Mercury 115 EFI (4-STROKE) (0T178500 THRU 0T800999) Parts & Diagrams

🔎 Mercury 115 EFI (4-STROKE) Reference Library — Exploded parts diagrams (33 diagrams), specifications, common issues, and maintenance checklist.

The Mercury 115 EFI (4-STROKE) is a 4-Stroke, Inline 4-Cylinder, SOHC, 8-valve outboard motor. Powers center-console boats, larger pontoons, and offshore-capable fishing craft.

Quick Reference Specifications

Specification	Value
Engine Type	4-Stroke, Inline 4-Cylinder, SOHC, 8-valve
Horsepower	115 HP
Displacement	2100 cc (2.1L)
Bore x Stroke	90 mm x 81 mm
Spark Plug (Type & Gap)	NGK SILZKR7B11
Engine Oil Capacity	5.0 L (5.28 qt)
Recommended Engine Oil	Mercury FourStroke Oil 10W-30
Gear Case Oil Capacity	24 fl oz (710 mL)
Idle Speed (in gear)	650 ± 50 RPM (in gear)
Full Throttle RPM Range	5000-6000
Fuel	Unleaded Gasoline, 87 Octane min.

Always verify specifications against your owner's manual for your specific serial number range.

Common Issues & Recommended Parts

Below are common maintenance scenarios for the Mercury 115 EFI (4-STROKE):

Water Pump / Overheating: If the tell-tale stream is weak or absent, the water pump impeller likely needs replacement. Inspect annually or every 100 hours. → Recommended: Water Pump Impeller Kit
Engine Oil / Maintenance Light: 4-stroke engines require regular oil and filter changes. Use marine-grade oil rated for your engine. Change every 100 hours or annually. → Recommended: Oil Filter, Engine Oil
Fuel Injector Issues (EFI models): Rough idle or misfires may indicate clogged fuel injectors. Use fuel stabilizer and clean injectors periodically. → Recommended: Fuel Injector, Fuel Filter
Gear Case Oil Leak: Check lower unit seals if gear oil appears milky (water contamination). Replace seals and gaskets during lower unit service. → Recommended: Lower Unit Seal Kit, Drain Plug Gaskets
Anode Corrosion: Inspect sacrificial anodes regularly, especially in saltwater. Replace when 50% depleted to protect against galvanic corrosion. → Recommended: Zinc/Aluminum Anode Kit

Parts Diagrams & OEM Part Numbers

Expand the sections below to view detailed exploded parts diagrams and find the exact OEM replacement components for your Mercury 115 EFI (4-STROKE).

▶Bottom Cowl (26 parts)

Ref	OEM Part #	Part Name
1	100-878587A1	BOTTOM COWL ASSEMBLY Comment: (Port)
2	100-8M0113913	BOTTOM COWL ASSEMBLY Comment: (Starboard)
3	8M0109217	SEAL, Cowl (41.00 Inches)
4	878547T	INSERT
5	10-82130040	SCREW, (M6 x 40)
6	831209	RETAINER
7	858742	BOOT, Idle Exhaust
8	8M0039078	GROMMET
9	22-827948	FITTING
10	12-855576	WASHER
11	54-816311T	TIE STRAP, (8.00 Inches)
12	32-8M0108355	HOSE, (57.00 Inches Bulk) (Cut To 5.00 Inch Length)
13	32-881535	HOSE, (32.00 Inches)
14	32-9912688	TUBING, (36.00 Inches Bulk) (26.00 Inch)
15	22-817518	TEE
16	10-82130020	SCREW, (M6 x 20)
17	25-889724	GROMMET
18	87-8M0042301	SWITCH ASSEMBLY
19	10-824868	SCREW, (M6 x 75)
20	889740A02	FRONT HANDLE, Black
21	23-33589	BUSHING
22	25-48462	O-RING, (.614 x .070)
23	8219423	PAWL
24	12-69057	WASHER, (.281 x .734 x .063)
25	11-401366	NUT, (M6) Stainless Steel
26	13541	PLUG, Male

▶Crankshaft, Pistons And Connecting Rods (11 parts)

Ref	OEM Part #	Part Name
-	881421T04	POWERHEAD ASSEMBLY Comment: SN# 0T409000 & Up
1	2406-880894T	CRANKSHAFT
2	26-8040992	SEAL, Oil
3	26-8041002	SEAL, Oil
4	31-804101T20	BEARING Comment: (Red)
5	31-804102T30	BEARING Comment: (Red)
6	31-804103T20	BEARING Comment: (Red)
7	2715-880895A16	PISTON ASSEMBLY Comment: (.25MM Oversize)
8	10-880896	BOLT, (M8 x 38)
9	39-880898T02	RING SET, Piston Comment: (.25 MM Oversize)
10	31-880899T30	BEARING Comment: (Red)

▶Cylinder Block (37 parts)

Ref	OEM Part #	Part Name
-	881421T04	POWERHEAD ASSEMBLY Comment: SN# 0T409000 & Up
1	892-881422T05	CYLINDER BLOCK
2	17-82364M	PIN, Dowel
3	27-858732002	GASKET
4	10-8M0101617	BOLT, (M8 x 55)
5	10-804072	BOLT, (M10 x 135)
6	25-855690	GROMMET
7	804073	LIFTING EYE
8	10-8257021	BOLT, (M6 x 20)
9	19-825953	PLUG, (M14 x 12)
10	27-81990M	GASKET
11	35-8M0162830	FILTER, Oil
12	10-804097	BOLT
13	881424T02	COVER, Outer Exhaust
14	27-804076003	GASKET
15	10-881427	BOLT, (M6 x 30)
16	10-881425	SCREW
17	27-881426	GASKET
18	NSS	NOT SOLD SEPARATE, Anode Comment: Order Cover
19	25-804086	GROMMET
20	804085	COVER
21	10-8524741	BOLT, (M6 x 20)
22	10-827207	BOLT, (M8 x 25)
23	25-804082	GROMMET
24	804080001	VALVE, Pressure Control
25	24-804081	SPRING
26	27-804084	GASKET
27	804083001	COVER
28	10-881428	BOLT, (M6 x 16)
29	54-804089	CLIP
30	32-804088	HOSE
31	56762	CLAMP
32	16-8587331	STUD
33	12-8M0214963	WASHER, (.406 x .750 x .105) Stainless Steel
34	11-40140	NUT, (M10)
35	10-81893435	SCREW, (M8 x 35)
36	881600	CAP, Rubber

