Mercury 40 LIGHTNING (International) (0N000001 THRU 0N056164) Outboard Motor Parts Diagram & Catalog – Free PDF Download

by JLM Marine 30 Apr 2025 0 Comments

Mercury 40 LIGHTNING (International) Outboard Motor Parts Diagram & Catalog – Free PDF Download

Accessories

Below is the parts list for Mercury 40 LIGHTNING (International) Accessories:

Position No.	Part Name	OEM Number	Supersedes
1	SINGLE REMOTE CONTROL Comment: (Trim In Handle)	8M0223091
1	REMOTE CONTROL Comment: (No Trim)	8M0046402	802616A02 (No Trim)
2	SCREW	10-853989
3	SPACER	23-853990
4	WASHER	12-853991
5	NUT, (M6) Stainless Steel	11-400212
6	TERMINAL EYE	85-8539921
7	E RING	53-160572
8	GROMMET	25-853993
-	CAP (No Trim)	853741
-	METER/SENDER KIT, Trim	802611A2
9	TRIM METER KIT	802611A1
10	BULB	88-802612
11	DAMPER	802613
12	BRACKET	802614
13	INSULATED WASHER	12-802615
14	WASHER	12-16335
15	LOCKWASHER	13-168181
16	NUT	11-802617
17	SENDER, Trim	851875
18	CLAMP	54-17169
19	SCREW	10-8555445
20	BOLT	10-16705	10-95302
21	WASHER, Stainless Steel	12-953921
22	LEAD WIRE	84-8M0078284	84-802998A 2
23	TOOL KIT	91-802618
24	ROPE	50-12066Q10
25	FLUSH PLUG	168411
26	TEMPERATURE GAUGE, Water	79-804632T01	79-804632A 1
27	BULB	88-804634
28	DAMPER	802613
29	BRACKET	804635
30	NUT	11-802617
31	LOCKWASHER	13-168181
32	SENSOR, Water Temperature	804636
33	LEAD WIRE	84-804637
34	HOUSING KIT, XL Extension	8M0127367
-	MANIFOLD ASSEMBLY, Intake	802810A1
-	STARTER MOTOR KIT	8M0188346
-	TACHOMETER	79-804375A1
-	RECTIFIER KIT	888768
-	CAP (No Trim)	853741

Air Silencer

Below is the parts list for Mercury 40 LIGHTNING (International) Air Silencer:

Position No.	Part Name	OEM Number	Supersedes
1	AIR SILENCER Comment: (Lightning)	855556
1	AIR SILENCER Comment: (Lightning XR/50)	8555561
2	LOCK PLATE	855557
3	SCREW, (M5 x 16)	10-855558
4	COVER	855559
5	SEAL, Rubber	26-855560
6	SCREW, Tapping	10-162572
7	C-LINK	8M0163143
8	ROD, Snap	16333
9	STOPPER (Electric)	855562
10	LINK ROD	855563001	855563
11	CAP	855564
12	CAP	853745
13	NUT	11-16081
14	ROD	8555611
15	ROD, Snap	16333
16	BUSHING	23-851858005	23-16176 3
17	KNOB, Choke	8M0155127
18	O-RING Comment: (Lightning)	25-161783
18	GASKET Comment: (Lightning XR/50)	27-802807
-	REPAIR KIT, Carburetor	853780A2
-	GASKET SET, Powerhead Comment: SN# 0N016161 & Below	27-8M0081614	27-8M0062092, 27-8M0047034, 27-812937A03, 27-812937A02, 27-812937A98 SN# 0N016161 & Below
-	GASKET SET, Powerhead Comment: SN# 0N016162 & Up	27-8M0081614	27-8M0062092, 27-8M0047034, 27-812937A03, 27-812937A02, 27-812937A98 SN# 0N016162 & Up

Bottom Cowl

Below is the parts list for Mercury 40 LIGHTNING (International) Bottom Cowl:

Position No.	Part Name	OEM Number	Supersedes
1	BOTTOM COWL Comment: (Black)	2189-8537773
1	BOTTOM COWL Comment: (Gray)	2189-8537774
2	MOUNT, Rubber	23-8537437
3	GROMMET	25-16823
4	GROMMET (Manual)	25-162263
5	GROMMET (Non-Oil Injection)	25-16226
6	PILOT LAMP (Oil Injection)	804057
7	GROMMET	25-16226
8	GROMMET	25-8518502
9	GROMMET	25-8518503
10	GROMMET	25-162284
11	PLUG	19-855549
12	BRACKET	8518364
13	SCREW	10-823042075	10-851866 5
14	LOCKWASHER	13-168181
15	BOLT	10-8248324
16	GROMMET (Handle)	25-8518506
16	GROMMET (Remote Control)	25-8518504
17	SWITCH (Power Trim)	87-851883
18	BOLT, (M6 x 12) (Power Trim)	10-8230427
19	GROMMET (Power Trim)	25-953871
20	GROMMET (Manual Tilt)	25-8518507
21	BOLT (Manual Tilt)	10-168288
22	GROMMET (Manual Tilt)	25-16226
23	BOLT	10-16830
24	LOCKWASHER, (M6)	13-400256
25	WASHER	12-161404
26	SPACER	23-853715007
27	WASHER	12-953922
28	WAVE WASHER	13-16221
29	COVER HOOK	8M0146267
30	BOLT	10-8230427
31	LOCKWASHER, (M6)	13-400256
32	WASHER, Stainless Steel	12-953921
33	HOOK LEVER Comment: (Black)	162184
33	HOOK LEVER Comment: (Gray)	162185
34	SEAL	26-16219
35	BUSHING	23-16220
36	CLAMP (Power Trim)	54-813275
37	BOLT (Power Trim)	10-162231
38	LANYARD SWITCH (Handle)	87-804051A1
39	LANYARD (Handle)	823054
40	GROMMET	25-8518505
41	MAIN SWITCH (Electric)	87-804052A1
42	KEY (Electric) Comment:	802989,301,301	804053 (#301)
42	KEY (Electric) Comment:	8029891,302,302
42	KEY (Electric) Comment:	8029892,303,303
43	NEUTRAL SWITCH (Electric)	87-8M0127937
44	WASHER (Electric)	12-9539211
45	CLAMP (Electric)	54-813275
46	BOLT (Handle)	10-162231

Carburetor

Below is the parts list for Mercury 40 LIGHTNING (International) Carburetor:

Position No.	Part Name	OEM Number	Supersedes
1	CARBURETOR Comment: (Upper) (Lightning)	3303-853720A10	3303-853720A 2 (Upper) (Lightning)
1	CARBURETOR Comment: (Upper) (Lightning XR/50)	3303-853720A09	3303-853720A 5 (Upper) (Lightning XR/50)
2	CARBURETOR Comment: (Center) (Lightning)	3303-853720A11	3303-853720A 3 (Center) (Lightning)
2	CARBURETOR Comment: (Center) (Lightning XR/50)	3303-853720A6
3	CARBURETOR Comment: (Lower) (Lightning)	3303-853720A13	3303-853720A 4 (Lower) (Lightning)
3	CARBURETOR Comment: (Lower) (Lightning XR/50)	3303-853720T12	3303-853720A 7 (Lower) (Lightning XR/50)
4	JET, Main Comment: (Lightning)	122,162503
4	JET, Main Comment: (Upper/Center-Lightning XR/50)	132,803883
4	JET, Main Comment: (Lower-Lightning XR/50)	135,162504
5	JET, Pilot Comment: (Lightning)	66,162513
5	JET, Pilot Comment: (Lightning XR/50)	80,803689	16251 4 (Lightning XR/50)
6	PLUG	19-855566
7	FLOAT NEEDLE	162545
8	PIN	17-162561
9	FLOAT	162532
10	SCREW	10-8536981
11	SCREW (Upper Carburetor)	10-8M0054702
12	SPRING, (11 mm) (Upper Carburetor)	24-162641
13	SCREW, Idle Adjusting	10-8129355
14	SPRING, (11 mm)	24-162641
15	FLOAT BOWL (Upper/Center Carburetor)	162583
15	FLOAT BOWL (Lower Carburetor)	162584
16	GASKET	27-855567
17	SCREW	10-162603
18	SCREW, Drain	10-8M0054703	10-16261 3
19	GASKET	27-8M0224378
20	MAIN NOZZLE Comment: (Lightning)	8126502
20	MAIN NOZZLE Comment: (Lightning XR/50)	812650018
21	COVER, Carburetor	8555401
22	GASKET	27-8555412
23	SCREW	10-809571003	10-855542 1
24	COVER (Lower Carburetor)	855568	803693
25	SCREW (Lower Carburetor)	10-8M0062252
26	GASKET (Lower Carburetor)	27-855569
27	CHECK VALVE (Lower Carburetor)	21-851812
28	SCREW (Lower Carburetor)	10-851813
29	NUT (Lower Carburetor)	11-851814
30	DIAPHRAGM (Lower Carburetor)	8537312
31	GASKET (Lower Carburetor)	27-8555691
32	HOUSING, Pump (Lower Carburetor)	8537291
-	REPAIR KIT, Carburetor	853780A2

Crankshaft, Piston and Connecting Rods

Below is the parts list for Mercury 40 LIGHTNING (International) Crankshaft, Piston and Connecting Rods:

Position No.	Part Name	OEM Number	Supersedes
1	CRANKSHAFT ASSEMBLY	400-8M0046560	474-9614T02
2	BEARING, Ball	30-16049T02
3	GEAR, Drive	43-855552
4	C CLIP	53-853714	53-803676
5	PIN, Piston	41-880810
6	CONNECTING ROD	629-880855
7	BEARING, Needle	31-880856
8	WASHER	12-880857
9	PISTON Comment: (Standard)	779-9615T02
9	PISTON Comment: (.5 Oversize)	96162
10	RING SET, Piston Comment: (Standard)	39-16054A5
10	RING SET, Piston Comment: (.5 Oversize)	39-16055A5
11	PIN, Piston	41-803680003
12	CLIP	53-160571
13	THRUST RING	853712
14	KEY	28-160531
15	BEARING, Main (Upper)	31-855553
16	SEAL, Oil	26-803879
17	O-RING	25-855554004	25-855554
18	BEARING, Needle	31-8130483
-	POWERHEAD ASSEMBLY Comment: (Lightning)	8M0146290
-	POWERHEAD ASSEMBLY Comment: (Lightning XR/50)	8M0147022
-	GASKET SET, Powerhead Comment: SN# 0N016161 & Below	27-8M0081614	27-8M0062092, 27-8M0047034, 27-812937A03, 27-812937A02, 27-812937A98 SN# 0N016161 & Below
-	GASKET SET, Powerhead Comment: SN# 0N016162 & Up	27-8M0081614	27-8M0062092, 27-8M0047034, 27-812937A03, 27-812937A02, 27-812937A98 SN# 0N016162 & Up

Cylinder Block

Below is the parts list for Mercury 40 LIGHTNING (International) Cylinder Block:

Position No.	Part Name	OEM Number	Supersedes
1	CYLINDER BLOCK Comment: (Lightning)	878-8M0082197	878-815013A11 (Lightning)
1	CYLINDER BLOCK Comment: (Lightning XR/50)	878-8M0082198	878-815013A 4 (Lightning XR/50)
2	BOLT	10-166951
3	WASHER	12-4002217
4	PIN, Dowel	17-16119
5	PIN, Dowel	17-9521812
6	BLEED VALVE Comment: SN# 0N009618 & Below	21-853696
6	NIPPLE Comment: SN# 0N009619 & Up	22-812960006
7	HOSE, (160 mm) Comment: SN# 0N009618 & Below	32-8M0057112
7	HOSE, Rubber with Arrow (730mm) Comment: SN# 0N009619 & Up	32-898101272
8	HOSE, Rubber (1 Meter) Comment: SN# 0N009618 & Below	32-8M0057112
8	HOSE, Rubber with Arrow (730mm) Comment: SN# 0N009619 & Up	32-898101272
9	HOSE, Rubber (1 Meter) Comment: SN# 0N009618 & Below	32-8M0057112
9	HOSE, Rubber with Arrow (730mm) Comment: SN# 0N009619 & Up	32-898101272
10	CLIP	54-95224
11	CYLINDER HEAD Comment: SN# 0N016162 & Up	979-96305
11	CYLINDER HEAD Comment: SN# 0N016161 & Below	979-96305
12	GASKET Comment: SN# 0N016162 & Up	27-8M0062091	27-812939 10 SN# 0N016162 & Up
12	GASKET Comment: SN# 0N016161 & Below	27-8M0062091	27-812939 10 SN# 0N016161 & Below
13	COVER	8M0231776
14	GASKET Comment: SN# 0N016162 & Up	27-8M0115016	27-812939 11 SN# 0N016162 & Up
14	GASKET Comment: SN# 0N016161 & Below	27-8129394
15	BOLT	10-8M0106717	10-8M0068940, 10-16698 2
16	WASHER	12-8M0106725	12-8M0106719, 12-8M0065568, 12-16238 1
17	BOLT	10-166953
18	WASHER	12-809931044	12-809931042, 13-815064, 12-95222
19	THERMOSTAT	8537041
20	COVER	8537051
21	GASKET	27-8537024
22	BOLT	10-823042
23	PLUG	19-855549
24	ANODE	97-823913Q	823913, 95271
25	BOLT, (M6 x 20)	10-167051
26	LIFTING EYE	8M0137792
27	BOLT	10-168304
28	WASHER	12-4002217
29	END CAP, Lower	1100-8537131
30	O-RING	25-8537091
31	SEAL, Oil	26-8M0056308
32	SEAL, Oil	26-8537078
33	BOLT, (M6 x 20)	10-167051
34	COVER, Exhaust	8M0081401	853706 1
35	COVER, Exhaust	8537062
36	GASKET	27-812939020	27-812939017, 27-812939 5
37	BOLT	10-8150683
38	WASHER	12-809931044	12-809931042, 13-815064, 12-95222
39	NIPPLE	22-898101961	22-812960 3
40	LINE, Fuel (1000 mm)	32-8M0057113	32-879194470, 32-95394 9
41	GROMMET (Electric)	25-855551
42	SPARK PLUG Comment: (Lightning)(NGK-B7HS-10)	33-8M0181925
42	SPARK PLUG, (NGK# BR7HS-10) Comment: (Lightning)(NGK-BR7HS-10)	33-8M0181925
42	PLUG Comment: (Lightning XR/50)(NGK-B8HS-10)	33-8M0181926
42	SPARK PLUG Comment: (Lightning XR/50)(NGK-BR8HS-10)	33-8M0181926
43	CLAMP	54-813275
44	BOLT	10-162231
45	COVER PLATE (Manual)	803992
46	GASKET (Manual)	27-8M0081613	27-855569004, 27-855569 2
47	SCREW (Manual)	10-162233
48	PIN, Dowel Comment: SN# 0N016162 & Up	17-16119
-	POWERHEAD ASSEMBLY Comment: (Lightning)	8M0146290
-	POWERHEAD ASSEMBLY Comment: (Lightning XR/50)	8M0147022
-	GASKET SET, Powerhead Comment: SN# 0N016161 & Below	27-8M0081614	27-8M0062092, 27-8M0047034, 27-812937A03, 27-812937A02, 27-812937A98 SN# 0N016161 & Below
-	GASKET SET, Powerhead Comment: SN# 0N016162 & Up	27-8M0081614	27-8M0062092, 27-8M0047034, 27-812937A03, 27-812937A02, 27-812937A98 SN# 0N016162 & Up

