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Mercury 40 (4-STROKE) (0G760300 THRU 0T408999) Outboard Motor Parts Diagram & Catalog – Free PDF Download

by JLM Marine 30 Apr 2025 0 Comments
Mercury 40 (4-STROKE) Outboard Motor Parts Diagram & Catalog – Free PDF Download

Accessories

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Below is the parts list for Mercury 40 (4-STROKE) Accessories:

Mercury 40 (4-STROKE) Accessories Diagram
Position No. Part Name OEM Number Supersedes
- HOSE ASSEMBLY, Fuel (8 Feet) (With Quick disconnect) 32-877680Q8
- HOSE ASSEMBLY, Fuel (12 Feet) (With Quick disconnect) 32-877680Q12 32-858620Q12, 32-858620A12, 32-827927A12
- HOSE ASSEMBLY, Fuel (8 Feet) (With Quick disconnect Engine End Only) 32-877681Q8
- HOSE ASSEMBLY, Fuel (12 Feet) (With Quick disconnect Engine End Only) 32-877681Q12 32-804792Q12, 32-804792Q, 32-858621Q12, 32-858621A12, 32-17146A12
- HOSE ASSEMBLY, Fuel (12 Feet) (No Fittings) 32-877683Q12 32-858623Q12, 32-858623A12, 32-822379A12, 32-819380A12, FA599752, FS409752, 32-819380A 3, F216752, FA409752, F289752, FA178752, FA216752, FA284752, FA289752, FS409952
- LINE ASSEMBLY, Fuel (Original Equipment) 32-877680Q8
- EXTENSION KIT, (22.5) Comment: (NON-BIGFOOT-Converts 20 In. to 22-1/2 In.) 824072A5
- HIGH OUTPUT ALTERNATOR KIT 398-852387A11
- SENDER KIT, Oil Pressure 8M0068785 828019A 1
- ATTACHING KIT, Remote Control 859185A1
- POWER TRIM KIT Comment: SN# 0T294064 & Below 8M0055001 830150A 7 SN# 0T294064 & Below
- POWER TRIM KIT Comment: SN# 0T294065 & Up 8M0055002 830150A 8 SN# 0T294065 & Up
- POWER TRIM KIT Comment: SN# 0T294064 & Below 8M0055008 855654A 5 SN# 0T294064 & Below
- POWER TRIM KIT Comment: SN# 0T294065 & Up 855654A6
- SENDER KIT, Power Trim 821400A2
- KEY SWITCH KIT, Remote Ignition 15000A7
- BRACKET ASSEMBLY, Steering (Without Carrying Handle) 816667A2
- TILLER HANDLE KIT, Electric Start Comment: (NON-BIGFOOT) 821455A22 821455A11 (NON-BIGFOOT)

Adaptor Plate

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Below is the parts list for Mercury 40 (4-STROKE) Adaptor Plate:

Mercury 40 (4-STROKE) Adaptor Plate Diagram
Position No. Part Name OEM Number Supersedes
1 DIPSTICK 8M0162935
2 DIPSTICK TUBE Comment: SN# 0T178499 & Below 825989003 825989 2 SN# 0T178499 & Below
3 DIPSTICK TUBE Comment: SN# 0T178500 & Up 825989003 825989 2 SN# 0T178500 & Up
4 SEAL 8560552
5 ADAPTOR PLATE Comment: SN# 0T178499 & Below 825228A24 825228 4 SN# 0T178499 & Below
6 PIN, Dowel Comment: SN# 0T178499 & Below 17-23784
7 HEAT SHIELD 8289151
8 ADAPTOR PLATE Comment: SN# 0T178500 & Up 825228A17 825228T 9 SN# 0T178500 & Up
9 PLUG 19-822464
10 SCREW, (M6 x 55) Comment: SN# 0T178500 & Up 10-4007455
11 CLAMP 54-855228 54-888988014
12 PIN, Dowel 17-23784
13 FITTING, Elbow - 90 Degree (.125-27) 22-629101
14 TIE STRAP, (8.00 Inches) 54-816311T 54-816311, 54-90077, 54-826785, F1877, F717046-1, F717046, MAF03001, 833188E, 54-F9301, 54-816311100, 54-898101111, 54-898101275
15 SEAL, Oil Comment: (NON-BIGFOOT) 26-828932 26-821756 (NON-BIGFOOT)
15 SEAL, Oil Comment: (BIGFOOT) 26-16977
16 BUSHING Comment: (NON-BIGFOOT) 23-856743
17 PLUG, Pipe 22-384073
18 GROMMET Comment: (NON-BIGFOOT) 25-822408001 25-822408 (NON-BIGFOOT)
19 GASKET 27-8M0213113
20 O-RING 25-845746
21 SCREW, (M6 x 20) Stainless Steel 10-8M0204741
22 DEFLECTOR, Oil 856592
23 BODY ASSEMBLY, Oil Pressure Relief 8M0210772
24 COTTER PIN 18-45882
25 PLUNGER 8252151
26 SPRING 24-825216
27 PLATE, Oil Pickup-Top 893765 854789
28 HOSE, Oil Pickup 32-854793
29 BAFFLE 893700 854791 1

Bottom Cowl

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Below is the parts list for Mercury 40 (4-STROKE) Bottom Cowl:

Mercury 40 (4-STROKE) Bottom Cowl Diagram
Position No. Part Name OEM Number Supersedes
1 BOTTOM COWL Comment: (SHORT-PORT) 4020-852554T1
1 BOTTOM COWL Comment: (LONG-PORT) 4020-826277T1
2 BOTTOM COWL Comment: (SHORT-STARBOARD) 4020-852555T5
2 BOTTOM COWL Comment: (LONG-STARBOARD) 4020-826278T7
3 SCREW, (M6 x 30) 10-82684430
4 WASHER, (.281 x .500 x .060) Stainless Steel 12-8M0204649
5 SEAL 825238002 825238 1
6 WASHER 12-855576
7 GASKET 27-855627
8 SCREW, (M6 x 60) 10-82684460
9 FITTING 22-827948
10 BOOT 826273001 826273
11 TIE STRAP, (8.00 Inches) 54-816311T 54-816311, 54-90077, 54-826785, F1877, F717046-1, F717046, MAF03001, 833188E, 54-F9301, 54-816311100, 54-898101111, 54-898101275
12 LEVER, Cowl Latch 825782F1
13 BUSHING 23-812707 23-71984, 23-F286818, 23-F286828, F480818
14 WASHER, Wave 13-12134
15 LATCH HOOK 893766 825783
16 SCREW, (M6 x 16) 10-1993716
17 GROMMET Comment: (NON POWER TRIM) 25-8M0179867
17 GROMMET Comment: (SPLIT - POWER TRIM) 25-19565002
18 PLUG Comment: (NON POWER TRIM) 812830T01 812830 1 (NON POWER TRIM)
19 SWITCH, Trim Comment: (POWER TRIM - DESIGN II) 87-8M0235191
20 SWITCH ASSEMBLY Comment: (POWER TRIM - DESIGN I) 87-8M0042301 87-896620, 87-856990, 87-850691, 87-18286A40 (POWER TRIM - DESIGN I)
21 RETAINER Comment: (NON POWER TRIM) 8M0032848 812443 1 (NON POWER TRIM)

Camshaft/Oil Pump

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Below is the parts list for Mercury 40 (4-STROKE) Camshaft/Oil Pump:

Mercury 40 (4-STROKE) Camshaft/Oil Pump Diagram
Position No. Part Name OEM Number Supersedes
1 SCREW, (M10 x 40) 10-82761140
2 WASHER 12-4002319
3 BELT 8M0151040
4 GEAR, Driven 833104T6
5 PIN, Dowel 17-825956
6 CAMSHAFT Comment: (MANUAL) 400-8M0183249
7 CAMSHAFT Comment: (ELECTRIC) 402-834781T1
8 PIN 17-826149 17-893566
9 PUMP ASSEMBLY, Oil 825058A1
10 O-RING 25-826152
11 O-RING 25-826154
12 O-RING 25-826153
13 SCREW, (M6 x 40) 10-4000333
- GASKET SET, Engine 27-825231A99

Carburetor(0T178499 and Below)

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Below is the parts list for Mercury 40 (4-STROKE) Carburetor(0T178499 and Below):

Mercury 40 (4-STROKE) Carburetor(0T178499 and Below) Diagram
Position No. Part Name OEM Number Supersedes
1 CARBURETOR Comment: (TOP) 3329-830276T27 3329-830276T10 (TOP)
1 CARBURETOR Comment: (CENTER) 3329-830276T11
1 CARBURETOR Comment: (BOTTOM) 3329-830276T12
2 SCREW 10-854246
3 PLATE 854245
4 NOT SOLD SEPARATE, Gasket NSS
5 ENRICHENER 854254T 803918T, 854254
6 NOT SOLD SEPARATE, O Ring NSS
7 PLATE 854255
8 IDLE JET 803919
9 JET 803912 803912 38
10 PLUG, Rubber 19-854248
11 JET 803915
12 VALVE, Float 854247
13 MAIN NOZZLE 803914
14 FLOAT 854253
15 NOT SOLD SEPARATE, Float Pin NSS
16 NOT SOLD SEPARATE, Gasket NSS
17 FLOAT BOWL Comment: (TOP) 803916
17 FLOAT BOWL Comment: (CENTER/BOTTOM) 803917
18 SCREW 10-8542463
19 SCREW, Drain 10-8542462
20 NOT SOLD SEPARATE, Washer NSS
21 SCREW, Synchronization Comment: (TOP/CENTER) 10-803925
21 SCREW Comment: (BOTTOM) 10-803913
22 SPRING Comment: (TOP/CENTER) 24-803923
23 SPRING Comment: (TOP/CENTER) 24-803924
24 SPRING Comment: (BOTTOM) 24-854249
25 NOT SOLD SEPARATE, Spring NSS
26 PLUNGER 854251
27 NOT SOLD SEPARATE, Rubber Bellows NSS
28 NOT SOLD SEPARATE, Screw-Plunger Retaining NSS
29 NOT SOLD SEPARATE, Plunger Rod NSS
- REPAIR KIT, Carburetor 854256

Carburetor(0T178500 and Up)

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Below is the parts list for Mercury 40 (4-STROKE) Carburetor(0T178500 and Up):