▶Cylinder Head (32 parts)

Ref	OEM Part #	Part Name
-	881421T04	POWERHEAD ASSEMBLY Comment: SN# 0T409000 & Up
1	881310T08	CYLINDER HEAD ASSEMBLY
2	17-804110	PIN, Guide
3	19-804111	PLUG
4	10-804112	BOLT, (M7 x 48)
5	17-804113	PIN, Dowel
6	10-804114	BOLT, (M7 x 37)
7	10-881311	BOLT, (M10 x 145)
8	23-8M0070515	COLLAR
9	27-8041151	GASKET
10	10-83124714	BOLT
11	12-831246	WASHER, Sealing
12	10-881312	BOLT, (M8 x 55)
13	NSS	NOT SOLD SEPARATE, Anode Comment: Order Cover
14	25-804086	GROMMET
15	804085	COVER
16	10-8524741	BOLT, (M6 x 20)
17	10-827207	BOLT, (M8 x 25)
18	33-881284Q	SPARK PLUG
19	881429	THERMOSTAT
20	8041271	COVER, Thermostat
21	10-8248326	SCREW, (M6 x 25 MM)
22	881313T1	COVER KIT
23	804119	COVER, Breather
24	10-804120	SCREW, (M4 x 8)
25	27-804123	GASKET
26	25-855690	GROMMET
27	10-858530	BOLT, (M6 x 30)
28	859578A1	PLUG ASSEMBLY, Oil
29	NSS	NOT SOLD SEPARATE, O-Ring
30	858752001	COVER
31	10-1993716	SCREW, (M6 x 16)

▶Drive Shaft Housing (22 parts)

Ref	OEM Part #	Part Name
1	1507-858576T2	HOUSING ASSEMBLY, Driveshaft
2	16-9035015	STUD, (M10 x 227) Comment: (X-Long)
3	16-8M0034462	STUD, (M10 x 190) Comment: (X-Long)
4	12-8M0214963	WASHER, (.406 x .750 x .105) Stainless Steel
5	11-40140	NUT, (M10)
6	22-85822A13	PICK UP ASSEMBLY, Speedometer
7	22-433351	CONNECTOR, 90 Degree (.125-27) Nylon
8	22-85822T	CONNECTOR, Straight
9	44343T1	MOUNT
10	10-898835001	BOLT, (M12 x 154)
11	12-30119	WASHER, (.875 Inch Outside Diameter)
12	11-8M0204662	NUT, (M12)
13	88238A10	CABLE ASSEMBLY, Ground
14	10-41508	SCREW, (.250-20 x .500) Stainless Steel
15	858916T	CLAMP
16	10-4010725	SCREW, (M8 x 25)
17	8M0142713	CAP
18	23-859550	BUSHING
19	17-24873	PIN, Alignment
20	22-855622	FITTING
21	12092A3	SPACER KIT Comment: (X-Long)
22	17-43044	PIN, Dowel - Without Hole (.375 x .625) Comment: (X-Long)

▶Electrical Components (51 parts)

Ref	OEM Part #	Part Name
0	891824020	COVER, Fuse Comment: (Green)
1	881363T	COVER
2	84-881364T04	HARNESS ASSEMBLY Comment: SN# 0T408999 & Below
3	88-832969T20	FUSE, 20 Ampere
4	88-8M0057159	FUSE, 30 Ampere
5	804289	PULLER, Fuse
6	881362	BRACKET
7	10-8813511	SCREW
8	881352T	RELAY
9	12-82214M	WASHER
10	13-82212M	LOCKWASHER
11	10-96671M	SCREW
12	85-804284001	BOOT
13	881350T	RELAY
14	10-881351	SCREW
15	54-881353	CLAMP
16	10-8813511	SCREW
17	881359T	BRACKET
18	54-881361	CLAMP
19	54-881360	CLAMP
20	10-804270	BOLT, (M6 x 28)
21	25-881304	GROMMET
22	23-804344003	BUSHING
23	882751A3	RELAY ASSEMBLY Comment: (Design I)
24	84-881357	LEAD WIRE Comment: (Design I)
25	881358	CAP Comment: (Design I)
26	10-8248324	SCREW, (M6 x 16)
27	10-8257021	BOLT, (M6 x 20)
28	10-804604	BOLT, (M6 x 20)
29	84-88439A33	CABLE ASSEMBLY, Positive - Battery
30	84-88439A10	CABLE ASSEMBLY, Negative - Battery
31	11-401388	NUT, (M8) Stainless Steel
32	10-8M0204741	SCREW, (M6 x 20) Stainless Steel
33	84-858723T1	HARNESS ASSEMBLY, Adaptor/Trim
34	84-858914T1	HARNESS ASSEMBLY, Trim Motor Adaptor
35	84-858740T4	HARNESS ASSEMBLY, Adaptor Assembly Remote
36	92753	RETAINER
37	859249T1	CONNECTOR
38	54-816311T	TIE STRAP, (8.00 Inches)
39	37-8272822	DECAL, Warning, High Voltage
40	37-881865	DECAL, Caution-Start in Gear, Start in Gear
41	882751A3	TRIM RELAY KIT Comment: (Design II)
42	84-826802A24	HARNESS ASSEMBLY, Trim Comment: (Design II)
43	8M0207773	RELAY ASSEMBLY Comment: (Design II)
44	25-818967	GROMMET Comment: (Design II)
45	23-8M0214955	BUSHING Comment: (Design II)
46	NSS	NOT SOLD SEPARATE, Decal Comment: (Design II)
47	828102	BRACKET Comment: (Design II)
48	10-824868	SCREW, (M6 x 75) Comment: (Design II)
49	12-8M0214930	WASHER Comment: (Design II)
50	23-823807	BUSHING Comment: (Design II)

