5HP Outboard Motor Parts Diagram & Catalog – Free PDF Download

Use the Table of Contents below to jump to each diagram. For more details, click the part name or the OEM number to view its detailed page. A free PDF version of the catalog can be downloaded at the bottom of this page.

CARBURETOR
CLAMP AND SWIVEL BRACKET
CRANKSHAFT, PISTON AND CONNECTING ROD
CYLINDER BLOCK AND CRANKCASE
DRIVE SHAFT HOUSING
GEAR HOUSING (DRIVE SHAFT)
GEAR HOUSING (PROPELLER SHAFT)
MISCELLANEOUS PARTS/ACCESSORIES
RECOIL STARTER AND FLYWHEEL
TOP COWL, FUEL TANK AND CARBURETOR

CARBURETOR

Below is the parts list for Mercury 3.5HP CARBURETOR:

Position No.	Part Name	OEM Number
1	CARBURETOR ASSEMBLY	1385-7568
2	THROTTLE VALVE	1393-7759
3	JET NEEDLE	1393-7772
4	"E" RING, NEEDLE JET	1393-7770
5	RETAINER	1393-7774
6	ROD	1393-7760
7	SPRING, ROD	1393-7758
8	GASKET, COVER	1393-7757
9	COVER, MIXING CHAMBER	1393-7756
10	GASKET, INLET NEEDLE	1393-7767
11	INLET NEEDLE AND SEAT	1393-7768
12	PIN, FLOAT	1393-7769
13	FLOAT	1393-7762
14	PILOT JET	15,1393-7766
15	NEEDLE JET	1393-7771
16	MAIN JET	150,1393-7773
16	MAIN JET	140,1393-9201
16	MAIN JET	130,1393-9202
16	MAIN JET	120,1393-9203
17	GASKET, FLOAT BOWL	1393-7763
18	FLOAT BOWL (#N.S.S.)
19	SCREW, FLOAT BOWL	1393-7765
20	SPRING, ADJUSTING SCREW	1393-6158
21	SCREW, ADJUSTING - LOW SPEED	1393-7750
22	SCREW, ADJUSTING - IDLE SPEED	1393-7761
23	PLUNGER	1393-7751
24	SPRING, PLUNGER	1393-7752
25	CAP, PLUNGER	1393-7753
26	CLIP, PLUNGER CAP	1393-7754
27	CAP	1393-7755
28	LEVER	1393-7764

CLAMP AND SWIVEL BRACKET

Below is the parts list for Mercury 3.5HP CLAMP AND SWIVEL BRACKET:

Position No.	Part Name	OEM Number	Supersedes
1	CLAMP BRACKET ASSEMBLY (PORT)	1479-7291A1
2	CLAMP BRACKET ASSEMBLY (STARBOARD)	1478-7289A1
3	THUMB SCREW ASSEMBLY	10-77190A4
4	HANDLE, THUMB SCREW	78971
5	GROOVE PIN, THUMB SCREW	17-78970
6	WASHER, THUMB SCREW	12-73719
7	SCREW, THUMB SCREW WASHER	10-768042
8	SCREW, CLAMP BRACKET	10-96917
9	WASHER, CLAMP BRACKET SCREW	12-34931
10	NUT, CLAMP BRACKET SCREW	11-8M0204726
11	STUD, CLAMP BRACKET	16-68925
12	LOCKWASHER, CLAMP BRACKET STUD	13-26992
13	NUT, CLAMP BRACKET STUD	11-29598
14	TILT PIN ASSEMBLY	17-68929A2
15	SPRING, TILT PIN	24-62143
16	SWIVEL BRACKET ASSEMBLY	1477-7400A2
17	SCREW, SWIVEL BRACKET (1-3/8")	10-69067
18	GREASE FITTING, SWIVEL BRACKET	22-8M0169589
19	TILT LEVER ASSEMBLY	76110A1
20	SPRING, TORSION - PORT	24-68932
21	ROC, REVERSE LOCK	68968
22	LEVER, REVERSE LOCK	68972
23	SPRING, TORSION - STARBOARD	24-73124
24	GREASE FITTING	22-8M0169589
25	ADJUSTMENT SCREW ASSEMBLY	79793A1
26	"O" RING, ADJUSTMENT SCREW	25-20385
27	CLIP, SAFETY CHAIN	54-8M0085928	54-30954
28	WASHER, CLAMP BRACKET STUD	12-37998