Mercury 40 (4-STROKE) Carburetor(0T178500 and Up) Diagram
Position No. Part Name OEM Number Supersedes
1 CARBURETOR Comment: (Top) 3329-830276T31
1 CARBURETOR Comment: (Center) 3329-830276T32
1 CARBURETOR Comment: (Bottom) 3329-830276T33
2 SCREW 10-854246
3 PLATE 854245
4 GASKET 27-8542572
5 ENRICHENER 854254T2
6 NOT SOLD SEPARATE, O Ring NSS
7 PLATE 854255
8 CAP 19-880814
9 SCREW, Adjusting 10-880841
10 O-RING 25-880842
11 SPRING 24-880815
12 JET, Pilot 80391242
13 O-RING 25-880843
14 PLUG 19-880844
15 JET, Main 80391595
16 MAIN NOZZLE 8039143
17 VALVE, Float 854247
18 FLOAT 8542531
19 PIN, Float 17-8542581
20 SCREW 10-880845
21 GASKET 27-8542573
22 FLOAT BOWL Comment: (Top) 8039161
22 FLOAT BOWL Comment: (Center/Bottom) 8039171
23 SCREW 10-8542463
24 SCREW, Drain 10-8542464
25 WASHER 12-8542591
26 SCREW, Synchronization Comment: (Top/Center) 10-803925
27 SPRING Comment: (Top/Center) 24-880846
28 SPRING Comment: (Top/Center) 24-803923
29 SCREW Comment: (Bottom) 10-803913
30 SPRING Comment: (Bottom) 24-854249
31 SPRING 24-880847
32 PLUNGER 8542511
33 SCREW 10-880848
34 NOT SOLD SEPARATE, Rubber Bellows NSS
35 PLUNGER ROD 880849
- REPAIR KIT, Carburetor 8542561

Crankshaft, Piston and Connecting Rods

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Below is the parts list for Mercury 40 (4-STROKE) Crankshaft, Piston and Connecting Rods:

Mercury 40 (4-STROKE) Crankshaft, Piston and Connecting Rods Diagram
Position No. Part Name OEM Number Supersedes
1 CRANKSHAFT ASSEMBLY 401-834774T1
1 CRANKSHAFT Comment: (BIGFOOT) 401-834774T2
2 KEY 28-893761
3 KEY, Woodruff 28-91800
4 SEAL 8M0151047
5 SEAL 8M0151048
6 CONNECTING ROD 600-893530T01 662-856065T 1
7 BOLT 10-8M0049884
8 BEARING, Brown 23-893630 23-825021
8 BEARING, Black 23-893630001 23-825021 1
8 BEARING, Blue 23-893630002 23-825021 2
9 PISTON ASSEMBLY Comment: (STANDARD) 700-893524T08 700-893524T07, 713-856064A 1 (STANDARD)
9 PISTON Comment: (.25 O/S)(BARE PISTON) 700-893524T01 713-856064 2 (.25 O/S)(BARE PISTON)
9 PISTON Comment: (.50 O/S)(BARE PISTON) 700-893524T02 713-856064 3 (.50 O/S)(BARE PISTON)
10 RING SET, Piston (TOP) Comment: (STANDARD) 39-893525A01 39-833099A 1 (STANDARD)
10 RING, Piston (TOP) Comment: (.25MM O/S) 39-893525A02 39-833100T 2 (.25MM O/S)
10 RING, Piston (TOP) Comment: (.50MM O/S) 39-893525A03 39-833100T 3 (.50MM O/S)
11 NOT SOLD SEPARATE, Piston Ring (Second) Comment: (STANDARD) NSS
11 NOT SOLD SEPARATE, Piston Ring (Second) Comment: (.25MM O/S) NSS
11 RING, Piston (Second) Comment: (.50MM O/S) 39-893525A03 39-833100T 3 (.50MM O/S)
12 RING, Oil 39-893950 39-893527, 39-833101 1
13 PIN, Piston 41-893863 41-825016
14 RETAINER 40-825017 40-825017F
15 GEAR, Drive 833102T 833102
- GASKET SET, Engine 27-825231A99
- POWERHEAD ASSEMBLY 61-803017T01 61-803017T99
- POWERHEAD ASSEMBLY Comment: (BIGFOOT) 61-803016T01 61-803016T99 (BIGFOOT)

Cylinder Block

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Below is the parts list for Mercury 40 (4-STROKE) Cylinder Block:

Mercury 40 (4-STROKE) Cylinder Block Diagram
Position No. Part Name OEM Number Supersedes
1 CYLINDER BLOCK 803-850082T34 803-850082T 5
1 CYLINDER BLOCK Comment: (BIGFOOT) 800-893500T02
2 PIN, Dowel 17-825010
3 PLUG 22-479452
4 PLUG, Pipe (1/2-14) 22-384073
5 PIPE PLUG (3/4-14) 22-416223
6 BEARING, Brown Comment: (BROWN) 23-893631 23-825024 (BROWN)
6 BEARING, Black Comment: (BLACK) 23-893631001 23-825024 1 (BLACK)
6 BEARING, Blue Comment: (BLUE) 23-893631002 23-825024 2 (BLUE)
7 NIPPLE, (M20) 822625
8 SCREW, (M8 x 82) 10-82506182
9 SCREW, (M6 x 35) 10-8M0205943
10 GASKET 27-8M0213112
11 FILTER ASSEMBLY, Oil 35-8M0162830
12 GASKET 27-8M4500244 27-834775005, 27-834775004, 27-834775 3
13 COVER, Exhaust 8M0183025
14 PLUG 22-479452
15 THERMOSTAT 855676003 825212001, 825212, 855676
16 GASKET 27-8M0177107
17 COVER 8M0188835
18 SCREW, (M6 x 35) 10-8M0205943
19 FITTING, Elbow 90 Degree (.125-27 x .250) Nylon 22-996642
20 TIE STRAP, (8.00 Inches) 54-816311T 54-816311, 54-90077, 54-826785, F1877, F717046-1, F717046, MAF03001, 833188E, 54-F9301, 54-816311100, 54-898101111, 54-898101275
21 TUBING, (28.00 Inches Bulk) (Cut to 11 Inches) 32-8M0108349 32-8M0047448, 32-830757130, 32-830757 80
22 SENSOR ASSEMBLY, Temperature 8M0214984
23 O-RING, (.301 x .070) 25-627021
24 LIFTING EYE 893697 852560 1
25 SCREW, (M8 x 35) 10-857139
26 NOT SOLD SEPARATE, Plug-Serial Number NSS
27 HOSE, (48.00 Inches Bulk) (Cut to 19 Inches) Comment: SN# 0T178500 & Up 32-77653101
27 HOSE, (48.00 Inches Bulk) (Cut to 18 Inches) Comment: SN# 0T178499 & Below 32-77653101
28 BRACKET, Trim Relay Comment: (Power Trim) SN# 0T294232 & Up 882831
29 SCREW, (M6 x 16) Comment: (Power Trim) SN# 0T294232 & Up 10-8248324
30 SCREW, (M6 x 30) Comment: (Power Trim) SN# 0T294232 & Up 10-82129130
- GASKET SET, Engine 27-825231A99
- POWERHEAD ASSEMBLY 61-803017T01 61-803017T99
- POWERHEAD ASSEMBLY Comment: (BIGFOOT) 61-803016T01 61-803016T99 (BIGFOOT)

Cylinder Head

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Below is the parts list for Mercury 40 (4-STROKE) Cylinder Head:

Mercury 40 (4-STROKE) Cylinder Head Diagram
Position No. Part Name OEM Number Supersedes
- CYLINDER HEAD Comment: (ELECTRIC) 8M0205506
- CYLINDER HEAD Comment: (MANUAL) 893504T02 877568T 9 (MANUAL)
1 CYLINDER HEAD 834778T2
2 GUIDE 8M0054272 825037001, 825037
3 CIRCLIP 53-825038 825722
4 ANODE 826887M
5 GROMMET 25-825040
6 COVER 826888M
7 SCREW, (M6 x 20) Stainless Steel 10-8M0204741
8 BOLT 10-827607
9 GASKET 27-827610
10 SCREW, (M6 x 10) 10-84088M
11 GASKET 27-827610
12 SEAL, Oil 26-825048
13 PIPE PLUG 22-822644
14 O-RING 25-8M0162934
15 COVER 8M0174399
16 NOT SOLD SEPARATE, Decal-Servicing Referral NSS
17 NOT SOLD SEPARATE, Decal-Engine Oil/Valve Clearance NSS
18 GASKET 27-8M0118180
19 SCREW, (M6 x 20) Stainless Steel 10-8M0204741
20 SCREW, (M6 x 25) 10-893745025
21 SCREW, (M9 x 95) 10-82503395
22 PIN, Dowel 17-825010
23 PLUG ASSEMBLY, Oil 859578A1
24 NOT SOLD SEPARATE, O Ring NSS
25 PLATE, Baffle 855236
26 SCREW, (M4 x 10) 10-4005785
27 FITTING, Elbow - 90 Degree (.125-27) 22-629101
28 BREATHER PIPE 22-825054
29 BRACKET Comment: (HANDLE) 830294T1
30 SCREW, (M6 x 13) Stainless Steel Comment: (HANDLE) 10-40011126
31 J CLIP Comment: (USE WHERE APPLICABLE) 54-8M0024808
- GASKET SET, Engine 27-825231A99
- POWERHEAD ASSEMBLY 61-803017T01 61-803017T99
- POWERHEAD ASSEMBLY Comment: (BIGFOOT) 61-803016T01 61-803016T99 (BIGFOOT)

Driveshaft Housing

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Below is the parts list for Mercury 40 (4-STROKE) Driveshaft Housing:

Mercury 40 (4-STROKE) Driveshaft Housing Diagram
Position No. Part Name OEM Number Supersedes
1 SEAL, Water Tube 42941001
2 HOUSING, Driveshaft Comment: (Short) SN# 0T178500 & Up 1501-850168T5
2 HOUSING ASSEMBLY, Driveshaft Comment: (Long) SN# 0T178500 & Up 3532-825218T7
2 HOUSING, Driveshaft Comment: (Short) SN# 0T178499 & Below 1501-850168T3
2 HOUSING ASSEMBLY, Driveshaft Comment: (Long) SN# 0T178499 & Below 3532-825218T5
3 NOT SOLD SEPARATE, Exhaust Pipe Comment: (SHORT) NSS
3 PIPE, Exhaust Comment: (LONG) 825220T06
4 SCREW, (M8 x 110) Stainless Steel 10-824459110
5 SCREW, (M8 x 45) (M8 X 45) 10-88960845
6 PLUG, Drain 8288181
7 GASKET 27-8M0204692
8 BUMPER 826276
9 GROMMET Comment: (LONG) 8M0151042
10 STUD, (M10 x 50) Comment: (NON-BIGFOOT) 16-823984
10 STUD, (M10 x 100) Comment: (BIGFOOT) 16-903501
11 WASHER, (.406 x .750 x .105) Stainless Steel 12-8M0214963
12 NUT, (M10) 11-40140
13 TUBE, Water Comment: (SHORT) 32-897970A01 32-850169002, 32-850169 (SHORT)
13 TUBE, Water Comment: (LONG) 32-897971A01 32-888591001, 32-888591, 32-825250 1 (LONG)
14 GUIDE 54-828529
15 BUMPER Comment: (LONG) 8M0043364 828706 (LONG)
16 HOUSING, Driveshaft Comment: (Bigfoot) SN# 0T178500 & Up 1503-852421T07 1503-852421T 5 (Bigfoot) SN# 0T178500 & Up
16 HOUSING ASSEMBLY, Driveshaft Comment: (Bigfoot) SN# 0T178499 & Below 1503-852421T3
17 PLATE Comment: (BIGFOOT) 893770 854471 (BIGFOOT)
18 SCREW, (M10 x 25 MM) Comment: (BIGFOOT) 10-1993325
19 SPEEDOMETER PICK UP Comment: (BIGFOOT) 22-85822A7
20 CONNECTOR, Straight Comment: (BIGFOOT) 22-85822T
21 FITTING Comment: (BIGFOOT) 22-8M0181450
22 SPACER Comment: (BIGFOOT) 23-813745 23-43041 (BIGFOOT)
23 COUPLING Comment: (BIGFOOT) 43585
24 BUSHING Comment: (BIGFOOT) 23-855623
25 WASHER, (.453 x .812 x .105) Stainless Steel Comment: (BIGFOOT) 12-45176
26 TIE STRAP, (8.00 Inches) Comment: (BIGFOOT) 54-816311T 54-816311, 54-90077, 54-826785, F1877, F717046-1, F717046, MAF03001, 833188E, 54-F9301, 54-816311100, 54-898101111, 54-898101275 (BIGFOOT)