▶Exhaust Plate (30 parts)

Ref	OEM Part #	Part Name
1	858582T	ADAPTOR PLATE ASSEMBLY
2	17-23784	PIN, Dowel
3	22-880090	FITTING
4	21-817519A2	CHECK VALVE ASSEMBLY, Drain
5	25-12602002	GROMMET
6	27-8585831	GASKET
7	858572T01	SUMP, Oil
8	858584A1	TUBE ASSEMBLY, Exhaust
9	25-881295	O-RING
10	25-89417004	GROMMET
11	32-8M0026129	TUBE, Water Comment: (X-Long) (Saltwater)
12	814080001	SEAL, Upper
13	858571T	TUBE, Oil Pick Up
14	25-859082	O-RING
15	10-8M0204741	SCREW, (M6 x 20) Stainless Steel
16	10-8M0214957	SCREW, (M6 x 30)
17	8596021	DIPSTICK
18	23-48237	BUSHING
19	858577A3	SHIFT SHAFT
20	859177A3	SHIFT LINK
21	NSS	NOT SOLD SEPARATE, Bushing
22	879997	SHIFT SLIDER
23	11-401386	NUT, (M6) Stainless Steel
24	23-11289	SPACER Comment: (X-Long)
25	43585	COUPLING
26	18-859746	COTTER PIN
27	8M0039073	SEAL
28	8288181	PLUG, Drain
29	27-8M0204692	GASKET
30	10-82483213	SCREW, (M6 x 60)

▶Flywheel (25 parts)

Ref	OEM Part #	Part Name
-	881421T04	POWERHEAD ASSEMBLY Comment: SN# 0T409000 & Up
1	881343T1	FLYWHEEL COVER
2	10-804348	BOLT, (M6 x 20)
3	825665	COLLAR
4	25-11416T	GROMMET
5	11-804265A1	NUT/WASHER KIT, Hex (36 mm) Comment: SN# 0T599000 & Up
6	12-804264	WASHER Comment: SN# 0T598999 & Below
7	280-881335T	FLYWHEEL
8	881337T	COIL, Pulser
9	398-881336T2	STATOR
10	10-881338	SCREW, (M6 x 28)
11	10-881339002	SCREW, (M4 x 8)
12	54-881340	CLAMP
13	10-804603	BOLT, (M6 x 30)
14	17-825010	PIN, Dowel
15	881341	ROTOR
16	28-881342	KEY
17	804266001	TIMING PLATE
18	10-804267	SCREW
19	NSS	NOT SOLD SEPARATE, Decal, Warning Neutral
20	NSS	NOT SOLD SEPARATE, Decal, Warning Spinning Flywheel
21	NSS	NOT SOLD SEPARATE, Decal, Servicing Referral
22	NSS	NOT SOLD SEPARATE, Decal, Engine Oil, Valve
23	NSS	NOT SOLD SEPARATE, Decal, Emergency Starting
24	37-881839A03	DECAL, EPA Label Information Comment: (2003)

▶Fuel Injection Nozzle (28 parts)

Ref	OEM Part #	Part Name
-	881440T04	INTAKE ASSEMBLY Comment: SN# 0T409000 & Up
1	880888T02	REGULATOR, Fuel Pressure
2	10-881524	SCREW, (M6 x 12)
3	13-881525	LOCKWASHER
4	54-881531	CLIP
5	32-881528	HOSE
6	10-881509	SCREW, (M5 x 15)
7	54-881530	CLIP
8	10-84088M	SCREW, (M6 x 10)
9	27-827610	GASKET
10	23-888260	COLLAR
11	881527T01	COOLER
12	10-881507	BOLT, (M6 x 25)
13	12-881533	WASHER
14	8M0214940	TIE STRAP, (5.50 Inches)
15	32-881536	HOSE
16	32-881529	HOSE
17	56762	CLAMP
18	881518T	DELIVERY PIPE
19	880887T1	INJECTOR
20	25-885183A1	O-RING KIT
21	881520	CAP
22	10-881534	BOLT, (M6 x 10)
23	10-881532	BOLT, (M8 x 45)
24	12-881508	WASHER
25	23-881526	COLLAR
26	881521T	NIPPLE
27	25-881522	O-RING

▶Fuel Injection Pump (33 parts)

Ref	OEM Part #	Part Name
-	881440T04	INTAKE ASSEMBLY Comment: SN# 0T409000 & Up
1	881316T2	COVER Comment: SN# 0T409000 & Up
2	25-881318	O-RING
3	881329	NEEDLE VALVE KIT
4	NSS	NOT SOLD SEPARATE, Seat
5	881320	FLOAT
6	17-881321	PIN, Float
7	881319T	BODY
8	881327	PLATE
9	10-8813261	SCREW, (M3 x 8)
10	10-881326	SCREW, (M4 x 16)
11	27-881325	GASKET
12	25-881322	DAMPER
13	8M0123823	PUMP, Fuel
14	35-881323T	FILTER
15	881324	COVER
16	10-8813262	SCREW, Drain
17	27-881328	GASKET
18	32-881330A02	HOSE KIT
19	54-881331	CLIP
20	54-881559	CLIP
21	32-881565	HOSE
22	32-881560	HOSE
23	22-8815581	TEE Comment: SN# 0T409000 & Up
24	32-881554	HOSE
25	32-881554	HOSE
26	32-881554	HOSE
27	32-881554	HOSE
28	32-881555	HOSE
29	32-881557	HOSE
30	32-881556	HOSE
31	25-8813221	DAMPER
32	23-881332	COLLAR

▶Fuel Pump (38 parts)