CRANKSHAFT, PISTON AND CONNECTING ROD

Below is the parts list for Mercury 3.5HP CRANKSHAFT, PISTON AND CONNECTING ROD:

Position No.	Part Name	OEM Number
1	CRANKSHAFT	427-7334A2
2	CARRIER ASSEMBLY	79952A1
3	WASHER, CARRIER (EARLY MODELS)	12-79960
4	CONNECTING ROD ASSEMBLY	608-7395A2
5	SCREW, CONNECTING ROD	10-87374
6	NEEDLE BEARING, CRANKPIN	29-26815
7	NUT, CONNECTING ROD SCREW	11-20061
8	WASHER,NEEDLE BEARING RETAINTING	12-65967
9	NEEDLE BEARING, PISTION PIN	29-31505
10	PISTON AND PISTON PIN ASSEMBLY	719-7391T3
11	LOCK RING, PISTON PIN	40-21666
12	PISTON RING	39-21665A12

CYLINDER BLOCK AND CRANKCASE

Below is the parts list for Mercury 3.5HP CYLINDER BLOCK AND CRANKCASE:

Position No.	Part Name	OEM Number	Supersedes
1	CYLINDER BLOCK AND CRANKCASE ASSEMBLY	843-8694A3
2	STUD, CARBURETOR	16-66021
3	DOWEL PIN, CRANKCASE TO CYLINDER BLOCK	17-8M0084726	17-85500
4	FITTING, BLEED DRAIN	22-89275
5	HOSE, BLEED DRAIN (8")	32-9912688
6	ELBOW, BLEED DRAIN	22-887801
7	PLUG, CYLINDER BLOCK	22-390721
8	SCREW, CRANKCASE TO CYLINDER BLOCK (1-1/2")	10-73280
9	SCREW, CRANKCASE TO CYLINDER BLOCK (1")	10-76621
10	REED BLOCK	70726
11	REED, INLET VALVE	34-35836
12	RETAINER, REED	34-22215
13	SCREW, REED AND RETAINER TO BLOCK (1/4")	10-28430
14	GASKET, REED BLOCK TO CRANKCASE	27-357391
15	BALL BEARING, CRANKCASE (LOWER)	30-72961
16	SPACER, LOWER BALL BEARING	23-89794
17	OIL SEAL, CRANKCASE (LOWER)	26-56397
18	SHIM ASSEMBLY, UPPER HOUSING (.002-3-5-10)	15-31412A1
19	BEARING HOUSING ASSEMBLY	1132-7536A2
20	BALL BEARING, BEARING HOUSING	30-72961
21	ROLLER BEARING, BEARING HOUSING	31-31410
22	OIL SEAL, BEARING HOUSING	26-66301
23	"O" RING, BEARING HOUSING	25-20863
24	SCREW, BEARING HOUSING (1/2")	10-39002
25	TAB, GROUND - BEARING HOUSING SCREW	88222
26	COVER, TRANSFER COVER	35658
27	GASKET, TRANSFER PORT COVER	27-35657
28	SCREW, TRANSFER PORT COVER (5/8")	10-20720
29	COVER, CYLINDER BLOCK	1029-7527
30	GASKET, CYLINDER BLOCK COVER	27-416151
31	SCREW, CYLINDER BLOCK COVER (1")	10-8M0214943
32	GASKET, CYLINDER BLOCK	27-416141
33	PLATE, BAFFLE - EXHAUST MANIFOLD	46234
34	GASKET, BAFFLE PLATE	27-416141
35	COVER, EXHAUST MANIFOLD	46171
36	SCREW, PLATE/MANIFOLD COVER (3/4")	10-49668
-	GASKET KIT	27-98540A83