Electrical Components(0G960499 and Below)

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Below is the parts list for Mercury 40 (4-STROKE) Electrical Components(0G960499 and Below):

Mercury 40 (4-STROKE) Electrical Components(0G960499 and Below) Diagram
Position No. Part Name OEM Number Supersedes
1 SOLENOID ASSEMBLY Comment: (ELECTRIC) 89-8M0185146
2 BUSHING Comment: (ELECTRIC) 23-8M0214955
3 GROMMET Comment: (ELECTRIC) 25-818967
4 NUT, Brass Comment: (ELECTRIC) 8-32,11-26419
5 NUT, (.250-20) Brass Comment: (ELECTRIC) 11-94330
6 CABLE ASSEMBLY, Battery - Positive Comment: (ELECTRIC) 84-88439A9
7 BOOT, Insulator - Black Comment: (ELECTRIC) 85-79695T
8 CABLE ASSEMBLY Comment: (ELECTRIC) 84-93388A13
9 CABLE ASSEMBLY, Battery - Negative Comment: (ELECTRIC) 84-88439A4
10 STARTER MOTOR ASSEMBLY Comment: (ELECTRIC) 50-893887T 50-888160T, 50-884045T, 50-859170T 1 (ELECTRIC)
11 SCREW, (M8 x 45) Stainless Steel Comment: (ELECTRIC) 10-40011153
11 SCREW, (M8 x 25) Stainless Steel Comment: (MANUAL) 10-40011149
12 SCREW, (M6 x 30) Comment: (ELECTRIC) 10-82684430
12 SCREW, (M6 x 16) Comment: (MANUAL) 10-8248324
13 J CLIP Comment: (ELECTRIC) 54-8M0024808
14 PRESSURE SWITCH 87-8M0098207 87-8M0070107, 87-828040 1
15 SENSOR 8M0082988 8M0030022, 828358 2
16 SCREW, (M5 x 16) Stainless Steel 10-40011107
17 SCREW, (M6 x 25) 10-82130025
18 WASHER, (.265 x .750 x .048) Stainless Steel 12-65567
19 PLATE 859224 856604
20 BUSHING 23-822003
21 GROMMET 25-8M0190980
22 ECM, Engine Control Module 87843302S
23 BUSHING 23-8539201
24 SCREW, (M6 x 40) 10-82129140
25 SPARK PLUG, NGK-DPR6EA-9 33-827858Q 33-827858
26 NOT SOLD SEPARATE, Decal-Coil Identification NSS
27 COIL, Ignition 339-830404T3
28 SCREW, (M6 x 20) Stainless Steel 10-8M0204741
29 HARNESS ASSEMBLY, Engine Wiring Comment: (MANUAL) 84-856158A2
29 HARNESS ASSEMBLY, Engine Wiring Comment: (ELECTRIC) 84-854781A2
30 FUSE, Yellow - 20 Ampere Comment: (ELECTRIC) 88-812619 88-860608 (ELECTRIC)
31 COVER, Fuse Comment: (ELECTRIC) 828054
32 CLAMP, Connector Comment: (ELECTRIC) 8261151
33 SCREW, (M6 x 16) Comment: (ELECTRIC) 10-8248324
34 HARNESS ASSEMBLY, Extension Comment: (ELECTRIC HANDLE) 84-852375A6
35 TIE STRAP, (8.00 Inches) 54-816311T 54-816311, 54-90077, 54-826785, F1877, F717046-1, F717046, MAF03001, 833188E, 54-F9301, 54-816311100, 54-898101111, 54-898101275
36 J CLIP Comment: (MANUAL) 54-47483
37 REGULATOR, Voltage Comment: (ELECTRIC) 883071T 854514T, 854514, 856747 (ELECTRIC)
38 J CLIP Comment: (ELECTRIC) 54-8M0024808
39 SCREW, (M6 x 40) Comment: (ELECTRIC) 10-8248329
39 SCREW, (M6 x 16) Comment: (MANUAL) 10-8248324
40 SCREW, (M6 x 10) Comment: (ELECTRIC) 10-82129110
41 PLUG, Male Comment: (Quantity of 2 on Manual) 13541
42 SCREW, (M6 x 16) 10-8248324
43 CABLE ASSEMBLY 84-858884A1
- POWERHEAD ASSEMBLY 61-803017T01 61-803017T99
- POWERHEAD ASSEMBLY Comment: (BIGFOOT) 61-803016T01 61-803016T99 (BIGFOOT)

Electrical Components(0G960500 and Up)

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Below is the parts list for Mercury 40 (4-STROKE) Electrical Components(0G960500 and Up):

Mercury 40 (4-STROKE) Electrical Components(0G960500 and Up) Diagram
Position No. Part Name OEM Number Supersedes
1 SOLENOID ASSEMBLY Comment: (ELECTRIC) 89-8M0185146
2 BUSHING Comment: (ELECTRIC) 23-8M0214955
3 GROMMET Comment: (ELECTRIC) 25-818967
4 NUT, Brass Comment: (ELECTRIC) 8-32,11-26419
5 NUT, (.250-20) Brass Comment: (ELECTRIC) 11-94330
6 CABLE ASSEMBLY, Battery - Positive Comment: (ELECTRIC) 84-88439A9
7 BOOT, Insulator - Red Comment: (ELECTRIC) 85-8500671
8 CABLE ASSEMBLY Comment: (ELECTRIC) 84-93388A13
9 CABLE ASSEMBLY, Battery - Negative Comment: (ELECTRIC) 84-88439A4
10 STARTER MOTOR ASSEMBLY Comment: (ELECTRIC) 50-893887T 50-888160T, 50-884045T, 50-859170T 1 (ELECTRIC)
11 SCREW, (M8 x 45) Stainless Steel Comment: (ELECTRIC) 10-40011153
11 SCREW, (M8 x 25) Stainless Steel Comment: (MANUAL) 10-40011149
12 SCREW, (M6 x 30) Comment: (ELECTRIC) 10-82684430
12 SCREW, (M6 x 16) Comment: (MANUAL) 10-8248324
13 PRESSURE SWITCH 87-8M0098207 87-8M0070107, 87-828040 1
14 SENSOR 8M0082988 8M0030022, 828358 2
15 SCREW, (M5 x 16) Stainless Steel 10-40011107
16 SCREW, (M6 x 25) 10-82130025
17 WASHER 12-8M0214930
18 PLATE 859224 856604
19 RETAINER Comment: (ELECTRIC) 856836001 856836, 856039 (ELECTRIC)
20 BRACKET Comment: (ELECTRIC) 856040
21 SCREW, (M6 x 14) Comment: (ELECTRIC) 10-82129114
22 RETAINER Comment: (ELECTRIC)(Quantity of 2 on Handle) 92753
23 BUSHING 23-856954
24 GROMMET 25-8M0190980
25 ECM, Engine Control Module Comment: SN# 0T178500 & Up 87843302S
25 ECM, Engine Control Module Comment: SN# 0T178499 & Below 87843302S
26 BUSHING 23-8539201
27 SCREW, (M6 x 40) 10-82129140
28 SPARK PLUG, NGK-DPR6EA-9 33-827858Q 33-827858
29 COIL ASSEMBLY, Ignition 339-858942T1
30 SCREW, (M6 x 20) Stainless Steel 10-8M0204741
31 HARNESS ASSEMBLY, Engine Wiring Comment: (MANUAL) 84-859196T1
32 HARNESS ASSEMBLY, Engine Wiring Comment: (ELECTRIC) SN# 0T294065 & Up 84-859197T3
32 HARNESS ASSEMBLY, Engine Wiring Comment: (ELECTRIC) SN# 0T178500 THRU 0T294064 84-859197T2
32 HARNESS ASSEMBLY, Engine Wiring Comment: (ELECTRIC) SN# 0T178499 & Below 84-859197T1
33 FUSE, Yellow - 20 Ampere Comment: (ELECTRIC) 88-812619 88-860608 (ELECTRIC)
34 COVER, Fuse Comment: (ELECTRIC) 828054
35 HARNESS ASSEMBLY, Extension Comment: (ELECTRIC HANDLE) 84-852375A6
36 TIE STRAP, (8.00 Inches) 54-816311T 54-816311, 54-90077, 54-826785, F1877, F717046-1, F717046, MAF03001, 833188E, 54-F9301, 54-816311100, 54-898101111, 54-898101275
37 J CLIP Comment: (MANUAL) 54-8M0024808
38 REGULATOR, Voltage Comment: (ELECTRIC) 883071T1
39 BRACKET Comment: (ELECTRIC) 893771 858413 (ELECTRIC)
40 FOAM PAD Comment: (ELECTRIC) 8308971
41 SCREW, (M6 x 40) Comment: (ELECTRIC) 10-8248329
41 SCREW, (M6 x 16) Comment: (MANUAL) 10-8248324
42 SCREW, (M6 x 10) Comment: (ELECTRIC) 10-82129110
43 PLUG, Male Comment: (MALE) 13541
44 CABLE ASSEMBLY Comment: (Use where Applicable) 84-877860T1
45 SCREW, (M6 x 16) 10-8248324
46 J CLIP Comment: (ELECTRIC-NON POWER TRIM) 54-8M0024808
47 SCREW, (M6 x 16) Comment: (ELECTRIC-NON POWER TRIM) 10-8248324
- POWERHEAD ASSEMBLY 61-803017T01 61-803017T99
- POWERHEAD ASSEMBLY Comment: (BIGFOOT) 61-803016T01 61-803016T99 (BIGFOOT)

Flywheel

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Below is the parts list for Mercury 40 (4-STROKE) Flywheel:

Mercury 40 (4-STROKE) Flywheel Diagram
Position No. Part Name OEM Number Supersedes
1 FLYWHEEL COVER Comment: (ELECTRIC) 859284T2
2 SCREW, (M6 x 25 MM) Comment: (ELECTRIC) 10-8248326
3 DECAL, EPA Label Information Comment: (ELECTRIC)(1999) 37-856985A22 37-856985 22 (ELECTRIC)(1999)
3 DECAL, EPA Label Information Comment: (ELECTRIC)(2000) 37-804654A00
3 DECAL, EPA Label Information Comment: (ELECTRIC)(2001) 37-804654A01
4 FLYWHEEL Comment: (ELECTRIC) 284-832010T32 284-832010T31, 284-832010T26, 284-832010T14, 284-832010A 8 (ELECTRIC)
5 FLYWHEEL Comment: (MANUAL) 284-832010T27 284-832010T16, 284-832010A 4 (MANUAL)
6 NOT SOLD SEPARATE, Decal-Warning Spinning Flywheel NSS
7 NOT SOLD SEPARATE, Decal-Timing Marks NSS
8 NOT SOLD SEPARATE, Decal-Warning-Neutral NSS
9 NUT 11-893789 11-81773M
10 WASHER 12-893762 12-84436M
11 SCREW, (M5 x 25) Comment: SN# 0G960499 & Below 10-4007325
11 SCREW, (M5 x 25) Comment: (Manual) SN# 0G960500 & Up 10-4007325
11 SCREW, (M5 x 30) Comment: (Electric) SN# 0G960500 & Up 10-4013930
12 STATOR Comment: (Electric) SN# 0G960500 & Up 398-852387T7
12 STATOR Comment: (Manual) SN# 0G960500 & Up 398-852386T6
12 STATOR Comment: (Electric) SN# 0G960499 & Below 398-852387T9
12 STATOR Comment: (Manual) SN# 0G960499 & Below 398-852386T8
13 LOAD RING 834838

Fuel Lines

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Below is the parts list for Mercury 40 (4-STROKE) Fuel Lines:

Mercury 40 (4-STROKE) Fuel Lines Diagram
Position No. Part Name OEM Number Supersedes
1 HOSE 32-856607
2 HOSE 32-856609
3 LINKAGE 856610
4 BUSHING 23-803896
5 TIE STRAP 823548T 823548, 54-856608
6 HOSE 32-856613
7 HOSE and SLEEVE 32-856611
8 CONNECTOR 22-822771
9 FITTING, 45 Degree Comment: SN# 0T178500 & Up 22-878404
10 HOSE Comment: SN# 0T178500 & Up 32-878423
11 TUBING, (17.00 Inches Bulk) (Cut to 3-1/2 Inches) Comment: SN# 0T178500 & Up 32-85682239
12 HOSE (90MM) Comment: SN# 0T178500 & Up 32-82381310
13 CLIP Comment: SN# 0T178500 & Up 54-878425
14 TIE STRAP, (4.00 Inches) 56762
15 WASHER 12-8542592
16 COTTER PIN 18-880850
17 Y-CONNECTOR Comment: SN# 0T178500 & Up 22-878593

Fuel Pump

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Below is the parts list for Mercury 40 (4-STROKE) Fuel Pump:

Mercury 40 (4-STROKE) Fuel Pump Diagram
Position No. Part Name OEM Number Supersedes
1 FILTER, Fuel 35-877565T1
2 TIE STRAP, (8.00 Inches) 54-816311T 54-816311, 54-90077, 54-826785, F1877, F717046-1, F717046, MAF03001, 833188E, 54-F9301, 54-816311100, 54-898101111, 54-898101275
3 HOSE, (57.00 Inches Bulk) (Cut to 14 Inches) 32-8M0108355 32-8M0047428, 32-830756109, 32-99127109, 32-877821
4 HOSE, (57.00 Inches Bulk) (Cut to 19 Inches) 32-8M0108355 32-8M0047428, 32-830756109, 32-99127109, 32-877821
5 CONNECTOR ASSEMBLY, Fuel 22-8M0148585
- O-RING, Fuel Connector 25-16524
6 PUMP, Fuel 826398T3
7 SCREW, (M5 x 35) 10-809564
8 COVER 809565
9 DIAPHRAGM 8095611
10 SCREW, (M3 x 5) 10-41889M
11 NUT 11-82537M
12 CHECK VALVE 21-41888M
13 DIAPHRAGM 8095612
14 PIN 17-8095661
15 SPRING 24-809562
16 NUT, (M5) 11-82388M
17 SPRING 24-8095621
18 PLUNGER 8095631
19 O-RING 25-8M0052669 25-825492
20 SCREW, (M6 x 30) 10-82684430
21 PLUG 19-854310 806899
22 J CLIP 54-8M0024808
23 DEFLECTOR, Cowl 8M0007776 893698001, 856603 1
- GASKET SET, Engine 27-825231A99

Gear Housing(Driveshaft-2.31:1 Gear Ratio)

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Below is the parts list for Mercury 40 (4-STROKE) Gear Housing(Driveshaft-2.31:1 Gear Ratio):

Mercury 40 (4-STROKE) Gear Housing(Driveshaft-2.31:1 Gear Ratio) Diagram
Position No. Part Name OEM Number Supersedes
- GEAR HOUSING ASSEMBLY, Complete 1667-9011G86
1 GEAR HOUSING ASSEMBLY, Basic 1667-9011G59
2 PIN, Dowel - With Hole (.375 x .625) (FRONT) 17-8M0084244 17-43043
3 TUBE, Oiler 43046
4 SCREW KIT, (.375-16 x .250) 10-79953Q04
4 FITTING KIT, Magnetic, Plug Fill/Drain 22-8M0058389 22-67892A06
5 WASHER, Fiber 12-191833
6 PIN, Dowel - Without Hole (.375 x .625) (REAR) 17-43044
7 TRIM TAB 31640T07
8 SCREW, (.437-14 x 1.250) Stainless Steel 10-825427 10-15942
9 WASHER, (.453 x .812 x .105) Black Oxide 12-451761
10 CARRIER ASSEMBLY 43040T1
11 NOT SOLD SEPARATE, Needle Bearing NSS
12 ANODE 97-826134Q 826134, 826134A 1
13 NUT, (M6) 11-401386
14 SCREW, (M6 x 40) 10-4000333
15 GEAR, Pinion (13 Teeth) 43-44484T
16 NUT, (.625-18) 11-35921
17 CAM, Shift Control 850307
18 BEARING ASSEMBLY, Tapered Roller 31-42677A1
19 SHIM SET 15-44492A1
20 DRIVESHAFT ASSEMBLY 45-854808A1
21 SLEEVE/RING KIT 42461A1
22 NOT SOLD SEPARATE, Ring Seal NSS
23 COVER ASSEMBLY, Water Pump 43055A4
24 GASKET 27-430331
25 GASKET 27-8M0214931
26 SEAL, Oil (LOWER) 26-43036
27 SEAL, Oil (UPPER) 26-43035
28 GASKET 27-8172771
29 HOUSING KIT, Upper Water Pump 817275A2
30 FACEPLATE 8M0204709
31 SCREW, (M6 x 30) 10-8M0214957
32 SEAL 8M0204658
33 KEY 28-8M0204723
34 IMPELLER 47-43026T2
35 SCREW, (M6 x 25 MM) 10-8248326
36 SHIFT SHAFT ASSEMBLY 853906A1
37 E RING 53-29641
38 BUSHING ASSEMBLY 23-43052A4
39 O-RING, (1.424 x .103) 25-8M0204681
40 SEAL, Oil 26-8M0204708
41 SCREW, (M6 x 25 MM) 10-8248326
42 FACE SEAL 26-861415 26-816575
- SEAL KIT, Gear Housing 26-43035A4
- REPAIR KIT, Water Pump 46-8M0113799
- REPAIR KIT, Water Pump Impeller 47-8M0100526 47-43026Q06

Gear Housing(Driveshaft-2:1 Gear Ratio)

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Below is the parts list for Mercury 40 (4-STROKE) Gear Housing(Driveshaft-2:1 Gear Ratio):

Mercury 40 (4-STROKE) Gear Housing(Driveshaft-2:1 Gear Ratio) Diagram
Position No. Part Name OEM Number Supersedes
- GEAR HOUSING ASSEMBLY, (3.44 Inch/87.37 mm Torpedo Diameter) Complete Comment: (SHORT) 1682-821306T54 1682-821306T38 (SHORT)
- GEAR HOUSING ASSEMBLY, Complete Comment: (LONG) 1682-821306T17 1682-821306A17 (LONG)
1 GEAR HOUSING ASSEMBLY, Basic Comment: (BASIC) 1682-821306T12 1682-821306A12 (BASIC)
2 SEAL/PLATE KIT 818226A1
3 NOT SOLD SEPARATE, Plate NSS
4 SCREW KIT, (.375-16 x .250) (.375-16 X .25) 10-79953Q04
5 WASHER, Fiber 12-191833
6 SCREW KIT, (.375-16 x .250) 10-79953Q04
6 FITTING KIT, Magnetic, Plug Fill/Drain Comment: (MAGNETIC) 22-8M0058389 22-67892A06 (MAGNETIC)
7 WASHER, Fiber 12-191833
8 NUT, (.437-20) 11-55910
9 GEAR, Pinion - 13 Teeth 43-821326T1
10 BEARING ASSEMBLY 31-821321A2
11 NOT SOLD SEPARATE, Cup NSS
12 SCREW, (M6 x 16) 10-8248324
13 HOUSING ASSEMBLY, Water Pump Upper 46-821351A3
14 SEAL Comment: (SHORT - 1-3/4) 8M0204658
14 SEAL Comment: (LONG - 2-1/4) 8235471
15 WASHER 12-866451
16 KEY 28-8M0214993
17 WASHER 12-866451
18 GASKET, Upper Water Pump 27-822189
19 GASKET, Lower Water Pump (LOWER) 27-8M0214956
20 FACE PLATE 8213542
21 IMPELLER 47-8M0204712
22 BASE ASSEMBLY, Water Pump 46-821307A2
23 SEAL 26-821309
24 SEAL 26-821310
25 O-RING, (1.421 x .139) 25-821308
26 DRIVESHAFT Comment: (SHORT) 45-826193T2
26 DRIVESHAFT Comment: (LONG) 45-826194A1
27 BEARING, Ball 30-821311
28 TIE STRAP 823548T 823548, 54-856608
29 BOOT 822158
30 RETAINER 821827
31 O-RING, (1.609 x .139) 25-26855
32 O-RING, (.239 x .174) 25-85594
33 WASHER 12-814803 12-93853
34 SHIFT SHAFT Comment: (SHORT) 827865A2
34 SHIFT SHAFT Comment: (LONG) 827865A1
35 WASHER, (.281 x .500 x .060) Stainless Steel 12-8M0204649
36 PIN, (.078 x .437) 17-85593
37 CAM, Shift 8213161
38 PIN, (.125 x .625) 17-822369
- SEAL KIT 823547A2
- REPAIR KIT, Water Pump 821354A2