Ref	OEM Part #	Part Name
-	881310T09	CYLINDER HEAD ASSEMBLY
1	880890T1	PUMP, Fuel
2	NSS	NOT SOLD SEPARATE, Body
3	24-881544	SPRING
4	881545	PLUNGER
5	24-881546	SPRING
6	881547	DIAPHRAGM
7	17-881548	PIN
8	NSS	NOT SOLD SEPARATE, Body
9	NSS	NOT SOLD SEPARATE, Diaphragm
10	NSS	NOT SOLD SEPARATE, Body
11	10-881550	SCREW
12	11-881333	NUT
13	25-8M0050719	O-RING
14	56762	CLAMP
15	10-804256	BOLT, (M6 x 30)
16	32-881543002	HOSE
17	881542	BRACKET
18	10-811188T	BOLT, (M6 x 16)
19	11-82382M	NUT
20	35-881538T02	FILTER ASSEMBLY
21	35-8M0168897	ELEMENT
22	25-826966T	O-RING
23	881541	FLOAT
24	881539	CUP
25	56762	CLAMP
26	804260	BRACKET
27	10-804112	BOLT, (M7 x 48)
28	17-804113	PIN, Dowel
29	12-84292M	WASHER
30	804257	LEVER, Fuel Change
31	881334	SHAFT
32	17-82738M	PIN
33	32-8M0108349	TUBING, (.312) (70.00 Inches Bulk), Cut to 55.00 Inch Length.
34	54-816311T	TIE STRAP, (8.00 Inches)
35	22-822769	CONNECTOR
36	NSS	NOT SOLD SEPARATE, Cap
37	32-828547T1	CONDUIT, (.500 Inside Diameter x 3.00 Feet Bulk)

▶Gear Housing(Propshaft) (2.07:1) (S/N-0T590053 And Below) (30 parts)

Ref	OEM Part #	Part Name
-	52-803489T1	REPAIR KIT, Clutch/Cam
1	1667-9011G59	GEAR HOUSING ASSEMBLY, Basic
2	31-30894A1	BEARING SET, Cup And Cone
3	NSS	NOT SOLD SEPARATE, Cup
4	43-881260A5	GEAR ASSEMBLY, Forward (29 Teeth)
5	31-30895T	BEARING, Needle
6	53-856823	RING, Retaining
7	850315A1	FOLLOWER KIT, Cam
8	30-44530	BALL
9	NSS	NOT SOLD SEPARATE, Slide
10	24-850327	SPRING
11	52-850048T	CLUTCH
12	17-8M0100263	PIN, Cross
13	24-30893	SPRING
14	44-8M0140445	PROPELLER SHAFT
15	43-850036T	GEAR, Reverse - 29 Teeth
16	8M0168901	CARRIER ASSEMBLY, Bearing
17	25-8M0214974	O-RING, (3.609 x .139)
18	31-30956T	BEARING, Needle
19	26-8M0205728	SEAL, Oil, Inner
20	26-8M0205729	SEAL, Oil, Outer
21	31-12578T	BEARING, Roller
22	12-12577	THRUST WASHER
23	31-12576	BEARING, Thrust
24	16-8M0034456	STUD, (M8 x 48)
25	12-855941	WASHER, (.323 x .590 x .112) Stainless Steel
26	11-401378	NUT, (M8)
27	15-44491A1	SHIM SET
28	8227731	INSERT, Threaded
29	NSS	NOT SOLD SEPARATE, Decal, Gear Housing Identification

▶Gear Housing(Propshaft) (2.07:1) (S/N-0T590054 And Up) (30 parts)

Ref	OEM Part #	Part Name
-	52-803489T1	REPAIR KIT, Clutch/Cam
1	1667-9011G59	GEAR HOUSING ASSEMBLY, Basic
2	31-30894A1	BEARING SET, Cup And Cone
3	NSS	NOT SOLD SEPARATE, Cup
4	43-881260A3	GEAR, Forward - 29 Teeth
5	31-30895T	BEARING, Needle
6	53-856823	RING, Retaining
7	850315A1	FOLLOWER KIT, Cam
8	30-44530	BALL
9	NSS	NOT SOLD SEPARATE, Slide
10	24-850327	SPRING
11	52-850048T	CLUTCH
12	17-8M0100263	PIN, Cross
13	24-30893	SPRING
14	44-8M0140445	PROPELLER SHAFT
15	43-850036T	GEAR, Reverse - 29 Teeth
16	8M0168901	CARRIER ASSEMBLY, Bearing
17	25-8M0214974	O-RING, (3.609 x .139)
18	31-30956T	BEARING, Needle
19	26-8M0205728	SEAL, Oil, Inner
20	26-8M0205729	SEAL, Oil, Outer
21	31-12578T	BEARING, Roller
22	12-12577	THRUST WASHER
23	31-12576	BEARING, Thrust
24	16-8M0034456	STUD, (M8 x 48)
25	12-855941	WASHER, (.323 x .590 x .112) Stainless Steel
26	11-401378	NUT, (M8)
27	15-44491A1	SHIM SET
28	8227731	INSERT, Threaded
29	NSS	NOT SOLD SEPARATE, Decal, Gear Housing Pinion Indentation

▶Gear Housing, Driveshaft (2.07:1) (S/N-0T590053 And Below) (43 parts)