DRIVE SHAFT HOUSING

Below is the parts list for Mercury 3.5HP DRIVE SHAFT HOUSING:

Position No.	Part Name	OEM Number
1	DRIVE SHAFT HOUSING ASSEMBLY	1580-8526A1
2	STUD, DRIVE SHAFT HOUSING (SHORT SHAFT)	16-68927
2	STUD, DRIVE SHAFT HOUSING (LONG SHAFT	16-75321
3	SCREW, GREASE FILLER	10-79953Q04
4	WASHER, GREASE FILLER SCREW	12-191833
5	WATER TUBE (SHORT SHAFT)	32-88996
5	WATER TUBE (LONG SHAFT)	32-88997
6	SEAL, WATER TUBE	26-36556
7	SPACER, WATER TUBE SEAL	23-13127
8	CLAMP, CO-PILOT	54-79791
9	MOUNT, RUBBER - DRIVE SHAFT HOUSING	88669
10	BUSHING, RUBBER MOUNT	23-74308
11	BRACKET ASSEMBLY, STEERING ARM	98168A1
12	SCREW, STEERING ARM BRACKET (1")	10-75840
13	HANDLE, STEERING	98288
14	GRIP, STEERING HANDLE	87668
15	SCREW, STEERING HANDLE TO BRACKET	10-98292
16	WASHER, STEERING HANDLE SCREW	12-98289
17	WASHER, STEERING HANDLE SCREW	12-98290
18	WASHER, STEERING HANDLE SCREW	12-98291
19	NUT, GEAR HOUSING STUD	11-82670911
20	HANDLE, SHIFT	86055T
21	SHAFT, SHIFT	86056A1
22	SCREW, SHIFT HANDLE TO SHAFT (1-1/4")	10-69560
23	LOCKWASHER, SHIFT HANDLE SCREW	13-26996
24	CAM, SHIFT DETENT	66414
25	ROLL PIN, CAM TO SHIFT SHAFT	17-25905
26	BUSHING, SHIFT SHAFT	23-26856
27	"O" RING, SHIFT SHAFT	25-16524
28	ARM, SHIFT	72733
29	SET SCREW SHIFT ARM (5/16")	10-72734
30	COTTER PIN, SHIFT SHAFT	18-210711
31	SCREW, DRIVE SHAFT HOUSING TO POWERHEAD	10-69067
32	PLATE, ADAPTOR	98319
33	GASKET, PLATE	27-41631
34	GASKET, POWERHEAD	27-41632
35	HANDLE, CARRING	87664
36	SCREW, HANDLE TO ADAPTOR PALTE (5/8")	10-28635
37	WASHER, HANDLE SCREW	12-21249
38	SPRING, DETENT	24-39627
39	PLATE, DETENT SPRING	39601
40	SCREW, DETENT SPRING (1/2")	10-25764
41	SPACER, DRIVE SHAFT HOUSING (5") (LONG SHAFT)	75311T
42	SUPPORT BLOCK, DRIVE SHAFT (LONG SHAFT)	94909
43	SCREW, SUPPORT BLOCK (LONG SHAFT)	10-69570

GEAR HOUSING (DRIVE SHAFT)

Below is the parts list for Mercury 3.5HP GEAR HOUSING (DRIVE SHAFT):