Gear Housing(Prop Shaft - 2.31:1 - S/N-0T625303 and below)

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Below is the parts list for Mercury 40 (4-STROKE) Gear Housing(Prop Shaft - 2.31:1 - S/N-0T625303 and below):

Mercury 40 (4-STROKE) Gear Housing(Prop Shaft - 2.31:1 - S/N-0T625303 and below) Diagram
Position No. Part Name OEM Number Supersedes
- GEAR HOUSING ASSEMBLY, Complete 1667-9011G86
1 GEAR HOUSING ASSEMBLY, Basic 1667-9011G59
2 BEARING SET, Cup And Cone 31-30894A1
3 NOT SOLD SEPARATE, Cup NSS
4 GEAR ASSEMBLY, Forward - 30 Teeth 43-859472A3
5 BEARING, Needle 31-30895T
6 RING, Retaining 53-856823
7 FOLLOWER KIT, Cam 850315A1
8 BALL 30-44530
9 NOT SOLD SEPARATE, Slide NSS
10 SPRING 24-850327
11 CLUTCH 52-850048T 52-850048
12 PIN, Cross 17-8M0100263 17-8M0084681, 17-8M0020941, 17-30632
13 SPRING 24-30893
14 PROPELLER SHAFT 44-8M0140445
15 GEAR, Reverse (30 Teeth) 43-850034T 43-850034
16 CARRIER ASSEMBLY, Bearing 8M0168901
17 O-RING, (3.609 x .139) 25-8M0214974
18 BEARING, Needle 31-30956T
19 SEAL, Oil (INNER) 26-8M0205728
20 SEAL, Oil (OUTER) 26-8M0205729
21 BEARING, Roller 31-12578T
22 THRUST WASHER 12-12577
23 BEARING, Thrust 31-12576
24 STUD, (M8 x 48) 16-8M0034456 16-42917 2
25 WASHER, (.323 x .590 x .112) Stainless Steel 12-855941
26 NUT, (M8) 11-401378
27 SHIM SET 15-44491A1
28 INSERT, Threaded 8227731
29 NOT SOLD SEPARATE, Decal NSS
30 NOT SOLD SEPARATE, Decal-Prop Operation NSS
31 THRUST WASHER 13191Q01
32 PROP NUT KIT, (.750-16) 11-52707Q1
33 TAB WASHER 14-816629Q 14-816629, 14-31210, 14-816629B
34 SCREW, (M10 x 45) 10-4000380
35 WASHER, (.406 x .750 x .105) Stainless Steel 12-8M0214963
- SEAL KIT, Gear Housing 26-43035A4

Gear Housing, Propeller Shaft - 2:1 Gear Ratio

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Below is the parts list for Mercury 40 (4-STROKE) Gear Housing, Propeller Shaft - 2:1 Gear Ratio:

Mercury 40 (4-STROKE) Gear Housing, Propeller Shaft - 2:1 Gear Ratio Diagram
Position No. Part Name OEM Number Supersedes
- GEAR HOUSING ASSEMBLY, (3.44 Inch/87.37 mm Torpedo Diameter) Complete Comment: (SHORT) 1682-821306T54 1682-821306T38 (SHORT)
- GEAR HOUSING ASSEMBLY, Complete Comment: (LONG) 1682-821306T17 1682-821306A17 (LONG)
1 GEAR HOUSING ASSEMBLY, Basic Comment: (BASIC) 1682-821306T12 1682-821306A12 (BASIC)
39 PIN, Dowel 17-821327
40 GASKET 27-823942
41 TUBE 32-8M0026108 32-821828
42 PLUG, Rubber 19-824928001 19-824928, 19-32297
43 SCREEN 821829
44 TRIM TAB 822157T2
45 SCREW, (M8 x 20) 10-82497020
46 WASHER 12-72397
47 GEAR ASSEMBLY, Forward - 26 Teeth 43-821315T1
48 BEARING ASSEMBLY, Roller 31-8M0103470 31-99328A 1
49 NOT SOLD SEPARATE, Cup NSS
50 BEARING, Roller 31-41326
51 FOLLOWER, Cam 821578
52 SPRING 24-8261991
53 PIN 17-8M0020999 17-85093
54 CLUTCH 52-821314T 52-821314
55 SPRING 24-38114
56 PROPELLER SHAFT 44-8M0140441
57 GEAR, Reverse - 26 Teeth 43-821312T1
58 BEARING, Ball 30-20839T
59 CARRIER ASSEMBLY, Bearing 8M0168900
60 O-RING 25-815460
61 BEARING, Needle 31-21700
62 SEAL, Oil 26-8M0205511
63 SEAL, Oil 26-8M0203757
64 WASHER, (.323 x .590 x .112) Stainless Steel 12-855941
65 SCREW, (M8 x 30) 10-85594030
66 INSERT, Threaded 8227731
67 NOT SOLD SEPARATE, Decal (2:1) NSS
68 THRUST HUB 73345A1
69 PROP NUT KIT 11-69578Q1
70 TAB WASHER 14-8M0214942
71 SCREW, (M10 x 45) 10-4000380
72 WASHER, (.406 x .750 x .105) Stainless Steel 12-8M0214963
73 PLUG 19-95925
- SEAL KIT 823547A2

Intake

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Below is the parts list for Mercury 40 (4-STROKE) Intake:

Mercury 40 (4-STROKE) Intake Diagram
Position No. Part Name OEM Number Supersedes
1 SCREW, (M6 x 90) 10-82615890
2 INTAKE, Air 856126T
3 O-RING 25-856525
4 PLATE 834783T
5 ISOLATOR Comment: (40) 834784T
5 ISOLATOR Comment: (30) 834784T1
6 PLUG 19-827633
7 ATTENUATOR, Sound 856127A2
8 SCREW, (M6 x 20) Stainless Steel 10-8M0204741
9 BUSHING 23-17044M
10 TIE STRAP, (11.750 Inches) 54-850181
11 SEAL 26-856128001 26-856128
12 O-RING 25-8250572
13 PIN, Dowel 17-23784
14 SCREW, (M6 x 25 MM) 10-8248326
15 BREATHER HOSE 32-8M0182223
16 TIE STRAP, (8.00 Inches) 54-816311T 54-816311, 54-90077, 54-826785, F1877, F717046-1, F717046, MAF03001, 833188E, 54-F9301, 54-816311100, 54-898101111, 54-898101275
- GASKET SET, Engine 27-825231A99

Intake/Exhaust Valves

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Below is the parts list for Mercury 40 (4-STROKE) Intake/Exhaust Valves:

Mercury 40 (4-STROKE) Intake/Exhaust Valves Diagram
Position No. Part Name OEM Number Supersedes
1 VALVE, Exhaust 8M0119204
2 VALVE, Intake 832990T1
3 WASHER, Valve Spring 12-825044
4 SEAL, Valve Stem 26-822647
5 SPRING, Valve Outer 24-823678
6 RETAINER 822650
7 KEY 28-893554 28-822651
8 ROCKER ARM 898821A01
9 SCREW 10-825046
10 NUT 11-826150 11-858274
11 SHAFT, Rocker 834780T1
12 PLUG 19-825042
13 BRACKET 825050
14 PLATE 825051
15 SPRING 24-825052
16 SPRING 24-854713
17 SCREW, (M8 x 30) 10-82641030
- GASKET SET, Engine 27-825231A99

Linkage(Electric Bigfoot)

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Below is the parts list for Mercury 40 (4-STROKE) Linkage(Electric Bigfoot):

Mercury 40 (4-STROKE) Linkage(Electric Bigfoot) Diagram
Position No. Part Name OEM Number Supersedes
1 SCREW, (M8 x 70) Stainless Steel 10-40011158
2 SCREW, Adjusting (M6 x 55) 10-814776 10-42978
3 NUT, (M6) 11-401196
4 CAP 42942
5 LEVER ASSEMBLY, Throttle Comment: (DESIGN II) 822682A4
6 RETAINER Comment: (DESIGN II) 883160
7 BUSHING 23-825078
8 RETAINER 822459
9 LEVER, Shift 8259571
10 BRACKET 827706A4
11 LATCH 98889
12 SCREW, (M6 x 16) 10-8248324
13 SLEEVE 23-15885
14 SHIFT ROD 893777 850162
15 GUIDE, Shift Rod 8501631
16 SHIFT LINK 893769A01 850255A 1
17 BUSHING 23-48475
18 WASHER, (.281 x .500 x .060) Stainless Steel 12-8M0204649
19 NUT, (M6) 11-401386
20 COTTER PIN 18-210711
21 LEVER ASSEMBLY, Shift Shaft 850166T2
22 BUSHING 23-850165
23 CAM, Throttle 8535853
24 SPACER 23-309772
25 WASHER 12-4002314
26 SCREW, (M5 x 16) 10-40056107
27 LEVER, Throttle Comment: (DESIGN I) 822682A4
28 RETAINER Comment: (DESIGN I) 826587 826587 1 (DESIGN I)

Linkage(Manual Bigfoot-0G960499 and Below)

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Below is the parts list for Mercury 40 (4-STROKE) Linkage(Manual Bigfoot-0G960499 and Below):

Mercury 40 (4-STROKE) Linkage(Manual Bigfoot-0G960499 and Below) Diagram
Position No. Part Name OEM Number Supersedes
1 SCREW, (M8 x 70) Stainless Steel 10-40011158
2 SCREW, Adjusting (M6 x 55) 10-814776 10-42978
3 NUT, (M6) 11-401196
4 CAP 42942
5 RETAINER 826587 826587 1
6 LEVER, Throttle 822682A4
7 BUSHING 23-825078
8 RETAINER 822459
9 LEVER, Shift 8259571
10 BRACKET 827706A4
11 LATCH 98889
12 SCREW, (M6 x 16) 10-8248324
13 SLEEVE 23-15885
14 GUIDE, Shift Rod 8501631
15 SHIFT LINK 893769A01 850255A 1
16 BUSHING 23-48475
17 WASHER, (.281 x .500 x .060) Stainless Steel 12-8M0204649
18 NUT, (M6) 11-401386
19 COTTER PIN 18-210711
20 LEVER ASSEMBLY, Shift Shaft 850166T2
21 BUSHING 23-850165
22 CAM, Throttle 8535853
23 SPACER 23-309772
24 WASHER 12-4002314
25 SCREW, (M5 x 16) 10-40056107
26 ROD 854467
27 DETENT/SPRING KIT 12016A2
28 NOT SOLD SEPARATE, Spring NSS

Linkage(Manual Bigfoot-0G960500 and Up)

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Below is the parts list for Mercury 40 (4-STROKE) Linkage(Manual Bigfoot-0G960500 and Up):