Ref	OEM Part #	Part Name
-	47-8M0100526	REPAIR KIT, Water Pump Impeller
1	1667-9011G59	GEAR HOUSING ASSEMBLY, Basic
2	17-8M0084244	PIN, Dowel - With Hole (.375 x .625) , Front
3	43046	TUBE, Oiler
4	10-79953Q04	SCREW KIT, (.375-16 x .250) Drain
5	12-191833	WASHER
6	17-43044	PIN, Dowel - Without Hole (.375 x .625), Rear
7	31640T07	TRIM TAB
8	10-825427	SCREW, (.437-14 x 1.250) Stainless Steel
9	12-451761	WASHER, (.453 x .812 x .105) Black Oxide
10	43040T1	CARRIER ASSEMBLY
11	NSS	NOT SOLD SEPARATE, Needle Bearing
12	97-826134Q	ANODE
13	11-401386	NUT, (M6) Stainless Steel
14	10-4000333	SCREW, (M6 x 40)
15	43-881260A5	GEAR, Pinion (14 Teeth) Comment: (Replacement Requires Re-Shimming)
16	11-35921	NUT, (.625-18)
17	850307	CAM, Shift Control
18	31-883047A1	BEARING ASSEMBLY, Tapered Roller Comment: (Use With Pinion Stamped 43-881259)
19	15-44492A1	SHIM SET
20	45-878575T1	DRIVESHAFT ASSEMBLY Comment: (X-Long)
21	42461A1	SLEEVE/RING KIT
22	NSS	NOT SOLD SEPARATE, Seal Ring
23	43055A4	COVER ASSEMBLY, Water Pump
24	27-430331	GASKET
25	27-8M0214931	GASKET
26	26-43036	SEAL, Oil, Lower
27	26-43035	SEAL, Oil, Upper
28	27-8172771	GASKET
29	817275A2	HOUSING KIT, Upper Water Pump
30	8M0204709	FACEPLATE
31	10-82684430	SCREW, (M6 x 30)
32	430232	SEAL
33	28-8M0204723	KEY
34	47-43026T2	IMPELLER
35	10-82684425	SCREW, (M6 x 25)
36	853908A1	SHIFT SHAFT ASSEMBLY Comment: (X-Long)
37	53-29641	E RING
38	23-43052A4	BUSHING ASSEMBLY
39	25-8M0204681	O-RING, (1.424 x .103)
40	26-8M0204708	SEAL, Oil
41	10-82684425	SCREW, (M6 x 25)
42	26-861415	FACE SEAL

▶Gear Housing, Driveshaft (2.07:1) (S/N-0T590054 And Up) (44 parts)

Ref	OEM Part #	Part Name
-	47-8M0100526	REPAIR KIT, Water Pump Impeller
0	1667-9011J4	GEAR HOUSING ASSEMBLY, Complete Comment: (X-Long)
1	1667-9011G59	GEAR HOUSING ASSEMBLY, Basic
2	17-8M0084244	PIN, Dowel - With Hole (.375 x .625) , Front
3	43046	TUBE, Oiler
4	10-79953Q04	SCREW KIT, (.375-16 x .250) Drain
5	12-191833	WASHER
6	17-43044	PIN, Dowel - Without Hole (.375 x .625), Rear
7	31640T07	TRIM TAB
8	10-825427	SCREW, (.437-14 x 1.250) Stainless Steel
9	12-451761	WASHER, (.453 x .812 x .105) Black Oxide
10	43040T1	CARRIER ASSEMBLY
11	NSS	NOT SOLD SEPARATE, Neeedle Bearing
12	97-826134Q	ANODE
13	11-401386	NUT, (M6) Stainless Steel
14	10-4000333	SCREW, (M6 x 40)
15	NSS	NOT SOLD SEPARATE, Pinion Gear, (14 Teeth) Comment: (Part Of 43-881260A3)
16	11-35921	NUT, (.625-18)
17	850307	CAM, Shift Control
18	31-883047A1	BEARING ASSEMBLY, Tapered Roller
19	15-44492A1	SHIM SET
20	45-878575T1	DRIVESHAFT ASSEMBLY Comment: (X-Long)
21	42461A1	SLEEVE/RING KIT
22	NSS	NOT SOLD SEPARATE, Seal Ring
23	43055A4	COVER ASSEMBLY, Water Pump
24	27-430331	GASKET
25	27-8M0214931	GASKET
26	26-43036	SEAL, Oil, Lower
27	26-43035	SEAL, Oil, Upper
28	27-8172771	GASKET
29	817275A2	HOUSING KIT, Upper Water Pump
30	8M0204709	FACEPLATE
31	10-82684430	SCREW, (M6 x 30)
32	430232	SEAL
33	28-8M0204723	KEY
34	47-43026T2	IMPELLER
35	10-82684425	SCREW, (M6 x 25)
36	853908A1	SHIFT SHAFT ASSEMBLY Comment: (X-Long)
37	53-29641	E RING
38	45-43032A4	DRIVESHAFT ASSEMBLY
39	25-8M0204681	O-RING, (1.424 x .103)
40	26-8M0204708	SEAL, Oil
41	10-82684425	SCREW, (M6 x 25)
42	26-861415	FACE SEAL

▶Ignition Components (14 parts)

Ref	OEM Part #	Part Name
1	880891T14	CONTROL ASSEMBLY, Engine Comment: SN# 0T598999 & Below
2	10-804270	BOLT, (M6 x 28)
3	25-881304	GROMMET
4	23-804344003	BUSHING
5	881346T	RECTIFIER/REGULATOR ASSEMBLY
6	10-853536	BOLT, (M6 x 25)
7	10-804604	BOLT, (M6 x 20)
8	300-8M0123821	COIL, Ignition
9	339-8M0121257	COIL, Ignition
10	881345	PLATE
11	54-816311T	TIE STRAP, (8.00 Inches)
12	10-853536	BOLT, (M6 x 25)
13	54-804276	CLAMP
14	54-804277	CLAMP

▶Intake (36 parts)

Ref	OEM Part #	Part Name
-	881440T04	INTAKE ASSEMBLY Comment: SN# 0T409000 & Up
1	880886T	MANIFOLD
2	25-881513	O-RING
3	17-881512	PIN, Dowel
4	10-881507	BOLT, (M6 x 25)
5	881441T4	THROTTLE BODY ASSEMBLY Comment: SN# 0T409000 & Up
6	24-881444	SPRING
7	10-881445	SCREW Comment: SN# 0T408999 & Below
8	10-881510	BOLT, (M8 x 70)
9	12-881508	WASHER
10	881441T3	THROTTLE BODY ASSEMBLY Comment: SN# 0T409000 & Up
11	10-881442	SCREW
12	24-881444	SPRING
13	10-881443	SCREW
14	10-881445	SCREW Comment: SN# 0T408999 & Below
15	881514	LINK JOINT
16	881515	LINK JOINT
17	11-83763M	NUT
18	880884T	SENSOR, Throttle
19	25-881504	O-RING
20	10-881502002	SCREW
21	12-881450	WASHER
22	881516	BRACKET
23	10-881971A1	SCREW
24	881511	HOSE
25	881446T	BODY
26	881447T	CONTROL VALVE
27	25-881448	O-RING
28	10-881449002	SCREW, (M4 x 12)
29	12-881450	WASHER
30	35-881501T	FILTER
31	880885T	SENSOR, Pressure
32	10-881509	SCREW, (M5 x 15)
33	10-881505	BOLT, (M6 x 24)
34	10-881506	BOLT, (M6 x 60)
35	84-881517T1	HARNESS ASSEMBLY

