Carburetor Repair Kit – Fits Yamaha/Mercury/Mariner 25HP-40HP 4-Stroke Outboards

Carburetor Repair Kit – Fits Yamaha/Mercury/Mariner 25HP-40HP 4-Stroke Outboards

This carburetor repair kit provides the essential components needed to rebuild and restore the carburetor on Yamaha, Mercury, and Mariner 25HP to 40HP 4-stroke outboard engines. It is designed to fit a wide range of models, primarily from 2001 to 2009, including Yamaha F20A, F25A/E, F30A, F40B, and T25B/T series engines.

This kit is a direct replacement for Yamaha part numbers 65W-W0093-02-00, 65W-W0093-01-00, and 67C-W0093-00-00, as well as Mercury/Mariner part number 8542561, ensuring a precise fit and reliable performance.

• Installation Type: Direct Fit
• Fuel Compatibility: Gasoline
• Complete Service Kit: Includes all necessary gaskets, seals, float, needle valve, and hardware for a full carburetor overall.

Part Number Cross-Reference

Use this table to confirm equivalent part numbers across OEM and aftermarket brands.

Compatible Engine Models

Confirm your engine model/year in the table below. For Yamaha owners, here’s a guide to help you identify your engine’s serial/model: Yamaha Serial Number Guide. You can also review exploded diagrams to verify part numbers: Yamaha Parts Diagrams & Catalog.

For Mercury owners, here’s a guide to help you identify your engine’s serial/model: Mercury Serial Number Guide. You can also review exploded diagrams to verify part numbers: Mercury Parts Diagrams & Catalog.

Technical Specifications

Package Contents

• 1 x Gasket (65W-14126-10-00)
• 1 x Valve, Needle (6AH-14546-00-00)
• 1 x Pin, Float Arm (6H4-14548-00-00)
• 1 x Cover, Plunger Cap (65W-14373-02-00)
• 1 x O-Ring (67C-14397-00-00)
• 1 x Spring, Plunger (65W-14335-00-00)
• 1 x Gasket, Float Chamber (65W-14384-00-00)
• 1 x Gasket (65W-14398-00-00)
• 4 x Screw, With Washer (97980-04114-00)
• 1 x Float (63V-14985-00-00)
• 1 x Clip (633-14159-00-00)

Installation Guide

1. Ensure the engine is off and cool. Disconnect the battery and shut off the fuel supply line.
2. Carefully remove the engine cowling and air silencer box to access the carburetor.
3. Disconnect fuel lines and throttle linkages from the carburetor, noting their positions for reassembly.
4. Unbolt and remove the carburetor from the intake manifold.
5. On a clean workbench, disassemble the carburetor, organizing all parts carefully.
6. Remove and discard the old gaskets, seals, needle valve, and other components included in the new kit.
7. Thoroughly clean all metal carburetor components with a dedicated carburetor cleaner and compressed air.
8. Install the new components from the kit in the reverse order of disassembly.
9. Ensure the new float is correctly aligned and the needle valve moves freely.
10. Reinstall the rebuilt carburetor onto the engine, tightening all bolts to the manufacturer's specifications.
11. Reconnect fuel lines and linkages, open the fuel valve, and prime the system.
12. Start the engine, check for any fuel leaks, and adjust the idle speed as needed.

Troubleshooting & F.A.Q.

Q: How do I confirm this kit fits my outboard?

A: Review the "Compatible Engine Models" section and cross-reference your engine's model, horsepower, and year. Additionally, check your existing carburetor's part number against the numbers listed in our "Part Number Cross-Reference" table to ensure a match.

Q: What are the common signs that my carburetor needs to be rebuilt?

A: Symptoms indicating a need for a rebuild include difficulty starting the engine, rough or unstable idling, stalling at low speeds, fuel leaking from the carburetor body, bogging down on acceleration, or a general loss of performance.

Q: How often should I service my carburetor with a kit like this one?

A: The service interval can vary widely based on hours of use, fuel quality, and storage conditions. It is good practice to consider a rebuild every 2-3 seasons for preventative maintenance or immediately if you notice any performance issues.

Q: OEM vs. Aftermarket?

A: This listing is an aftermarket replacement part (not an OEM component). We build to OEM specifications using comparable-grade materials. Production is done in an ISO9002-certified facility, and each batch is inspected for consistent performance.

Q: How fast do you ship and how much does it cost?

A: We offer fast global shipping—typically 5–15 days worldwide—and standard shipping is free. Expedited options are available at checkout depending on your location.

Q: What is your warranty and return policy?

A: This product includes a 1-year warranty against manufacturing defects under normal use. If something goes wrong, contact our support team with your order details. Returns are accepted within our standard return window (unused & in original condition); please see our policy page or reach out for instructions.

Important Notes

• Verify that the product images and specifications match your original part. If discrepancies exist—even if your model is listed—do not proceed with the purchase.
• This product is an aftermarket replacement part and is not an OEM component.
• Professional installation is recommended to ensure safety and optimal performance.

Why Choose JLM MARINE?

• Quality Assured: As a trusted manufacturer for over 20 years, we supply top marine brands globally.
• Fast Global Shipping: Free delivery worldwide in 5–15 days.
• Direct from Manufacturer: Competitive pricing without compromising quality.