Mercury 40 (4-STROKE) Linkage(Manual Bigfoot-0G960500 and Up) Diagram
Position No. Part Name OEM Number Supersedes
1 SCREW, (M8 x 70) Stainless Steel 10-40011158
2 SCREW, Adjusting (M6 x 55) 10-814776 10-42978
3 NUT, (M6) 11-401196
4 CAP 42942
5 LEVER ASSEMBLY, Throttle Comment: (DESIGN II) 822682A4
6 SCREW, (M6 x 25 MM) 10-8248326
7 SHIFT GUIDE 858245
8 SCREW, (M5 x 12) 10-82239312
9 SHIFT SLIDE 858246
10 DETENT/SPRING KIT 12016A2
11 NOT SOLD SEPARATE, Spring NSS
12 SHIFT ROD 858247
13 COTTER PIN 18-210711
14 NUT, (M6) 11-401386
15 WASHER, (.281 x .500 x .060) Stainless Steel 12-8M0204649
16 SHIFT LINK 858248
17 BUSHING 23-48475
18 LEVER ASSEMBLY, Shift Shaft 850166T2
19 BUSHING 23-850165
20 CAM, Throttle 8535853
21 SPACER 23-309772
22 WASHER 12-4002314
23 SCREW, (M5 x 16) 10-40056107
24 LEVER, Throttle Comment: (DESIGN I) 822682A4

Linkage(Non Bigfoot)

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Below is the parts list for Mercury 40 (4-STROKE) Linkage(Non Bigfoot):

Mercury 40 (4-STROKE) Linkage(Non Bigfoot) Diagram
Position No. Part Name OEM Number Supersedes
1 SCREW, (M8 x 70) Stainless Steel 10-40011158
2 SCREW, Adjusting (M6 x 55) Comment: (30 HP) 10-814776 10-42978 (30 HP)
3 NUT, (M6) Comment: (30 HP) 11-401196
4 BUSHING Comment: (30 HP) 23-823807 23-42806 (30 HP)
5 SCREW, Adjusting (M6 x 55) Comment: (40 HP) 10-814776 10-42978 (40 HP)
6 NUT, (M6) Comment: (40 HP) 11-401196
7 CAP Comment: (40 HP) 42942
8 LEVER ASSEMBLY, Throttle Comment: (DESIGN II) 822682A4
9 RETAINER Comment: (ELECTRIC)(DESIGN II) 883160
10 BUSHING 23-825078
11 RETAINER Comment: (NON HANDLE) 822459
12 LEVER, Shift Comment: (NON HANDLE) 8259571
13 BRACKET Comment: (NON HANDLE) 827706A4
14 LATCH Comment: (NON HANDLE) 98889
15 SCREW, (M6 x 16) Comment: (NON HANDLE) 10-8248324
16 SLEEVE Comment: (NON HANDLE) 23-15885
17 SHIFT ROD Comment: (NON HANDLE) 882820 826271 (NON HANDLE)
18 CAM, Throttle 8535853
19 SPACER 23-309772
20 WASHER 12-4002314
21 SCREW, (M5 x 16) 10-40056107
22 SHIFT SHAFT ASSEMBLY, Horizontal 826588A4
23 RETAINER 8277071
24 WASHER, (.281 x .500 x .060) Stainless Steel 12-8M0204649
25 COTTER PIN 18-210711
26 SPRING, Detent 24-826077
27 SPRING, Backing 24-824993
28 SPRING, Plate 824994
29 SCREW, (M5 x 16) Stainless Steel 10-40011107
30 SWITCH Comment: (ELECTRIC HANDLE MODELS) 87-8M0052927 87-813960A 3 (ELECTRIC HANDLE MODELS)
31 SCREW, (M3.5 x 20) Stainless Steel Comment: (ELECTRIC HANDLE MODELS) 10-88075020
32 PLATE Comment: (ELECTRIC HANDLE MODELS) 824923
33 LEVER, Throttle Comment: (DESIGN I) 822682A4
34 RETAINER Comment: (DESIGN I) 826587 826587 1 (DESIGN I)

Manual Starter

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Below is the parts list for Mercury 40 (4-STROKE) Manual Starter:

Mercury 40 (4-STROKE) Manual Starter Diagram
Position No. Part Name OEM Number Supersedes
- STARTER ASSEMBLY, Recoil 835253A13 835253T 6
1 HOUSING ASSEMBLY, Recoil 835253A12 835253A 8
2 CAM 8167122
3 SPRING 24-8267911
4 SEAL 8M0026455 835255 2
5 ROLLER 835256T 835256
6 BUSHING 23-852987T 23-852987
7 WASHER 826414T 12-826414
8 SCREW, (M6 x 30) 10-82684430
9 LOCKWASHER 13-826229
10 SPRING 24-86857T01
11 SHEAVE ASSEMBLY, Starter 50-854317T5
12 CAM 868501
13 SPRING 24-86851T02
14 RING, Retaining 53-86849T01
15 SPRING 24-868523
16 CAM 86853T01
17 SCREW, (.250-20 x .625) 10-826253 10-97516, 10-818838
18 ROPE 50-12066Q10
19 LEVER, Interlock 856073 852449
20 RETAINER 856072T 856072
21 SPRING 24-856138T03 24-856138 3
22 BUSHING 854779T 854779
23 SCREW, (#10-16 x 1.00) 10-8182491
24 HANDLE ASSEMBLY 85174A1
25 NOT SOLD SEPARATE NSS
26 SCREW, (M6 x 25 MM) 10-8248326
27 CABLE, Interlock 856754 816748 6
28 SCREW, (#10-16 x .625) 10-8214281
29 WASHER, (.220 x .500 x .030) Stainless Steel 12-73288
30 COTTER PIN 18-26811
31 SCREW, (M5 x 16) Stainless Steel 10-40011107
32 DECAL, EPA Label Information Comment: (1999) 37-856985A22 37-856985 22 (1999)
32 DECAL, EPA Label Information Comment: (2000) 37-804654A00
32 DECAL, EPA Label Information Comment: (2001) 37-804654A01

Manual Tilt

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Below is the parts list for Mercury 40 (4-STROKE) Manual Tilt:

Mercury 40 (4-STROKE) Manual Tilt Diagram
Position No. Part Name OEM Number Supersedes
- MANUAL TRIM ASSEMBLY 8M0118570
1 SHOCK ROD ASSEMBLY 8M0118572
2 PISTON ASSEMBLY, Trim Memory 893903A01
3 O-RING KIT, Cylinder 25-893917A01 25-809872A 1
4 NOT SOLD SEPARATE, O Ring NSS
5 CYLINDER ASSEMBLY 893918A01 811224A 1
6 SCREW AND SEAL KIT 893919A01 813433A 2
7 ACCUMULATOR ASSEMBLY 893920A01 813454A 2
8 VALVE BODY ASSEMBLY 893921A01 813455T 4
9 CAM KIT 893923A01 813457A 3
10 VALVE KIT, Velocity 893924A01 809881A 1
11 REPAIR KIT 893925A01 809882A 1
12 CABLE ASSEMBLY, Ground 8M0207768
- O-RING KIT 25-893922A01 25-809880A 2
13 PIN 17-19607
14 PIN, Trilobe 17-821539 17-13794, 17-19603

Power Trim

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Below is the parts list for Mercury 40 (4-STROKE) Power Trim:

Mercury 40 (4-STROKE) Power Trim Diagram
Position No. Part Name OEM Number Supersedes
- PUMP/MOTOR ASSEMBLY Comment: (NON-BIGFOOT) 8M0055006 893518T01, 830150T10, 830150T 6 (NON-BIGFOOT)
- PUMP/MOTOR ASSEMBLY Comment: (BIGFOOT) 8M0055011 893517T01, 855654T09, 855654T08, 855654T 4 (BIGFOOT)
1 SHOCK ROD KIT 893943A01 855833A 1
2 PISTON ASSEMBLY, Memory 8M0171822
3 O-RING KIT, Rebuild 25-8M0171819
4 NOT SOLD SEPARATE, O Ring NSS
5 CYLINDER ASSEMBLY 893904T01 811228A 1
6 VALVE KIT, Trim Limit Comment: (NON-BIGFOOT) 893905A02 809873A 1 (NON-BIGFOOT)
6 VALVE KIT, Trim Limit Comment: (BIGFOOT) 893944A01 809873A 2 (BIGFOOT)
7 PUMP ASSEMBLY 893906A02 809874A 1
8 MOTOR KIT 893907A02 809885A 2
9 PLUG 22-8134351
10 MANUAL RELEASE ASSEMBLY 893929A01 813442A 2
11 MANIFOLD KIT 893909A02 809875A 1
12 SCREW KIT (MOTOR) 10-809876A1
13 DRIVESHAFT/SEAL KIT 809877A1
14 FILTER KIT 35-893912A02 809878A 1
15 POPPET KIT 893913A02 809879A 1
16 CABLE ASSEMBLY 88238A18
- O-RING KIT (COMPLETE TRIM) 25-893914A02 25-809880A 1
17 PIN, Trilobe 17-821539 17-13794, 17-19603
18 PIN 17-19607
19 PIN 17-822869001 17-822869
- HARNESS ASSEMBLY, Trim Comment: SN# 0T178500 & Up 84-826802T21
- HARNESS/RELAY ASSEMBLY Comment: SN# 0T178499 & Below 84-826802A15
20 HARNESS ASSEMBLY, Trim Comment: SN# 0T178500 & Up 84-826802T19
20 HARNESS ASSEMBLY Comment: SN# 0T178499 & Below 84-826802A12
21 RELAY ASSEMBLY 8M0207773
22 BRACKET 828102
23 GROMMET 25-818967
24 BUSHING 23-8M0214955
25 NOT SOLD SEPARATE, Decal-Trim Relay NSS
26 SCREW, (M6 x 30) Comment: SN# 0T294064 & Below 10-82684430

Service and Support Material

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Below is the parts list for Mercury 40 (4-STROKE) Service and Support Material:

Mercury 40 (4-STROKE) Service and Support Material Diagram
Position No. Part Name OEM Number Supersedes
0 PARTS MANUAL, 30/40 Carb 4-Stroke (3 Cylinder) 90-803941
0 OWNERS MANUAL 90-10212010
0 OWNERS MANUAL Comment: (TRACKER) 90-10214010
0 SERVICE MANUAL 90-857046R1
0 DECAL SET Comment: (BLACK 30)(1999 MODEL YEAR AND ABOVE) 37-803640A00 37-803640A99 (BLACK 30)(1999 MODEL YEAR AND ABOVE)
0 DECAL SET Comment: (BLACK 40)(2000 MODEL YEAR AND ABOVE) 37-803641A00 37-803641A99 (BLACK 40)(2000 MODEL YEAR AND ABOVE)
0 DECAL SET Comment: (BLACK 40 BIGFOOT)(2000 MODEL YEAR AND ABOVE) 37-803644A00 37-803644A99 (BLACK 40 BIGFOOT)(2000 MODEL YEAR AND ABOVE)
0 DECAL SET Comment: (BLACK 40)(1999 MODEL YEAR) 37-803641A00 37-803641A99 (BLACK 40)(1999 MODEL YEAR)
0 DECAL SET Comment: (BLACK 40 BIGFOOT)(1999 MODEL YEAR) 37-803644A00 37-803644A99 (BLACK 40 BIGFOOT)(1999 MODEL YEAR)
0 DECAL SET Comment: (GRAY 30)(1999/2000 MODEL YEARS) 37-803642A03 37-803642A01, 37-803642A99 (GRAY 30)(1999/2000 MODEL YEARS)
0 DECAL SET Comment: (GRAY 40)(1999/2000 MODEL YEARS) 37-803643A03 37-803643A01, 37-803643A99 (GRAY 40)(1999/2000 MODEL YEARS)
0 DECAL SET Comment: (GRAY 40 BIGFOOT)(1999/2000 MODEL YEARS) 37-803645A01 37-803645A99 (GRAY 40 BIGFOOT)(1999/2000 MODEL YEARS)
0 DECAL SET Comment: (GRAY 30)(2001 MODEL YEAR) 37-803642A03 37-803642A01, 37-803642A99 (GRAY 30)(2001 MODEL YEAR)
0 DECAL SET Comment: (GRAY 40)(2001 MODEL YEAR) 37-803643A03 37-803643A01, 37-803643A99 (GRAY 40)(2001 MODEL YEAR)
0 DECAL SET Comment: (GRAY 40 BIGFOOT)(2001 MODEL YEAR) 37-803645A01 37-803645A99 (GRAY 40 BIGFOOT)(2001 MODEL YEAR)
0 DECAL SET Comment: (TRACKER 30) 37-803946A99
0 DECAL SET Comment: (TRACKER 40) 37-803947A99
0 DECAL, EPA Label Information Comment: (1999) 37-856985A22 37-856985 22 (1999)
0 DECAL, EPA Label Information Comment: (2000) 37-804654A00
0 DECAL, EPA Label Information Comment: (2001) 37-804654A01

Starter Motor

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Below is the parts list for Mercury 40 (4-STROKE) Starter Motor:

Mercury 40 (4-STROKE) Starter Motor Diagram
Position No. Part Name OEM Number Supersedes
1 STARTER MOTOR ASSEMBLY Comment: (NUT DESIGN) 50-893887T 50-888160T, 50-884045T, 50-859170T 1 (NUT DESIGN)
1 STARTER MOTOR ASSEMBLY Comment: (RETAINING RING DESIGN) 50-893887T 50-888160T, 50-884045T, 50-859170T 1 (RETAINING RING DESIGN)
2 THRU BOLT 10-965661
3 DRIVE KIT Comment: (NUT DESIGN) 891752 90643 4 (NUT DESIGN)
4 DRIVE KIT Comment: (RETAINING RING DESIGN) 803945
5 ARMATURE Comment: (RETAINING RING DESIGN) 8236382
5 ARMATURE Comment: (NUT DESIGN) 8236384
6 PINION 68575T2
7 DRIVE CAP 8236392
8 CAP, Commutator 8119011
9 BRUSH/SPRING KIT 898265016 75384, 75384 1
10 HOLDER 898265014 61787
11 SCREW F15158
12 DECAL, Warning, High Voltage 37-8272822

Steering Arm

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Below is the parts list for Mercury 40 (4-STROKE) Steering Arm:

Mercury 40 (4-STROKE) Steering Arm Diagram
Position No. Part Name OEM Number Supersedes
1 NUT, (M12) 11-896963 11-859129, 11-90099
2 STRAP 893773002 827923 2, 893773001, 827923 1
3 MOUNT 8M0224385
4 WASHER, (12.80 mm x 24.0 mm x 2.4 mm) Stainless Steel Comment: (BIGFOOT) 12-4002321
5 SCREW, (M6 x 20) Stainless Steel 10-8M0204741
6 BUMPER 8M0156878
7 BUMPER Comment: (BIGFOOT) 8M0156878
8 RING, Retaining 53-89531
9 ARM, Steering 8M0118183
10 BRACKET Comment: (ELECTRIC) 8M0184092
11 TAB WASHER Comment: (ELECTRIC) 14-8M0009820 14-816669F 1 (ELECTRIC)
12 SCREW, (M10 x 30) Comment: (ELECTRIC) 10-4000377
13 BOLT, (M12 x 154) 10-898835001 10-42973
14 SPACER Comment: (SHORT) 23-8279973
14 SPACER Comment: (LONG) 23-8279971
15 SWIVEL TUBE Comment: (SHORT) 8M0219910
15 SWIVEL TUBE Comment: (LONG) 893590T01 826233T 4 (LONG)
16 CABLE ASSEMBLY 84-88238T01
17 CABLE ASSEMBLY, Ground 8M0207768
18 SCREW, (M10 x 105) Hex Flange - Stainless Steel 10-823567105 10-817430105
19 BRACKET 893703 828985
20 SCREW, (#10-16 x .380) 10-878607 10-817626
21 NUT, (M10) 11-40140
22 NUT, (.375-24) Comment: (HANDLE) 11-8M0204726
23 LEVER Comment: (HANDLE) 823792
24 WASHER Comment: (HANDLE) 12-29330
25 ROD (THREADED) Comment: (HANDLE) 821961
26 BRAKE PLATE Comment: (HANDLE) 821957
27 DISC Comment: (HANDLE) 8165621
28 PLATE Comment: (HANDLE) 8M0007471 823791 (HANDLE)
29 DISC Comment: (HANDLE) 8165621
30 SHOULDER SCREW, Hex Comment: (HANDLE) 10-768042

Swivel Bracket

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Below is the parts list for Mercury 40 (4-STROKE) Swivel Bracket:

Mercury 40 (4-STROKE) Swivel Bracket Diagram
Position No. Part Name OEM Number Supersedes
1 ATTACHING KIT, Engine Steering Comment: (ELECTRIC NON HANDLE) 19608A14
2 SCREW, (.375-24 x 1.500) Comment: (ELECTRIC NON HANDLE) 10-823919
3 WASHER, (.390 x .546 x .12) Comment: (ELECTRIC NON HANDLE) 12-8M0109680
4 WASHER, (.390 x .625 x .062) Stainless Steel Comment: (ELECTRIC NON HANDLE) 12-37828
5 NUT, (.375-24) Stainless Steel Comment: (ELECTRIC NON HANDLE) 11-8M0204726
6 PUCK Comment: (ELECTRIC NON HANDLE) 822397
7 BUSHING 23-8217711
8 SWIVEL BRACKET 1401-850066T01 1401-850066A 1
9 BEARING 23-19606
10 FITTING, Grease Comment: (QTY. OF 3 REQUIRED ON HANDLE VERSIONS) 22-8M0169589
11 DECAL, Co-Pilot 37-8237011
12 NOT SOLD SEPARATE, Decal-Serail Overlaminate NSS
13 BUSHING (LOWER) 23-821777
14 SEAL 26-8M0205512
15 SCREW, (M8 x 10) Stainless Steel Comment: (HANDLE) 10-4008910
15 SCREW, (M8 x 25) Stainless Steel Comment: (ELECTRIC) 10-40011149
16 SEAL Comment: (ELECTRIC) 8282451

Tiller Handle

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Below is the parts list for Mercury 40 (4-STROKE) Tiller Handle:

Mercury 40 (4-STROKE) Tiller Handle Diagram
Position No. Part Name OEM Number Supersedes
1 COVER KIT 822148T06 822148A 6
2 PULLEY 822150
3 NOT SOLD SEPARATE, Case NSS
4 SCREW, (#10-16 x .500) 10-878608 10-812832
5 CABLE ASSEMBLY, Throttle (30.50 Inches) 4324210
6 CABLE ASSEMBLY, Throttle (41.50 Inches) 4324211
7 SLEEVE, (12.00 Inches) 85-960099
8 SCREW, (M8 x 25 MM) 10-82526225
9 COVER 8M0072298 822407F 1
10 BUSHING 23-821477
11 ARM, Steering Handle 828813T1
- DECAL, Lanyard, Black 37-8M0032728
12 RETAINER 822441
13 SCREW, (M5 x 16) Stainless Steel Comment: (MANUAL) 10-40011107
14 SCREW, (M6 x 25) 10-8M0204707
15 LOCK, Throttle 892995 821971
16 SPRING 24-96203
17 KNOB, Throttle 821972T 821972
18 TILLER TUBE 8M0138696
19 DECAL 37-8242004
20 HANDLE, Throttle 821465
21 GRIP 8M0221732
22 SWITCH, Stop 87-8M0104614 87-823609A14, 87-823609A13
23 SCREW, (M5 x 12) Comment: (MANUAL) 10-82239312
24 WASHER Comment: (MANUAL) 12-8M0214930
25 ALARM Comment: (MANUAL) 84-8M0088388 816492A 8 (MANUAL)
26 CLIP 823687
27 SWITCH, Stop 87-11083A31
28 RETAINER, Brass 8M0032846 12044 1
29 BRACKET, Tiller 821455A4
30 WAVE WASHER 13-826792 13-34678 1, 13-822144
31 BUSHING 23-821477
32 WASHER 12-827314
33 CONDUIT, (.620 Inside Diameter x 3.00 Feet Bulk) 32-828547633
34 TIE STRAP, (8.00 Inches) 54-816311T 54-816311, 54-90077, 54-826785, F1877, F717046-1, F717046, MAF03001, 833188E, 54-F9301, 54-816311100, 54-898101111, 54-898101275
35 NOT SOLD SEPARATE, Decal-Shift (F-N-R) NSS
36 LANYARD ASSEMBLY 15920Q54
37 SCREW, (M8 x 35) Stainless Steel 10-40011151
38 HANDLE 830180A01 830180
39 BUSHING 23-830181
40 SHIFT ROD 8301821
41 TAB WASHER 14-8M0009820 14-816669F 1
42 SCREW, (M10 x 90) 10-82484890

Tools

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Below is the parts list for Mercury 40 (4-STROKE) Tools:

Mercury 40 (4-STROKE) Tools Diagram
Position No. Part Name OEM Number Supersedes
24 HEAT LAMP 91-63209
25 BEARING, Thrust 31-85560
26 REMOVER TOOL, Bearing 91-13779
- PULLER KIT, Bearing 91-31229A7
27 NOT SOLD SEPARATE, Expanding rod Comment: (P/N-CG-41-11) NSS
28 NOT SOLD SEPARATE, Collet Comment: (P/N-CG-41-14) NSS
29 NUT, (.625-18) 11-24156
30 WASHER 12-34961
31 PLATE 91-29310
32 SHAFT 91-31229
33 WRENCH TOOL, Driveshaft Bearing 91-36571T
34 DRIVER ROD TOOL, Needle Bearings 91-37323
35 MANDREL 91-15755T
36 DRIVE HEAD TOOL 91-36569T
37 PULLER 91-27780
38 PULLER PLATE 91-37241
39 DRIVER HEAD TOOL 91-37312T
40 INSTALLER TOOL, Needle Bearing 91-817011T 91-817011
41 HOLDING TOOL, Driveshaft 91-83180M
42 INSTALLER TOOL, Oil Seal 91-825197T 91-825197
43 INSTALLER TOOL, Seal 91-817007T 91-817007
44 MANDREL 91-825198
45 PILOT 91-825199
46 HOOK TOOL, Spring 91-825200A1
47 INSTALLER TOOL, Bearing 91-826872
48 TESTER KIT FT8950
49 LOCATION TOOL, Pinion 91-12349A05
50 INSTALLATION TOOL, Bearing 91-13945
51 DRIVER TOOL, Oil Seal 91-13949
52 RACE TOOL, Bearing 91-14308T02
53 INSTALLATION TOOL, Bearing 91-14309T02
54 WEAR SLEEVE INSTALLATION TOOL 91-14310T1
55 PRE LOAD TOOL, Bearing 91-14311A04
56 INDICATOR TOOL, Backlash 91-8M0053505 91-78473
57 MANDREL, Bearing Driver Cup 91-31106T
58 DRIVER, Oil Seal 91-31108T
59 PULLER ASSEMBLY, Slide Hammer 91-34569A1
60 PULLER JAW ASSEMBLY 91-46086A1
61 MANDREL 91-37350T
62 HOLDING TOOL, Driveshaft 91-56775T
63 DIAL INDICATOR TOOL 91-58222A1
64 PULLER TOOL 91-85716
65 ADAPTER KIT, Dial Indicator 91-83155
66 PULLER ASSEMBLY 91-83165T
67 INSTALLATION TOOL, Bearing 91-856875A1
1 FLUSHING ATTACHMENT 44357Q2
2 PUMP ASSEMBLY, Crankcase Oil 802889Q1
3 WRENCH, Oil Filter 91-802653Q02 91-802653Q 1
4 HOLDER TOOL, Flywheel 91-8M0161873
5 FLYWHEEL PULLER 91-83164M
6 TIMING LIGHT 91-99379
7 ADAPTOR TOOL, Direct Voltage 91-890451
8 TACH MULTI METER 91-854009A3
9 DIGITAL DIAGNOSTIC TESTER 91-823686A2
10 CARTRIDGE 91-8226086
11 HARNESS ASSEMBLY, Adaptor 84-822560A7
12 HARNESS ASSEMBLY, Adaptor 84-822560A10
13 GAUGE TOOL, Carburetor 91-36392
14 REMOVER TOOL, Valve Guide 91-809495001 91-809495A 1
15 INSTALLER TOOL, Valve Guide Bushing 91-809496A1
16 REAMER TOOL, Valve Guide 91-809497A1
17 COMPRESSOR TOOL, Valve Spring 91-809494A1
18 NOT SOLD SEPARATE, Valve Seat Cutter Kit Comment: (OBTAIN LOCALLY) NSS
19 COMPRESSOR TOOL, Piston Ring FT2997 FJ7081, FJ8785, FJ8786, FJ8787, FJ8788, FJ8789
20 STAND TOOL, Powerhead 91-827001A1
21 EXPANDER TOOL, Piston Ring 91-24697
22 SPANNER WRENCH 91-74951
23 DOWN PRESSURE KIT 91-822778A3

Top Cowl

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Below is the parts list for Mercury 40 (4-STROKE) Top Cowl:

Mercury 40 (4-STROKE) Top Cowl Diagram
Position No. Part Name OEM Number Supersedes
1 TOP COWL ASSEMBLY Comment: (MANUAL - BLACK) 102-834785T17 102-834785T 5 (MANUAL - BLACK)
1 TOP COWL ASSEMBLY Comment: (MANUAL - SILVER) 102-834785T6
2 TOP COWL ASSEMBLY Comment: (ELECTRIC - BLACK) 102-834785T22 102-834785T 7 (ELECTRIC - BLACK)
2 TOP COWL ASSEMBLY Comment: (ELECTRIC - SILVER) 102-834785T8
3 NOT SOLD SEPARATE, Induction Insert NSS
4 LATCH Comment: (BLACK) 826291F1
4 LATCH Comment: (SILVER) 826291F1
5 SCREW, (M4 x 14.5) 10-8231871
6 LOCKWASHER, Stainless Steel 8,13-26995
7 NUT, (M4) 11-8237515
8 SEAL 8M0153618
9 SOUND BLANKET KIT 834786A04 834786A 3
10 NOT SOLD SEPARATE, Sound Blanket-Top Comment: (ELECTRIC) NSS
11 NOT SOLD SEPARATE, Sound Blanket-Top Comment: (MANUAL) NSS
12 BRACKET ASSEMBLY, Latch Roller 893763 18173
13 SCREW, (M6 x 16) 10-4006731
14 BRACKET 8M0038412 822426 1
15 SCREW, (M4 x 14.5) 10-8231871
16 LOCKWASHER, Stainless Steel 8,13-26995
17 NUT, (M4) 11-8237515
18 ROPE AND HANDLE KIT, Manual Starting 47341A11

Transom Bracket

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Below is the parts list for Mercury 40 (4-STROKE) Transom Bracket:

Mercury 40 (4-STROKE) Transom Bracket Diagram
Position No. Part Name OEM Number Supersedes
1 BRACKET ASSEMBLY, Transom Comment: (PORT) 3418-822866T04 3418-822866A 1 (PORT)
1 CLAMP BRACKET ASSEMBLY Comment: (PORT - MANUAL LONG BIGFOOT) 3420-8M0084195 3420-822868A 1 (PORT - MANUAL LONG BIGFOOT)
2 FITTING, Grease 22-8M0169588
3 PIN, Groove 17-99604
4 BRACKET, Transom Comment: (STARBOARD) 3418-822865T05 3418-822865F 2 (STARBOARD)
4 CLAMP BRACKET Comment: (PORT - MANUAL LONG BIGFOOT) 3419-822867F1
5 LEVER ASSEMBLY, Tilt Lock 893704T01 19618A 2
6 SPRING 24-99622
7 NYLINER 23-65830
8 SPRING 24-812708
9 KNOB 812709 812709T, 812709F 1
10 PIN, Groove 17-99615
11 WASHER 12-19619
12 BRACKET, Anchor 18486F5
13 ANODE KIT 97-818298Q1
14 SCREW, (M6 x 25) 10-8M0204707
15 WASHER, (.281 x .500 x .060) Stainless Steel 12-8M0204649
16 SCREW, (M8 x 30) Comment: (30 MM) 10-4000354
16 SCREW, (M8 x 35) Comment: (35 MM) 10-4000355
17 LOCKWASHER, (M8) 13-400257
18 NUT, (M8) Stainless Steel 11-401388
19 PIN ASSEMBLY, Tilt Lock Comment: (NON POWER TRIM) 17-8M0026068 17-49930A 1 (NON POWER TRIM)
20 SPRING Comment: (NON POWER TRIM) 24-821461
21 TILT TUBE 8M0041938 8M0035070, 19614 1
22 NUT, (7/8-14) 11-858869 11-30499
23 SEAL KIT Comment: (NON-HANDLE) 19624A1
24 O-RING, (.583 x .103) Comment: (NON-HANDLE) 25-29619
25 SPACER Comment: (NON-HANDLE) 23-78861
26 CLIP Comment: (POWER TRIM) 54-22740
27 C WASHER Comment: (POWER TRIM) 8M0084613 69205 (POWER TRIM)
28 SCREW, (#10-16 x .600) Comment: (POWER TRIM) 10-878609 10-812832 1 (POWER TRIM)
29 SCREW, (.500-20 x 4.00) 10-814259
30 WASHER, (1.5 x 3.05 x 0.13) Stainless Steel 12-8M0204648
31 NUT, (.500-20) 11-82671117
32 LINK Comment: (NON POWER TRIM) 8M0084737
33 LEVER ASSEMBLY, Tilt Comment: (NON POWER TRIM) 19615A05
34 BUSHING Comment: (NON POWER TRIM) 23-812707 23-71984, 23-F286818, 23-F286828, F480818 (NON POWER TRIM)
35 WASHER, (.520 x .850 x .060) Nylon - Black Comment: (NON POWER TRIM) 12-8M0042643 12-19605 (NON POWER TRIM)
36 WAVE WASHER Comment: (NON POWER TRIM) 13-99611
37 TILT KNOB Comment: (NON POWER TRIM) 8M0007469 19621 (NON POWER TRIM)
38 SCREW, (.375-16 x .62) Comment: (NON POWER TRIM) 10-19611
39 SCREW, (M10 x 40) Stainless Steel 10-4009040
40 WASHER 12-4002319
41 NUT, (M10) 11-40140
42 DECAL, Tilt Lock 37-830253 37-814743 3, 37-826546
43 THUMB SCREW ASSEMBLY Comment: (MANUAL BIGFOOT) 10-818883A1
44 WASHER Comment: (MANUAL BIGFOOT) 12-818884
45 SHOULDER SCREW, Hex Comment: (MANUAL BIGFOOT) 10-768042
46 NOT SOLD SEPARATE, Handle Comment: (MANUAL BIGFOOT) NSS
47 NOT SOLD SEPARATE, Rivet Comment: (MANUAL BIGFOOT) NSS
48 NOT SOLD SEPARATE, Decal-Warning Comment: (MANUAL BIGFOOT) NSS

Trim Switch Kit

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Below is the parts list for Mercury 40 (4-STROKE) Trim Switch Kit:

Mercury 40 (4-STROKE) Trim Switch Kit Diagram
Position No. Part Name OEM Number Supersedes
- SWITCH KIT, Trim (10.00 Feet) 87-18286A18
1 RETAINER 18861
2 ADAPTOR 814820 812978
3 NOT SOLD SEPARATE, Switch NSS
4 FUSE, 20 Ampere 88-8M0207796
5 CABLE ASSEMBLY 84-95084A2
6 CABLE ASSEMBLY, (6.00 Inches) 84-11149A2
7 SCREW, (#10-32 x 2.25) 10-19209
7 SCREW, (#10-16 x 2.25) 10-813523

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For Mercury Owners:

To assist you in maintaining and repairing your marine engines, we hope the following resources may be of use:

About JLM Marine

Founded in 2002, JLM Marine has established itself as a dedicated manufacturer of high-quality marine parts, based in China. Our commitment to excellence in manufacturing has earned us the trust of top marine brands globally.

As a direct supplier, we bypass intermediaries, which allows us to offer competitive prices without compromising on quality. This approach not only supports cost-efficiency but also ensures that our customers receive the best value directly from the source.

We are excited to expand our reach through retail channels, bringing our expertise and commitment to quality directly to boat owners and enthusiasts worldwide.

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