▶Intake And Exhaust Valves (26 parts)

Ref	OEM Part #	Part Name
-	881421T04	POWERHEAD ASSEMBLY Comment: SN# 0T409000 & Up
1	57-804145	V BELT
2	10-804143001	BOLT, (M10 x 35)
3	43-804142T	GEAR, Driven
4	26-804144001	SEAL, Oil
5	17-804141	PIN, Dowel
6	2407-8M0057172	CAMSHAFT
7	2407-804139T	CAMSHAFT
8	804128T	VALVE, Intake
9	804129T	VALVE, Exhaust
10	804130	SEAT
11	26-804136	SEAL
12	26-804137	SEAL
13	24-804131	SPRING, Valve
14	804132	RETAINER
15	28-804135	COTTER VALVE
16	804138T	LIFTER, Valve
17	15-80460880	SHIM Comment: (2.975)
18	804149	PLATE, Valve
19	28-804153	KEY
20	804146	TENSIONER
21	10-804150	BOLT, (M10 x 45)
22	24-804147	SPRING
23	32-804148	HOSE
24	43-804151T	GEAR, Drive
25	11-881314003	NUT, (M40)

▶Intake Silencer (22 parts)

Ref	OEM Part #	Part Name
-	881421T04	POWERHEAD ASSEMBLY Comment: SN# 0T409000 & Up
1	881436T	SILENCER, Intake
2	880882T	THERMOSENSOR
3	25-881437	O-RING
4	10-804165	BOLT, (M6 x 16)
5	10-881816	BOLT, (M8 x 20)
6	881439	BRACKET
7	8M0059034	BRACKET
8	10-881435	BOLT, (M6 x 20)
9	892849	INDUCTION SILENCER
10	881269	BRACKET
11	10-8M0204741	SCREW, (M6 x 20) Stainless Steel
12	17-804160	PIN
13	27-881433	GASKET
14	32-804162	BREATHER PIPE
15	54-804163	CLAMP
16	10-804602	BOLT, (M6 x 12)
17	54-804089	CLIP
18	56762	CLAMP
19	10-881438	BOLT, (M6 x 105)
20	10-881431	BOLT, (M8 x 40)
21	881822	SCREEN

▶Key Chart, Ignition Switch (1 parts)

Ref	OEM Part #	Part Name
0	8949112	KEY, Ignition (2F)

▶Oil Pump (21 parts)

Ref	OEM Part #	Part Name
1	22-384073	PLUG, Pipe (.500-14)
2	22-479452	PLUG
3	25-62705001	O-RING
4	17-41275M	PIN, Dowel
5	881900T03	MOUNT
6	10-898487	BOLT, (M12 x 175)
7	12-32834	WASHER, Neoprene
8	12-8M0204648	WASHER, (1.5 x 3.05 x 0.13) Stainless Steel
9	11-896963	NUT, (M12)
10	10-4010750	SCREW, (M8 x 50)
11	858579T3	PUMP, Oil
12	10-8M0052670	BOLT, (M6 x 45)
13	26-804349	SEAL
14	878562T8	BRACKET, Shift Linkage
15	10-42975	DRIVE SCREW
16	10-82130020	SCREW, (M6 x 20)
17	878560	CUP
18	98889	LATCH
19	8M0043168	SEAL
20	87-8M0052930	SWITCH
21	10-88075020	SCREW, (M3 x 20)

▶Power Trim Components (22 parts)

Ref	OEM Part #	Part Name
-	25-893914A02	O-RING KIT, Complete Trim
1	8M0171821	SHOCK ROD KIT
2	25-8M0171819	O-RING KIT, Rebuild
3	8M0171822	PISTON ASSEMBLY, Memory
4	893916A01	CYLINDER ASSEMBLY
5	893905A02	VALVE KIT, Trim Limit
6	893906A02	PUMP ASSEMBLY
7	893907A02	MOTOR KIT
8	22-8134351	PLUG
9	893929A01	MANUAL RELEASE ASSEMBLY
10	893909A02	MANIFOLD KIT
11	10-809876A1	SCREW KIT, Motor
12	88238A18	CABLE ASSEMBLY
13	809877A1	DRIVESHAFT/SEAL KIT
14	35-893912A02	FILTER KIT
15	893913A02	POPPET KIT
16	17-821539	PIN, Trilobe
17	17-818898	PIN, Anchor
18	99625002	SHAFT
19	54-22740	CLIP
20	10-878609	SCREW, (#10-16 x .600)
21	8M0084613	C WASHER

▶Sensors (17 parts)

Ref	OEM Part #	Part Name
-	881421T04	POWERHEAD ASSEMBLY Comment: SN# 0T409000 & Up
1	804295T	THERMOSENSOR
2	804296	RETAINER
3	10-811188T	BOLT, (M6 x 16)
4	27-8042971	GASKET
5	54-83577M	CLAMP
6	10-84088M	SCREW, (M6 x 10)
7	881366	PLATE
8	10-804602	BOLT, (M6 x 12)
9	8042941	PLATE
10	10-811188T	BOLT, (M6 x 16)
11	84-881364T05	HARNESS ASSEMBLY
12	54-816311T	TIE STRAP, (8.00 Inches)
13	56762	CLAMP
14	87-8043071	SWITCH, Oil Pressure
15	84-881367A1	LEAD WIRE
16	10-804604	BOLT, (M6 x 20)

▶Service/Support Material (1 parts)