Driveshaft Housing

Below is the parts list for Mercury 40 LIGHTNING (International) Driveshaft Housing:

Position No.	Part Name	OEM Number	Supersedes
1	HOUSING, Driveshaft, Long Comment: (Black-Short)	1500-8M0077334	1599-812943 5 (Black-Short)
1	HOUSING, Driveshaft, Short Comment: (Black-Long/X-Long)	1599-8M0090843
1	HOUSING, Driveshaft Comment: (Gray-Long)	1599-8129434
2	BOLT	10-8M0054995	10-16126 4
3	WASHER	12-16192
4	SPLASH PLATE Comment: (Black)	851856T01	851856 1 (Black)
4	SPLASH PLATE Comment: (Gray)	8518562
5	GROMMET	25-851850
6	SCREW	10-898103237
7	WASHER, Stainless Steel	12-8M0108373
8	NUT	11-815057
9	SEAL, Rubber	8M0147035
10	GASKET	27-812939022	27-812939 6
11	PLATE, Exhaust Comment: (Black)	851852
11	PLATE, Exhaust Comment: (Gray)	8518521
12	GASKET	27-812939024	27-812939021, 27-812939016, 27-812939 7
13	SEAL, Rubber	8518511
14	BOLT	10-823042
15	PIN, Dowel	17-16119
16	EXTENSION, Exhaust	851853
17	BOLT	10-82304211
18	GASKET	27-812939019	27-812939 8
19	TUBE, Exhaust	851854
20	BOLT	10-82304211
21	GASKET	27-812939023	27-812939 9
22	GROMMET	25-8518501
23	HOUSING, Extension (X-Long)	853783003
24	BOLT (X-Long)	10-879194274	10-823042 12
25	RETAINER (X-Long)	853794
26	STOPPER (X-Long)	8107532
27	BOLT (X-Long)	10-8230427
28	SEAL (X-Long)	26-8537074
-	GASKET SET, Powerhead Comment: SN# 0N016161 & Below	27-8M0081614	27-8M0062092, 27-8M0047034, 27-812937A03, 27-812937A02, 27-812937A98 SN# 0N016161 & Below
-	GASKET SET, Powerhead Comment: SN# 0N016162 & Up	27-8M0081614	27-8M0062092, 27-8M0047034, 27-812937A03, 27-812937A02, 27-812937A98 SN# 0N016162 & Up
-	GASKET SET, Lower Unit	27-851887A08	27-851887A07, 27-851887A98

Electrical Components

Below is the parts list for Mercury 40 LIGHTNING (International) Electrical Components:

Position No.	Part Name	OEM Number	Supersedes
1	CD UNIT	16061005
2	O-RING	25-8M0127927
3	COIL, Ignition	16064006
4	BOOT, With Resistance	85-855543
5	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
6	BOLT, (M6 x 20)	10-167051
7	GASKET	27-851834
8	BRACKET, Electrical	8M0123143
9	COVER	851835
10	SCREW	10-8555442
11	MOUNT, Rubber	23-8537437
12	GROMMET	25-8518153
13	SPACER	23-853715007
14	BOLT	10-162232
15	WASHER	12-161404
16	FUSE	88-8538141
17	BOLT	10-953965
18	CLAMP (Electric)	54-813275
19	BOLT (Electric)	10-95396
-	GASKET SET, Powerhead Comment: SN# 0N016161 & Below	27-8M0081614	27-8M0062092, 27-8M0047034, 27-812937A03, 27-812937A02, 27-812937A98 SN# 0N016161 & Below
-	GASKET SET, Powerhead Comment: SN# 0N016162 & Up	27-8M0081614	27-8M0062092, 27-8M0047034, 27-812937A03, 27-812937A02, 27-812937A98 SN# 0N016162 & Up

Electrical Components(Electric Models)

Below is the parts list for Mercury 40 LIGHTNING (International) Electrical Components(Electric Models):

Position No.	Part Name	OEM Number	Supersedes
1	RECTIFIER	853811003	853811 2
2	SCREW	10-8555443
3	SOLENOID ASSEMBLY, Choke	853829A1
4	PLUNGER	853830
5	SCREW	10-162454
6	BRACKET	8M0098603	851836 3
7	SCREW	10-162233
8	HOOK	8555615
9	PIN, Dowel	17-952189
10	HARNESS ASSEMBLY	84-85374011
11	WIRE, Fuse	84-8537406
12	SOLENOID SWITCH	87-851839
13	SOLENOID SWITCH	87-8518391
14	CABLE	84-8537407
15	CABLE, Black	84-8537408
16	CABLE	84-8537409
17	CABLE	84-85374010
18	CAP	85-8538161
19	BOLT, (M6 x 12)	10-8230427
20	BUZZER ASSEMBLY, Overheat Comment: (Lightning XR/50)	802808A1
21	SENSOR ASSEMBLY, Overheat Comment: (Lightning XR/50)	802809A1
22	STOPPER Comment: (Lightning XR/50)	8107532
23	BOLT Comment: (Lightning XR/50)	10-167051
24	HARNESS ASSEMBLY (Handle)	84-85374012

Flywheel

Below is the parts list for Mercury 40 LIGHTNING (International) Flywheel:

Position No.	Part Name	OEM Number	Supersedes
1	FLYWHEEL	262-8150242
2	PLATE ASSEMBLY, Coil	8M0109038
3	TRIGGER	160663
4	PULSE HOLDER	8537381
5	STATOR	160582
6	SCREW	10-8230318
7	COIL, Charger (Set)	160742
8	SCREW	10-8230318
9	WIRE GUIDE	8537382
10	SCREW	10-8M0135299
11	CLAMP	54-851817
12	SCREW	10-8230314
13	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
14	TIMING PLATE	8537101
15	GUIDE PLATE	853711
16	BOLT	10-166954
17	LOCKWASHER	13-16818
18	SHIM Comment: (.15)	15-8537951
18	SHIM Comment: (.20)	15-8537952
18	SHIM Comment: (.25)	15-8537953
19	SCREW	10-8555441
20	NUT	11-851832
21	WASHER	12-8539911

Fuel Line

Below is the parts list for Mercury 40 LIGHTNING (International) Fuel Line:

Position No.	Part Name	OEM Number	Supersedes
1	FILTER ASSEMBLY, Fuel	35-8M0088825	35-853733T03, 35-853733T02, 35-853733A 2, 35-898101T68
2	CUP	8537351
3	O-RING	25-851815
4	FILTER	35-8537331
5	O-RING	25-8518151
6	NUT	11-400213
7	WASHER	12-16192
8	CHECK VALVE (Oil Injection)	21-8518121
9	LINE, Fuel (1000 mm) (Oil Injection)	32-8M0057113	32-879194470, 32-95394 9
10	LINE, Fuel (1000 mm) (Oil Injection)	32-8M0057113	32-879194470, 32-95394 9
11	LINE, Fuel (1000 mm) (Oil Injection)	32-8M0057113	32-879194470, 32-95394 9
12	HOSE, (80 mm) (Oil Injection)	32-8M0057113	32-879194470, 32-95394 9
13	CLIP, Stainless Steel (Oil Injection)	54-95395
14	CONNECTOR, Fuel	22-853736
15	NUT	11-17480
16	CLIP, Stainless Steel (Non-Oil Injection)	54-95395
17	LINE, Fuel (1000 mm) (Non-Oil Injection)	32-8M0057113	32-879194470, 32-95394 9
18	LINE, Fuel (1000 mm) (Non-Oil Injection)	32-8M0057113	32-879194470, 32-95394 9
-	GASKET SET, Powerhead Comment: SN# 0N016161 & Below	27-8M0081614	27-8M0062092, 27-8M0047034, 27-812937A03, 27-812937A02, 27-812937A98 SN# 0N016161 & Below
-	GASKET SET, Powerhead Comment: SN# 0N016162 & Up	27-8M0081614	27-8M0062092, 27-8M0047034, 27-812937A03, 27-812937A02, 27-812937A98 SN# 0N016162 & Up

Fuel Tank(Plastic- 6.6 Gallon)

Below is the parts list for Mercury 40 LIGHTNING (International) Fuel Tank(Plastic- 6.6 Gallon):

Position No.	Part Name	OEM Number	Supersedes
1	TANK ASSEMBLY, Fuel - Plastic 6.6 Gallon	1259-859063A1
2	GAUGE/CAP ASSEMBLY	823536
3	CONNECTOR KIT, Fuel	22-8M0175545
4	O-RING	25-823533	25-18471
5	SCREEN	35-823534	35-18029
6	HOSE ASSEMBLY, Fuel	32-858610A37	32-858610A16, 32-16789A42
7	CLAMP	54-853798
8	CONNECTOR, Fuel	22-8M0120628
9	BULB ASSEMBLY, Primer	13330Q07
10	CHECK VALVE ASSEMBLY (Inlet)	21-13331A3
11	CHECK VALVE ASSEMBLY (Outlet)	21-13331A4
12	CLAMP, Nylon (Large)	54-4158210
13	CLAMP, Nylon (Small)	54-41582Q7
14	CONNECTOR, (.250-18)	22-89771Q2
15	CLAMP, Nylon	54-41582Q7

Gear Housing(Driveshaft)

Below is the parts list for Mercury 40 LIGHTNING (International) Gear Housing(Driveshaft):

Position No.	Part Name	OEM Number	Supersedes
-	GEAR HOUSING ASSEMBLY, Complete Comment: (Black-Short)	1668-8M0046098	1668-825132A24, 1668-825132A14 (Black-Short)
-	GEAR HOUSING ASSEMBLY, Complete Comment: (Black-Long)	1668-825132T39	1668-825132T25, 1668-825132A25, 1668-825132A12 (Black-Long)
-	GEAR HOUSING ASSEMBLY, Complete Comment: (Gray-Long)	1668-825132A13
0	GEAR HOUSING ASSEMBLY, Complete Comment: (Black-X-Long)	825132A18
1	GEAR HOUSING ASSEMBLY, Basic Comment: (Black Short and Long)	1600-8M0127360
1	GEAR HOUSING ASSEMBLY, Basic Comment: (Gray Short and Long)	1668-825132A11
1	GEAR HOUSING ASSEMBLY, Basic Comment: (X/Long)	1600-8M0127361
2	BEARING, Needle	31-8130487
3	BOLT	10-879194274	10-823042 12
4	SCREW, Drain	22-8M0229353
5	GASKET	27-95220
6	STRAINER, Water (Set)	853763003	853763 1
7	SCREW	10-8555444
8	NUT	11-85372216
9	STRAINER, Water	8537632
10	BOLT	10-8248324
11	SCREW, Drain	22-953682
12	GASKET	27-95220011
13	DRIVESHAFT Comment: (Short)	45-161366
13	DRIVESHAFT Comment: (Long)	45-161365
13	DRIVESHAFT Comment: (X-Long)	45-16136007
14	BEARING, Ball	30-161283
15	SPRING	24-953836
16	GEAR, Pinion	43-16138004
17	NUT	11-85372217
18	SHIM Comment: (.1)	15-8M0224379
18	SHIM Comment: (.3)	15-851855003
18	SHIM Comment: (.5)	15-851855005
19	IMPELLER	47-161542
20	KEY	28-161551
21	HOUSING, Upper Water Pump	46-161563
22	INSERT	161573
23	GASKET	27-16158017
24	GUIDE PLATE	851857
25	GASKET	27-8M0155405
26	HOUSING, Water Pump Lower	46-8260532
27	PIN, Dowel	17-952188
28	SEAL, Oil	26-8537079
29	SHIM	15-8537954
30	O-RING	25-16131
31	BOLT	10-879194276	10-823042 14
32	SEAL	26-161682
33	TUBE, Water Comment: (Short)	32-161705
33	TUBE, Water Comment: (Long)	32-161704
33	TUBE, Water Comment: (X-Long)	32-16170007
34	SEAL	26-161712
35	COLLAR	23-9528615
36	SEAL	26-8537074
37	CAM	8M0172382
38	PIN	17-16179
39	CAM ROD Comment: (Short)	161865
39	CAM ROD Comment: (Long)	161863
39	CAM ROD Comment: (X-Long)	16186006
40	BUSHING	23-161762
41	O-RING	25-161772
42	O-RING	25-161782
43	STOPPER	8107532
44	BOLT	10-8230427
45	CONNECTOR	851859
46	PIN, Dowel	17-952189
-	GASKET SET, Lower Unit	27-851887A08	27-851887A07, 27-851887A98
-	REPAIR KIT, Water Pump	853792A10	853792A 3

Gear Housing, Propeller Shaft

Below is the parts list for Mercury 40 LIGHTNING (International) Gear Housing, Propeller Shaft:

Position No.	Part Name	OEM Number	Supersedes
-	GEAR HOUSING ASSEMBLY, Complete Comment: (Black-Short)	1668-8M0046098	1668-825132A24, 1668-825132A14 (Black-Short)
-	GEAR HOUSING ASSEMBLY, Complete Comment: (Black-Long)	1668-825132T39	1668-825132T25, 1668-825132A25, 1668-825132A12 (Black-Long)
-	GEAR HOUSING ASSEMBLY, Complete Comment: (Gray-Long)	1668-825132A13
-	GEAR HOUSING ASSEMBLY, Complete Comment: (Black-X-Long)	825132A18
1	GEAR HOUSING ASSEMBLY, Basic Comment: (Black Short and Long)	1600-8M0127360
1	GEAR HOUSING ASSEMBLY, Basic Comment: (Gray)	1668-825132A11
1	GEAR HOUSING ASSEMBLY, Basic Comment: (X/Long)	1600-8M0127361
47	BEARING, Needle	31-8130488
48	GEAR, Forward	43-8129442
49	SHIM Comment: (.3)	15-851860003
49	SHIM Comment: (.15)	15-851860015
49	SHIM Comment: (.1)	15-851860001
50	PROPELLER SHAFT	44-195132
51	CLUTCH	52-812946003	52-812946 2
52	PIN, Clutch	17-161502
53	SPRING	24-8126456
54	SPRING	24-176673
55	HOLDER, Spring	8537641
56	BALL, Steel	30-161322
57	FOLLOWER, Cam	161521
58	CARRIER ASSEMBLY, Bearing Comment: (Black)	8M0119562
58	CARRIER ASSEMBLY, Bearing Comment: (Gray)	825119A4
59	BEARING, Needle	31-8130487
60	SEAL, Oil	26-161302
61	BEARING, Ball	30-161323
62	O-RING	25-161312
63	GEAR, Reverse	43-8129453
64	WASHER	12-161408
65	BOLT	10-8M0086977	10-16263010
66	WASHER, Stainless Steel	12-16826
67	THRUST HUB	161453
68	PROPELLER Comment: (12.5 - Standard 40 Lightning)	48-802621005	48-802621 2 (12.5 - Standard 40 Lightning)
68	PROPELLER Comment: (14.5)	48-802621003	48-802621 (14.5)
68	PROPELLER Comment: (13.5 - Standard 40 Lightning XR/50)	48-802621004	48-802621 1 (13.5 - Standard 40 Lightning XR/50)
68	PROPELLER Comment: (11)	48-802628002	48-802628 (11)
68	PROPELLER Comment: (10)	48-802628003	48-802628 1 (10)
-	RUBBER HUB	8M0075316
69	THRUST HUB (Rear)	851861
70	WASHER	12-161409
71	PROP NUT	11-161472
72	COTTER PIN	18-8150265
73	TRIM TAB	853762	853762 1
74	BOLT, (M6 x 20)	10-167051
-	GASKET SET, Lower Unit	27-851887A08	27-851887A07, 27-851887A98