Position No.	Part Name	OEM Number	Supersedes
-	GEAR HOUSING ASS'Y COMPLETE (SHORT SHAFT)	1648-7811A22
-	GEAR HOUSING ASS'Y COMPLETE (LONG SHAFT)	1648-7811A23
1	GEAR HOUSING ASSEMBLY	1648-7811A9
2	STUD, GEAR HOUSING (2-1/8") (SHORT SHAFT)	16-68927
2	STUD, GEAR HOUSING (7-1/4") (LONG SHAFT)	16-75321
3	STUD, WATER PUMP (2-1/8")	16-68928
4	STUD, WATER PUMP (1-1/8")	16-70741
5	BEARING, GEAR HOUSING	23-77428
6	BUSHING, FLANGED - GEAR HOUSING	23-90770
7	PINION GEAR	43-90796
8	NUT, PINION GEAR	11-20922
9	DRIVE SHAFT (SHORT SHAFT)	45-87617
9	DRIVE SHAFT (LONG SHAFT)	45-87663
10	KEY, IMPELLER DRIVE	28-8M0032835	28-56655
11	GASKET, WATER PUMP - LOWER	27-68939
12	WATER PUMP HOUSING ASSEMBLY	46-90844A1
13	OIL SEAL, WATER PUMP	26-897153	26-96063
14	INSERT, WATER PUMP	70977T
15	WASHER, WATER PUMP	12-8M0204666
16	QUAD SEAL, WATER PUMP	25-74138
17	IMPELLER	47-89980
18	FACE PLATE, WATER PUMP	68955
19	WATER PUMP COVER ASSEMBLY	46-95965A2
20	OIL SEAL, WATER PUMP COVER	26-30913
21	SEAL, WATER TUBE	26-36558
22	SLEEVE, WATER TUBE GUIDE	23-31792T
23	O RING, DRIVE SHAFT	25-62704
24	RING, RUBBER - DRIVE SHAFT	25-30526
25	WASHER, WATER PUMP STUDS	12-30164
26	NUT, WATER PUMP STUDS	11-859124	11-45812
27	SCREW, VENT - GEAR HOUSING (1/4")	10-28653
28	WASHER, VENT SCREW	19643
29	SCREW, GREASE FILLER	10-79953Q04
30	WASHER, GREASE FILLER SCREW	12-191833
31	SHIFT SHAFT ( SHORT SHAFT )	72418T
31	SHIFT SHAFT ( LONG SHAFT )	75307
-	WATER PUMP KIT	46-90844A2
-	SEAL AND GASKET KIT	26-71140A1

GEAR HOUSING (PROPELLER SHAFT)

Below is the parts list for Mercury 3.5HP GEAR HOUSING (PROPELLER SHAFT):

Position No.	Part Name	OEM Number
-	GEAR HOUSING ASS'Y, COMPLETE (SHORT SHAFT)	1648-7811A22
-	GEAR HOUSING ASS'Y, COMPLETE (LONG SHAFT)	1648-7811A23
1	GEAR HOUSING ASSEMBLY	1648-7811A9
32	NUT, PROPELLER SHAFT	11-20696
33	WASHER, PROPELLER SHAFT	12-73672
34	DRIVE GEAR	43-90795A1
35	WASHER, SPECIAL - PROPELLER SHAFT	14-79603
36	SHIM ASSEMBLY, PROPELLER SHAFT (.002-3-5-10-20)	15-79602A1
37	RETAINING RING	53-79601
38	SPRING, CLUTCH	24-91813
39	PROPELLER SHAFT	44-93358
40	SPACER, PROPELER SHAFT	77424
41	BEARING CARRIER ASSEMBLY	99210A1
42	OIL SEAL	26-98309
43	COVER, GEAR HOUSING	75812
44	O RING, BEARING CARRIER	25-68935
45	KEY, BEARING CARRIER	28-32003
46	THRUST HUB, FORWARD	70588
47	PROPELLER ASSEMBLY	48-93357A10
48	THRUST HUB, AFT	93356
49	PROPELLER, NUT	11-82670911
50	NUT, DRIVE SHAFT HOUSING STUD	11-82670911

MISCELLANEOUS PARTS/ACCESSORIES

Below is the parts list for Mercury 3.5HP MISCELLANEOUS PARTS/ACCESSORIES:

Position No.	Part Name	OEM Number
--	MER 3.5 PARTS LIST	90-99410
--	GASKET SET	27-98540A83
--	DECAL SET (BLUE)	37-43148A84
--	DECAL SET (BROWN)	37-43148A84
--	OWNER'S GUIDE	90-11236