Ref	OEM Part #	Part Name
0	56-883040A1	TACH MODULE KIT

▶Starter Motor (32 parts)

Ref	OEM Part #	Part Name
-	50-881368T2	STARTER MOTOR ASSEMBLY Comment: SN# 0T409000 & Up
1	804314T	STATOR
2	804313T	ARMATURE
3	881369T1	HOLDER ASSEMBLY, Brush
4	804316	BRUSH SET
5	24-804317	SPRING
6	881370T	BRACKET
7	10-804337	SCREW, (M4 x 16)
8	10-804335	THRU BOLT, (M6 x 120)
9	804321T1	GEAR KIT
10	804322	CLUTCH
11	12-804330	WASHER KIT
12	804324	BRACKET
13	804326	RING GEAR
14	27-804327	GASKET
15	31-804325	BEARING
16	804323	SHAFT, Pinion
17	43-804329001	IDLER GEAR
18	804328	BRACKET
19	804331T	COVER
20	10-804336	BOLT, (M6 x 52)
21	804319	PINION
22	804320	STOP SET, Pinion
23	804332	LEVER KIT
24	804334	COVER
25	881371T1	RELAY, Starter Comment: SN# 0T409000 & Up
26	10-804605	BOLT, (M8 x 45)
27	881373	TERMINAL
28	13-881377	LOCKWASHER
29	11-82382M	NUT
30	11-881372	NUT
31	881374	COVER

▶Steering Handle Kit (38 parts)

Ref	OEM Part #	Part Name
-	816366A32	STEERING HANDLE KIT Comment: (2004 Model Year And Above)
NS	22-8M0169589	FITTING, Grease
1	12020A3	HANDLE ASSEMBLY, Steering Arm
2	23-42992T02	BUSHING
3	48414	HOUSING
4	48519	PLATE
5	27-48518	GASKET
6	10-878609	SCREW, (#10-16 x .600)
7	10-878608	SCREW, (#10-16 x .500)
8	54-889729	CLAMP
9	10-40007112	SCREW, (M5 x 40)
10	10-32,11-816874	WING NUT, , Wing
11	87-823609A15	SWITCH KIT, Stop - Throttle Handle
12	87-8M0104612	SWITCH ASSEMBLY, Stop
13	NSS	NOT SOLD SEPARATE, Insulator
14	12018A4	TUBE ASSEMBLY, Throttle
15	NSS	NOT SOLD SEPARATE, Drive Wheel
16	NSS	NOT SOLD SEPARATE, Roll Pin
17	10-62568	SCREW, (#10-16 x .375)
18	8M0221732	GRIP
19	54-648552	CLIP
20	11-40140	NUT, (M10)
21	8885241	CONDUIT, (9.03 Inches)
22	895665	GUIDE TUBE
23	89578	BARREL, Throttle Actuator
24	10-32,10-824081	SET SCREW,
25	12019003	CABLE ASSEMBLY
26	8M0204660	GUIDE, Cable
27	20007	ANCHOR, Cable End
28	8-32,10-8M0204644	SET SCREW,
29	10-823567105	SCREW, (M10 x 105) Hex Flange - Stainless Steel
30	48416	CAP
31	12-4002319	WASHER
32	12-12024	WASHER, (.402 x .787 x .039 Bellevi)
33	23-146011	SPACER
34	54-816311T	TIE STRAP, (8.00 Inches)
35	NSS	NOT SOLD SEPARATE, Decal, Throttle
36	25-889724	GROMMET, Hose Cable

▶Steering Handle Kit Components (50 parts)

Ref	OEM Part #	Part Name
-	816366A32	STEERING HANDLE KIT Comment: (2004 Model Year And Above)
1	816366T10	HANDLE, Bracket Comment: (2004 Model Year And Above)
2	10-881261	SCREW, (.313-24 x 3.50)
3	14-42981	TAB WASHER
4	822263	SPACER
5	84-12649A4	HARNESS ASSEMBLY
6	87-88107A5	SWITCH KIT, Key, With Keys Comment: (For Replacement Key - Order 89491--1 Thru 89491-12)(See Key Chart - Ignition Switch Section)
7	11-879755	NUT, Special - Black Nylon Comment: (Black Nylon)
8	13541	PLUG, Male
9	121051	GROMMET
10	19-889730	PLUG
11	8M0032846	RETAINER, Brass
12	8158041	COVER
13	10-878608	SCREW, (#10-16 x .500)
14	87-11083A4	SWITCH ASSEMBLY, Stop
15	15920Q54	LANYARD ASSEMBLY
16	84-11149A3	CABLE ASSEMBLY
17	889528T01	HORN ASSEMBLY
18	87-18286A19	SWITCH KIT, Trim (25.00 Feet), Trim
19	87-8M0052927	SWITCH
20	10-12110	SCREW, (#6-32 x .750)
21	54-648551	CLAMP
22	10-878608	SCREW, (#10-16 x .500)
23	10-849838	SCREW, (.375-24 x 1.250)
24	11-8M0204726	NUT, (.375-24) Stainless Steel
25	48419T01	ROD END Comment: (2004 Model Year And Above)
26	495637	ROD, Shift
27	23-26856	BUSHING
28	12-35950	WASHER, (.273 x .437 x .031) Stainless Steel
29	18-25191	COTTER PIN, Cotter
30	8163677	LEVER, Shift
31	16-8M0034452	STUD, (.375-24 x 1.125)
32	98530	KNOB
33	12016A2	DETENT/SPRING KIT
34	23-8159831	BUSHING
35	12-823970	WASHER
36	12-824610	WASHER, Plastic
37	12-814803	WASHER
38	14-8158051	TAB WASHER
39	10-4000357	SCREW, (M8 x 45)
40	56-52148A08	CO PILOT ASSEMBLY
41	52148002	PILOT ROD, (15.00 Inches)
42	11-52155A1	NUT ASSEMBLY
43	10-36137	SCREW, (.250-28 x 1.00)
44	821621	KNOB, Prong
45	873491	ROD, Link
46	23-26841	BUSHING
47	12-8M0042642	WASHER, (.323 x .563 x .063) Stainless Steel
48	11-826709111	NUT, (.312-24) Stainless Steel
49	11-64015	NUT, (.250-20)