Inlet Manifold and Reed Block

Below is the parts list for Mercury 40 LIGHTNING (International) Inlet Manifold and Reed Block:

Position No.	Part Name	OEM Number	Supersedes
1	MANIFOLD ASSEMBLY, Inlet Comment: (Lightning)	853717A2
1	MANIFOLD ASSEMBLY, Inlet Comment: (Lightning XR/50)	853717A3
2	GASKET	27-8M0047033	27-855555001, 27-855555
3	BOLT	10-168286
4	REED BLOCK Comment: (Lightning)	8537191
4	REED BLOCK Comment: (Lightning XR/50)	8537192
5	LINE, Fuel (1000 mm)	32-8M0057113	32-879194470, 32-95394 9
6	LINE, Fuel (1000 mm)	32-8M0057113	32-879194470, 32-95394 9
7	CLIP, Stainless Steel	54-95395
8	BOLT, (M6 x 85)	10-855809003	10-16329002
9	WASHER	12-809931044	12-809931042, 13-815064, 12-95222
10	LOCKWASHER	13-16818
11	CLAMP	54-813275
12	SCREW	10-95314
13	SCREW	10-8230317
-	POWERHEAD ASSEMBLY Comment: (Lightning)	8M0146290
-	POWERHEAD ASSEMBLY Comment: (Lightning XR/50)	8M0147022
-	GASKET SET, Powerhead Comment: SN# 0N016161 & Below	27-8M0081614	27-8M0062092, 27-8M0047034, 27-812937A03, 27-812937A02, 27-812937A98 SN# 0N016161 & Below
-	GASKET SET, Powerhead Comment: SN# 0N016162 & Up	27-8M0081614	27-8M0062092, 27-8M0047034, 27-812937A03, 27-812937A02, 27-812937A98 SN# 0N016162 & Up

Manual Tilt

Below is the parts list for Mercury 40 LIGHTNING (International) Manual Tilt:

Position No.	Part Name	OEM Number	Supersedes
1	GRIP	8M0183798
2	BUTTON	8M0051399	853776
3	SHAFT/BOLT, Reverse Lock Lever	10-803790001	804049
4	WASHER	12-16192
5	LEVER, Tilt Stopper	804048
6	WASHER, Stainless Steel	12-953921
7	SPRING	24-8040246
8	LINK	804050
9	SHAFT, Reverse Lock	804046
10	E RING	53-160572
11	SPRING	24-953832
12	STOP	853774
13	BRACKET	8251131
14	STOPPER, Tilt	8M0230676
15	PIN, Spring	17-9521813
16	SET PLATE	879194006	16210 1
17	BOLT	10-8230426
18	SPRING Comment: (Short)	24-8040244
18	SPRING Comment: (Long)(X-Long)	24-8040245
19	ROD, Reverse Lock	804047
20	LOCK, Reverse (Starboard)	804044
21	ARM, Reverse Lock	804045004	804045
22	LOCK, Reverse (Port)	8040441
23	COTTER PIN	18-8150261

Oil Injection Components

Below is the parts list for Mercury 40 LIGHTNING (International) Oil Injection Components:

Position No.	Part Name	OEM Number	Supersedes
1	PUMP ASSEMBLY, Oil	851840A1
2	O-RING	25-8518154
3	BOLT	10-851841
4	WASHER	12-953927
5	BOLT	10-8M0098600
6	LOCKWASHER, (M6)	13-400256
7	GEAR, Driven	43-8555521
8	BUSHING	23-851858
9	SNAP, Link Rod	163332
10	LINK ROD	8M0079379	855561 4
11	NUT	11-16081
12	CAP	853745
13	TANK, Oil	1270-851842
14	GROMMET	25-8518153
15	SPACER	23-853715007
16	MOUNT, Rubber	23-8537437
17	BOLT	10-162232
18	WASHER	12-161404
19	CAP	36-851843
20	GASKET	27-851844
21	HOOK	851845	851845002
22	CHECK VALVE	21-8518122
23	SENSOR	851846
24	FILTER ASSEMBLY, Oil	35-851847A1
25	CUP	8537351
26	O-RING	25-851815
27	FILTER	35-8518471
28	O-RING	25-8518151
29	NUT	11-400213
30	WASHER	12-16192
31	TUBING	32-8518481
32	TUBING, (1 Meter)	32-8518481
33	CLIP	54-8M0129429
34	TUBING, (230 mm)	32-8518482
35	CLIP	54-803525005	54-851849

Power Trim

Below is the parts list for Mercury 40 LIGHTNING (International) Power Trim:

Position No.	Part Name	OEM Number	Supersedes
1	STOP, Tilt Comment: (Black)	8251123
1	STOP, Tilt Comment: (Gray)	8251124
2	GRIP	16208
3	COLLAR	23-9528616
4	BOLT	10-8M0062251	10-823042 16
5	WASHER	12-168261
6	SPRING	24-953837
7	POWER TRIM ASSEMBLY Comment: (See Breakdown on Power Trim Components)	851873A1
8	PIN, Upper Cylinder	17-8M0115482
9	SLEEVE	23-8113682
10	BUSHING	23-161765
11	BOLT, (M6 x 14)	10-16223
12	WASHER	12-898101937	12-16238
13	PIN, Lower Cylinder	17-8518741
14	COLLAR	23-9528617
15	SLEEVE	23-8113682
16	BUSHING	23-16176011
17	NUT	11-85372219
18	WASHER	12-8M0060184	12-8M0060183, 12-851868 1
19	CLAMP	54-17169
20	SCREW	10-8555445

Power Trim Components

Below is the parts list for Mercury 40 LIGHTNING (International) Power Trim Components:

Position No.	Part Name	OEM Number	Supersedes
-	POWER TRIM ASSEMBLY	851873A1
1	MOTOR	8276751
2	BOLT	10-8518662
3	COLLAR	23-9528620
4	RELIEF VALVE (Down)	827672A2
5	O-RING	25-161314
6	PUMP	8276741
7	O-RING	25-161314
8	BOLT	10-8518663
9	BOLT	10-8518664
10	FILTER	35-851876
11	DRIVE JOINT	851877
12	O-RING	25-161315
13	RELIEF VALVE (Up)	827672A3
14	O-RING	25-8555541
15	O-RING	25-161316
16	FILTER	851878
17	VALVE SEAT ASSEMBLY	851879A1
18	O-RING	25-161317
19	O-RING	25-161318
20	VALVE SEAL ASSEMBLY	851879A2
21	O-RING	25-161317
22	O-RING	25-161318
23	SPOOL	851880
24	BACKUP RING	851881
25	SPRING	24-851882
26	ROD ASSEMBLY, Trim Piston	827670T03	827670A 3
27	O-RING	25-8555542
28	O-RING	25-8555543
29	BACKUP RING	8518811
30	PISTON	8276761
31	O-RING	25-8555543
32	BACKUP RING	8518811
33	WASHER	12-953929
34	COLLAR	23-9528618
35	SPRING	24-8518821
36	O-RING	25-161319
37	O-RING	25-8126411
38	MANUAL VALVE	8134421
39	C RING	53-953451
40	PLUG	19-8555491
41	O-RING	25-1613110

Recoil Starter

Below is the parts list for Mercury 40 LIGHTNING (International) Recoil Starter:

Position No.	Part Name	OEM Number	Supersedes
1	STARTER ASSEMBLY, Recoil	8M0225922
2	BUSHING	23-8518583
3	SLIDING PLATE	804026
4	SPRING, Starter	24-804024
5	REEL	804022
6	WASHER	12-9539212
7	C RING	53-804027
8	SPRING, Return	24-8040242
9	RATCHET	804023
10	SPRING, Friction	24-8040241
11	SLIDING PLATE	8040261
12	FRICTION PLATE	804025
13	BOLT	10-162637
14	ROPE, Starter	50-804028
15	HANDLE, Starter	804029
16	GUIDE	8M0054758
17	BOLT	10-162636
18	STOPPER, Reel	804031
19	ARM, Stopper	804032
20	SPRING, Stopper	24-8040243
21	WASHER	12-9539213
22	COTTER PIN	18-81502611
23	WIRE	84-85374013
24	HOLDER, Cable	804033
25	SCREW	10-804034
26	SLEEVE	23-8113683
27	SCREW, (M6 x 25)	10-8M0204707
28	LOCKWASHER, (M6)	13-400256
29	SCREW, (M6 x 25)	10-8M0204707
30	WASHER, Stainless Steel	12-16826
31	COLLAR, (9.3 mm)	23-8M0021168	23-95286 24
32	LOCK ARM, Starter	804036
33	PULLEY, Starter	8M0231222
34	BOLT	10-168307
35	LOCKWASHER, (M6)	13-400256

Remote Control Components

Below is the parts list for Mercury 40 LIGHTNING (International) Remote Control Components:

Position No.	Part Name	OEM Number	Supersedes
-	SINGLE REMOTE CONTROL	8M0223091
1	CAP	802977
2	PLUG	19-802978
3	GRIP	802974
4	LEVER, Control	802973
5	SCREW	10-823042067
6	NEUTRAL LOCK ARM	802975
7	SPRING	24-802976
8	SCREW	10-823042067
9	WASHER	12-8029651
10	DECAL	37-802987
11	SCREW, Adjusting	10-802986
12	WASHER	12-8029652
13	E RING	53-160572
14	COVER	802985
15	DETENT PLATE	802971
16	ROLLER	8029691
17	RETAINER	802972
18	SCREW	10-163341
19	BUSHING	23-8029633
20	THRUST PLATE	802968
21	GEAR, Drive	802967
22	BOLT	10-171741
23	NUT, Stainless Steel	11-16081
24	ROLLER	802969
25	ARM, Throttle	8M0135304
26	BUSHING	23-8029631
27	DRUM	802982
28	WAVE WASHER	13-8029661
29	SCREW	10-953861
30	BOLT	10-802979
31	WASHER	12-16192
32	REAR PANEL	802984
33	HOUSING, Rear	802980
34	SPRING	24-8029761
35	RETAINER	802983
36	ROLLER	8029692
37	SCREW	10-163341
38	BUSHING	23-8029632
39	FRICTION ARM, Throttle	802964
40	WAVE WASHER	13-802966
41	WASHER	12-802965
42	SHIFT GEAR	802962
43	BUSHING	23-802963
44	BOLT	10-95386
45	LEVER	8M0085508	802981
46	BUSHING	23-8029634
-	SINGLE REMOTE CONTROL	8M0223091
1	SCREW	10-8555446
2	SWITCH COVER	802995
3	SWITCH ASSEMBLY, Power Trim And Tilt	87-802994A1
4	NEUTRAL SWITCH	87-802997A1
5	SCREW	10-8555447
6	OVERHEAT BUZZER	802808A1
7	CABLE ASSEMBLY, Red (Red)	84-802998A1
8	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
9	SWITCH	87-802988A1
10	KEY Comment:	802989,301,301	804053 (#301)
10	KEY Comment:	8029891,302,302
10	KEY Comment:	8029892,303,303
11	COVER	802990
12	SAFETY SWITCH	87-802992A1
13	LANYARD	823054
14	HARNESS ASSEMBLY	84-802991A1

Service/Support Material

Below is the parts list for Mercury 40 LIGHTNING (International) Service/Support Material:

Part Name	OEM Number	Supersedes
PARTS MANUAL, 40 Lightning/40 Lightning XR40 Seapro/Marathon/50 International	90-80263898
DECAL SET Comment: (40 Black Lightning)	37-855973A98
DECAL SET Comment: (40 Gray Lightning)(1998-2000)	37-855975A01	37-855975A98, 37-856926 (40 Gray Lightning)(1998-2000)
DECAL SET Comment: (40 Black Lightning XR) (Sheet of 4 Decals)	37-856927
DECAL SET Comment: (40 Gray Lightning XR)(Sheet of 4 Decals)(1998-2000)	37-855975A01	37-855975A98, 37-856926 (40 Gray Lightning XR)(Sheet of 4 Decals)(1998-2000)
DECAL SET Comment: (40 Black Lightning XR)(2000)	37-877864A00
DECAL SET Comment: (All Gray 40)(2001/2002)	37-855975A01	37-855975A98, 37-856926 (All Gray 40)(2001/2002)
DECAL SET Comment: (Gray 40)(2003 and Above)	37-855975A03
DECAL SET Comment: (Gray 40 Lightning)(2003 and Above)	37-888722A03
DECAL SET Comment: (SeaPro 40)	37-892639A04
DECAL, Gang Run Comment: (Marathon 40)	37-858842001
NOT SOLD SEPARATE (50)(Decals not required-Military Only)	NSS
DECAL, Shift (F-N-R) Comment: (Gray)	37-87819110
DECAL, Shift (F-N-R) Comment: (Black)	37-85926610

Shift Components

Below is the parts list for Mercury 40 LIGHTNING (International) Shift Components:

Position No.	Part Name	OEM Number	Supersedes
1	SHIFT ROD	161864
2	LEVER, Shift Rod	161843
3	SHIFT ARM	851862
4	BUSHING	23-163361
5	WAVE WASHER	13-8537234
6	CLIP	54-851863
7	STOPPER	24-8M0138736
8	BOLT	10-8107551
9	CLAMP	8M0138737
10	SHIFT SHAFT	851865
11	WASHER	12-953925
12	CLIP	54-851863
13	SOCKET, Cable Joint	8M0079131	853745003, 853745 2
14	WASHER	12-953925
15	COTTER PIN	18-8150262
16	LEVER, Shift (Handle)	804037
17	SEAL (Handle)	26-16219

Starter Motor

Below is the parts list for Mercury 40 LIGHTNING (International) Starter Motor:

Position No.	Part Name	OEM Number	Supersedes
1	STARTER MOTOR ASSEMBLY	50-853805A3
2	PINION	8M0188338
3	WASHER	12-953926
4	HOLDER, Brush	8M0135544
5	SCREW	10-16821
6	BUSHING	23-8M0135546
7	O-RING	25-161784
8	BUSHING	23-8M0135545
9	WASHER, Stainless Steel	12-16826
10	LOCKWASHER, (M6)	13-400256
11	NUT, (M6) Stainless Steel	11-400212
12	BOLT	10-162632
13	LOCKWASHER	13-16079
14	WASHER	12-160721
15	SOLENOID, Starter	89-853809T	89-853809
16	SCREW	10-162233
17	BRACKET	8518362
18	BOLT	10-162234
19	COVER	851838
20	BOLT	10-823042073	10-898101955
21	BRACKET	851836
22	BRACKET	8518361
23	BOLT	10-823042073	10-898101955
24	BOLT	10-8230426
25	SCREW, (M6 x 25)	10-8M0204707
26	WASHER, Stainless Steel	12-953921
27	COLLAR	23-9528613
28	WASHER, Rubber	12-953923
29	MOUNT, Rubber	851837
30	CABLE	84-8537403
31	CAP	85-8538161
32	WIRE, Battery	84-8M0069792	84-853740 4
33	CAP	85-853816
34	BOLT	10-8230427
35	CLAMP	54-813275
36	BOLT	10-162231

Steering Drag Link Components

Below is the parts list for Mercury 40 LIGHTNING (International) Steering Drag Link Components:

Position No.	Part Name	OEM Number	Supersedes
-	DRAG LINK KIT, Steering	853824A2
1	CAP	853825
2	ROD, Drag Link	8538241
3	COLLAR	23-9528621
4	WASHER	12-9539210
5	NUT, Nylon	11-161473
6	COLLAR	23-9528622
7	BOLT	10-8518666
8	COTTER PIN	18-8150267
9	SOCKET, Cable Joint	8M0079131	853745003, 853745 2
10	WASHER	12-953925
11	COTTER PIN	18-8150262

Steering Handle

Below is the parts list for Mercury 40 LIGHTNING (International) Steering Handle:

Position No.	Part Name	OEM Number	Supersedes
1	HANDLE, Steering	803996
2	DECAL, Throttle	37-804020
3	GRIP	160861
4	SCREW	10-8150461
5	BUSHING	23-8518582
6	BUSHING	23-8518581
7	WAVE WASHER	13-804017
8	WASHER	12-804508	12-804016
9	HOLDER ASSEMBLY, Steering Handle	8M0077708
10	STUD	16-879194300	16-811653 3
11	WASHER	12-168261
12	NUT	11-85372215
13	WIRE, Throttle	84-804018001	84-804018
14	FRICTION PIECE	813026	16337
15	SCREW, Adjusting	10-16087
16	WASHER, Stainless Steel	12-16826
17	NUT, (M6) Stainless Steel	11-400212
18	SHAFT, Throttle	803998
19	BUSHING	23-16336
20	SPACER	23-16191
21	SPACER	23-8537152
22	COTTER PIN	18-8150263
23	BRACKET, Support	804055
24	BOLT, (M6 x 12)	10-8230427
25	STUD	16-8116541
26	WASHER	12-16192
27	NUT, Nylon	11-95374
28	BRACKET, Steering	804019005	804019
29	BOLT	10-162636
30	SCREW	10-85554410
31	WASHER, Stainless Steel	12-953921
32	CLAMP	54-953951
33	BOLT, (M6 x 12)	10-8230427
34	BRACKET, Throttle Link	8537392
35	BOLT	10-16223
36	WASHER, Stainless Steel	12-16826
-	HANDLE KIT	803996T09	803996A 1

Throttle Linkage

Below is the parts list for Mercury 40 LIGHTNING (International) Throttle Linkage:

Position No.	Part Name	OEM Number	Supersedes
1	ARM, Actuator	853742003	853742 1
2	BOLT	10-16201
3	WASHER	12-161404
4	COLLAR	23-9528612
5	BOLT	10-16830
6	NUT, (M6) Stainless Steel	11-400212
7	CAM, Throttle Comment: (Lightning XR/50)	8537501
7	CAM, Throttle Comment: (Lightning)	8537502
8	LEVER, Advancer	803156
9	BOLT	10-4000333
10	SPRING, Throttle Cam	24-803157
11	WASHER, Stainless Steel	12-953921
12	COLLAR	23-9528613
13	BALL JOINT	853744001	853744
14	LOCKWASHER, (M6)	13-400256
15	L-LINK	8M0054756	855561 2
16	L-LINK	8555616
17	CAP	853745
18	NUT	11-16081
19	SNAP, Link Rod	163332
20	SOCKET, Cable Joint	8M0079131	853745003, 853745 2
21	WASHER	12-953925
22	COTTER PIN	18-8150262
23	ARM, Throttle Stop (Handle)	803993
24	SCREW, (M6 x 25) (Handle)	10-8M0204707
25	WASHER, Stainless Steel (Handle)	12-16826
26	COLLAR, (9.3 mm) (Handle)	23-8M0021168	23-95286 24
27	S-LINK (Handle)	803994
28	SNAP, Link Rod (Handle)	803995

Tools

Below is the parts list for Mercury 40 LIGHTNING (International) Tools:

Position No.	Part Name	OEM Number	Supersedes
1	TOOL	91-8539966
2	TOOL	91-8539968
3	SNAP TOOL, Clutch Pin	91-80313314
4	COLLAR	23-9528623
5	O-RING	25-161773
6	MEASURING TOOL SHAFT	91-80313310
7	PULLER TOOL, Bearing	91-8M0050354	91-803133 11
8	WASHER	12-1614011
9	NUT	11-85372221
10	CLAMP TOOL, Backlash Measuring	91-80313312
11	BOLT	10-803134
12	PLATE TOOL, Dial Gauge	91-80313313
13	PULLER TOOL, Bearing	91-8M0060180	91-853996 4
14	NUT	11-85372220
15	WASHER	12-1614010
16	FLANGE	91-8031332
17	STOPPER TOOL, Shaft	91-8031338
18	SHAFT	91-8031333
19	GUIDE TOOL	91-8031334
20	RETAINER TOOL	91-8031335
21	FLANGE	91-8031336
22	STOPPER TOOL, Shaft	91-8031339
23	GUIDE TOOL	91-8031337
24	WRENCH TOOL	91-85399612
25	SOCKET TOOL	91-8031331
26	WRENCH TOOL	91-8M0101491	91-803133 15
27	INSTALL/REMOVER TOOL, Piston Pin	91-8539962
28	INSTALLER TOOL, Piston Ring	91-803133
29	FLYWHEEL PULLER KIT	91-804761
-	TOOL, Bearing Outer Press Rod	91-895212
-	TOOL, Bearing Outer Press Plate	91-895213
-	TOOL, Bearing Outer Press Guide	91-895214
-	TOOL, Bevel Gear A Set	91-895215001
-	TOOL, Conedisk Spring, D=12	91-895217
-	TOOL, Shimming Gauge	91-895218001
-	TOOL, Thickness Gauge	91-895219
-	TOOL	91-8M0059838	91-804552001
-	TOOL, Flywheel Stripper	91-8M0059838	91-804552001

Top Cowl

Below is the parts list for Mercury 40 LIGHTNING (International) Top Cowl:

Position No.	Part Name	OEM Number	Supersedes
1	TOP COWL ASSEMBLY Comment: (Black-Electric 40)	100-8M0069515	2189-853778A13, 2189-853778A 3 (Black-Electric 40)
1	TOP COWL ASSEMBLY Comment: (Silver-Electric 40)	100-8M0069534
1	TOP COWL ASSEMBLY Comment: (Black-Electric-Un-Decaled)	100-8M0069515	2189-853778A13, 2189-853778A 3 (Black-Electric-Un-Decaled)
1	TOP COWL ASSEMBLY Comment: (Silver-Electric-Un-Decaled)	2189-853778A14	2189-853778A 4 (Silver-Electric-Un-Decaled)
2	TOP COWL ASSEMBLY Comment: (Black-Manual 40)	100-8M0128853
2	TOP COWL ASSEMBLY Comment: (Silver-Manual 40)	100-8M0128854
2	TOP COWL ASSEMBLY Comment: (Black-Manual-Un-Decaled)	100-8M0128853
2	TOP COWL ASSEMBLY Comment: (Silver-Manual-Un-Decaled)	100-8M0128854
3	SEAL	8M0094876
4	CAP, Cowl Comment: (Black-Electric)	8537793
4	CAP, Cowl Comment: (Silver-Electric)	8537794
4	CAP, Cowl Comment: (Black-Manual)	8M0129135
4	CAP, Cowl Comment: (Silver Manual)	8M0129136
5	NUT, (M6) Stainless Steel	11-400212
6	WASHER, Stainless Steel	12-953921
7	SEAL (Electric)	8518513
8	COVER, Fill Comment: (Black-Electric)	851884
8	COVER, Fill Comment: (Silver-Electric)	8518841
9	HINGE (Electric)	8151051
10	PLATE, Spring (Electric)	851885
11	BOLT, (M6 x 14) (Electric)	10-16223
12	NUT, (M6) Stainless Steel (Electric)	11-400212
13	SEAL, Rubber (Manual)	25-162281

Transom and Swivel Brackets(Manual)

Below is the parts list for Mercury 40 LIGHTNING (International) Transom and Swivel Brackets(Manual):

Position No.	Part Name	OEM Number	Supersedes
1	CLAMP BRACKET Comment: (Starboard)	1400-8M0151529
2	CLAMP BRACKET Comment: (Port)	1400-8M0151531
3	TILT TUBE	898101191	853769
4	CAP NUT (Handle)	11-85372214
5	NUT	11-853722029	11-853722 13
6	BUSHING	23-8537435
7	BUSHING	23-8113681
8	BOLT	10-162638
9	DISTANCE PIECE	804040
10	LOCKWASHER, (M6)	13-400256
11	NUT, (M8) Stainless Steel	11-400213
12	THUMB SCREW ASSEMBLY	10-804042A1
13	PAD	12-95379
14	THRUST ROD	804041
15	SPRING	24-8126455
16	CAP	851872
17	BOLT	10-82304215
18	BOLT	10-8129356
19	LOCKING PLATE, Upper	851871
20	GROMMET	25-851870
21	RUBBER	8M0079616	853771 3
22	SWIVEL TUBE	8M0075036	8M0075085, 853770007, 853770
23	THRUST PLATE, Upper Comment: SN# 0N005308 & Up	162041
23	THRUST PLATE, Upper Comment: SN# 0N005307 & Below	162041
24	BUSHING	23-8537436
25	FRICTION PLATE	162052
26	SWIVEL BRACKET Comment: SN# 0N005308 & Up	3407-813029A12	3407-813029 11 SN# 0N005308 & Up
26	SWIVEL BRACKET Comment: SN# 0N005307 & Below	3407-813029A12	3407-813029 11 SN# 0N005307 & Below
27	SCREW, (M8 x 30)	10-4000354
28	SPRING	24-953831
29	GROUND WIRE	84-898101089	84-803779, 84-853740 1
30	BOLT, (M6 x 12)	10-8230427
31	ANODE	8239121
32	LOCKWASHER, (M6)	13-400256
33	BOLT	10-16830
34	O-RING	25-16109003
35	THRUST PLATE, Lower	16204004
36	BOLT	10-851866012	10-851866 1
37	WASHER	12-953928
38	WASHER	12-851867
39	MOUNT	8M0075315	853771 2
40	WASHER	12-879194343	12-95392014
41	BRACKET	8M0064214	853786007, 853786 2
42	C-RING	53-8537142
43	RUBBER DAMPER	8537732
44	NUT	11-85372218
45	COVER	851869
46	BOLT, (M6 x 20)	10-167051
47	GROUND WIRE	84-8537405
48	WASHER, Stainless Steel	12-16826
49	FITTING, Grease	22-824969
50	CAP	808599
51	ANODE	97-804043
52	BOLT	10-8M0147119

Transom and Swivel Brackets(Power Trim)

Below is the parts list for Mercury 40 LIGHTNING (International) Transom and Swivel Brackets(Power Trim):

Position No.	Part Name	OEM Number	Supersedes
1	BRACKET, Transom - Starboard Comment: (Black)	3406-96224
1	BRACKET, Transom - Starboard Comment: (Gray)	96225
2	BRACKET, Transom - Port Comment: (Black)	3406-96234
2	BRACKET, Transom - Port Comment: (Gray)	3406-803856	3406-879194042 (Gray)
3	BOLT	10-851866
4	NUT	11-853722029	11-853722 13
5	CAP NUT	11-85372214
6	BUSHING	23-161764
7	BUSHING	23-8113681
8	THRUST ROD	161982
9	CLAMP SCREW	10-162635
10	PAD	12-95379
11	SWIVEL BRACKET Comment: (Black)	3407-8130295
11	SWIVEL BRACKET Comment: (Gray)	3407-8130296
12	SWIVEL TUBE Comment: (Black)	8M0075036	8M0075085, 853770007, 853770 (Black)
12	SWIVEL TUBE Comment: (Gray)	8537701
13	BUSHING	23-8537436
14	FRICTION PLATE	162052
15	BOLT	10-8230423
16	SPRING	24-953831
17	THRUST PLATE, Upper	162041
18	THRUST PLATE, Lower	16204004
19	O-RING	25-16109003
20	C-RING	53-8537142
21	FITTING, Grease	22-824969
22	WASHER, Stainless Steel	12-16826
23	CAP	808599
24	MOUNT	8M0075315	853771 2
25	BRACKET Comment: (Black)	8M0064214	853786007, 853786 2 (Black)
25	YOKE, Bottom Comment: (Gray)	8537863
26	RUBBER DAMPER	8537732
27	BOLT	10-851866012	10-851866 1
28	WASHER	12-953928
29	WASHER	12-851867
30	NUT	11-85372218
31	WASHER	12-879194343	12-95392014
32	COVER Comment: (Black)	851869
32	COVER Comment: (Gray)	8518691
33	BOLT, (M6 x 20)	10-167051
34	GROUND WIRE	84-8537405
35	GROUND WIRE	84-898101089	84-803779, 84-853740 1
36	BOLT, (M6 x 12)	10-8230427
37	BOLT (Power Trim)	10-16705	10-95302
37	BOLT, (M6 x 12) (Handle)	10-8230427
38	WASHER, Stainless Steel	12-953921
39	RUBBER	8M0079616	853771 3
40	BOLT	10-8129356
41	GROMMET	25-851870
42	LOCKING PLATE, Upper	851871
43	CAP Comment: (Black)	851872
43	COVER Comment: (Gray)	8518721
44	BOLT	10-82304215
45	ANODE	8239121
46	BOLT	10-162232
47	COTTER PIN	18-8150266
48	BOLT	10-802619
49	WASHER	12-953928
50	WASHER	12-168262
51	NUT	11-802620

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Mercury / Mercruiser / Mariner Parts from JLM Marine

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.