RECOIL STARTER AND FLYWHEEL

Below is the parts list for Mercury 3.5HP RECOIL STARTER AND FLYWHEEL:

Position No.	Part Name	OEM Number
1	RECOIL STARTER	50-97175T
2	STARTER ROPE	50-12066Q10
3	HANDLE AND RETAINER ASSEMBLY, STARTER ROPE	79470A1
4	BRACKET ASSEMBLY, FLYWHEEL GUARD	93498A2
5	LEG, BRACKET	87934
6	GROMMET, BRACKET	25-90329
7	SCREW, BRACKET AND LEG ATTACHING (5/8")	10-28635
8	NUT, RECOIL STARTER ATTACHING	11-8267139
9	CUP, STARTER	87886
10	FLYWHEEL	256-7530
11	KEY, FLYWHEEL	28-20094
12	NUT, FLYWHEEL	11-20696
13	WASHER, RECOIL STARTER STUD	12-69057
14	HOUSING, IGNITION MODULE	98837
15	IGNITION MODULE	88182
16	RETAINER, IGNITION MODULE	88306
17	SCREW, WIRE TO HOUSING (5/16")	10-88307
18	BUTTON, FRICTION-HOUSING	88188
19	SPRING, COMPRESSION-FRICTION BUTTON	24-90304
20	SET SCREW, FRICTION BUTTON (1/2")	10-88186
21	IGNITION COIL	87885
22	LEAD WIRE ASSEMBLY	84-813715A1
23	PROTECTOR ASSEMBLY, SPARK PLUG	85-63709A1
24	SPARK PLUG (NGK #BP6HS-10)	33-8M0114743
24	SPARK PLUG (CHAMPION #QL81Y)	33-88090
25	SCREW, IGNITION COIL (3/4")	10-60605
26	TAB, IDLE STOP	88221
27	THROTTLE LEVER ASSMEBLY	43377A1
28	SCREW, THROTTLE LEVER	10-20665
29	WIRE ASSEMBLY, GROUND	84-65773A9

TOP COWL, FUEL TANK AND CARBURETOR

Below is the parts list for Mercury 3.5HP TOP COWL, FUEL TANK AND CARBURETOR:

Position No.	Part Name	OEM Number
1	TOP COWL	2178-8534A1
2	GASKET, TOP COWL	27-98807
3	FUEL TANK	1253-8082
4	GASKET, FUEL TANK	27-98808
5	FUEL CAP ASSEMBLY	36-41660A2
6	"O" RING, FUEL CAP	25-42573
7	SCREW, FUEL TANK TO POWERHEAD (1")	10-8M0214943
8	WASHER, FUEL TANK SCREW	12-69057
9	NUT, FUEL TANK SCREW	11-29031
10	FUEL LINE (12" AND 3-1/4")	32-9912878
11	CLAMP, FUEL LINE ATTACHING	54-68424
12	CARBURETOR	1385-7568
13	GASKET, CARBURETOR	27-70417
14	WASHER, CARBURETOR STUD	12-37998
15	NUT, CARBURETOR STUD	11-30506
16	CAM FOLLOWER	88223
17	NUT, CAM FOLLOWER TO CARBURETOR	11-4002027
18	SOUND BOX	98601
19	SCREW, SOUND BOX	10-98254
20	WASHER, SOUND BOX SCREW	12-69057
21	VALVE, FUEL SHUT-OFF	20-89398
22	FUEL FILTER	35-76934
23	BRACKET, FUEL TANK - REAR	97417
24	SCREW, FUEL TANK CLAMP	10-90565
25	WASHER, FUEL TANK SCREW	12-26825
26	BRACKET, FUEL TANK - FRONT	90501
27	BUMPER, FUEL TANK	23-90396
28	CLAMP, FUEL TANK ATTACHING	54-90497
29	MOULDING, TRIM - FUEL TANK CLAMP	714933

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