▶Swivel Bracket And Steering Arm (19 parts)

Ref	OEM Part #	Part Name
1	1400-8M0220957	SWIVEL BRACKET
2	26-87735	SEAL, Oil, Lower
3	23-818764	BUSHING
4	25-8M0214926	O-RING
5	23-816039	SPACER
6	22-8M0169589	FITTING, Grease
7	23-821207	BUSHING
8	10-64014	SCREW, (.250-28 x .500)
9	99661A35	SWIVEL PIN ASSEMBLY
10	92876A12	LINK ROD ASSEMBLY
11	10-849838	SCREW, (.375-24 x 1.250)
12	11-8M0204726	NUT, (.375-24) Stainless Steel
13	12-37828	WASHER, (.390 x .625 x .062) Stainless Steel
14	42961A06	YOKE ASSEMBLY, Bottom
15	53-67684	RING, Retaining
16	12-816432	THRUST WASHER
17	NSS	NOT SOLD SEPARATE, Decal, Serial Overlaminate
18	11288001	BUMPER, Bottom Yoke Comment: (Saltwater)
19	88882	BUMPER, Top Yoke Comment: (Saltwater)

▶Throttle Lever And Linkage (13 parts)

Ref	OEM Part #	Part Name
1	878550	LEVER, Throttle
2	12-84974M	WASHER
3	13-81868M	WAVE WASHER
4	11-8528162	NUT
5	23-881378	COLLAR
6	12-94524M	WASHER
7	24-804343	SPRING
8	878548	LEVER, Throttle Control
9	12-84974M	WASHER
10	13-81868M	WAVE WASHER
11	10-881375	BOLT, (M6 x 30)
12	12-35459	WASHER
13	18-859746	COTTER PIN

▶Tools 1 (27 parts)

Ref	OEM Part #	Part Name
1	91-8M0161873	HOLDER, Flywheel
2	91-83164M	FLYWHEEL PULLER
3	91-99379	TIMING LIGHT
4	91-890451	ADAPTOR TOOL, Direct Voltage
5	91-850439T1	TESTER, Eight Chamber
6	91-854009A3	TACH MULTI METER, DMT 2000 Digital
7	91-881825	HARNESS ASSEMBLY, Crank Position Sensor Test
8	91-875216	HOLDER TOOL, Brush
9	91-881824004	HARNESS ASSEMBLY, Stator Coil Test
10	91-881827	HARNESS ASSEMBLY, Throttle Position Test
11	91-881826	HARNESS ASSEMBLY, Ignition Coil Test
12	91-8098712	VACUUMMATE TOOL, Carburetor Tuner
13	91-881833A03	GAUGE, Air/Fuel Pressure
14	91-881834A1	GAUGE
15	NSS	NOT SOLD SEPARATE, Migh VAC Vacuum Gage Comment: (Obtain Locally)
16	99056A1	MALFUNCTION INDICATOR LAMP
17	91-881828	STARBIT TOOL KIT
18	91-804774001	REMOVER/INSTALLER TOOL, Valve Guide
19	91-804775	REAMER TOOL, Valve Guide
20	91-809494A1	COMPRESSOR TOOL, Valve Spring
21	NSS	NOT SOLD SEPARATE, Valve Seat Cutter Kit Comment: (Obtain Locally)
22	91-802653Q02	WRENCH, Oil Filter
23	FT2997	COMPRESSOR TOOL, Piston Ring
24	91-24697	EXPANDER TOOL, Piston Ring
25	91-804770A1	HOLDER TOOL, Crankshaft
26	91-875215A1	INSTALLER TOOL, Driveshaft Bushing
27	91-881847T	SOCKET, (76 mm Deep)

▶Tools 2 (32 parts)

Ref	OEM Part #	Part Name
28	91-74951	SPANNER WRENCH
29	NSS	NOT SOLD SEPARATE, Lock Ring Pliers Comment: (Snap-On SRP-4)
30	NSS	NOT SOLD SEPARATE, Expanding Rod Comment: (Snap-On CG41-11)
31	NSS	NOT SOLD SEPARATE, Collet Comment: (Snap-On CG41-12)
32	91-63209	HEAT LAMP
33	91-12349A05	LOCATION TOOL, Pinion
34	91-13945	INSTALLATION TOOL, Bearing
35	91-13949	DRIVER TOOL, Oil Seal
36	91-14308T02	RACE TOOL, Bearing
37	91-14309T02	INSTALLATION TOOL, Bearing
38	91-14310T1	WEAR SLEEVE INSTALLATION TOOL
39	91-14311A04	PRE LOAD TOOL, Bearing
40	91-15755T	MANDREL
41	91-196601	INDICATOR TOOL, Backlash
42	91-31106T	MANDREL, Bearing Driver Cup
43	91-31108T	DRIVER, Oil Seal
44	91-36569T	DRIVE HEAD TOOL
45	91-804776A1	HOLDING TOOL, Driveshaft
46	91-31229	SHAFT
47	11-24156	NUT, (.625-18)
48	91-34569A1	PULLER ASSEMBLY, Slide Hammer
49	91-37323	DRIVER ROD TOOL, Needle Bearings
50	91-37241	PULLER PLATE, Universal
51	91-37350T	MANDREL
52	91-46086A1	PULLER JAW ASSEMBLY
53	91-58222A1	DIAL INDICATOR TOOL
54	91-8M0053505	INDICATOR TOOL, Backlash
55	91-85716	PULLER BOLT TOOL, Bearing Carrier
56	91-83155	ADAPTER KIT, Dial Indicator
57	91-83165T	PULLER ASSEMBLY
58	91-856875A1	INSTALLATION TOOL, Bearing
59	91-877321A1	INSTALLATION TOOL, Bearing

▶Top Cowl (26 parts)

Ref	OEM Part #	Part Name
1	4021-827328T10	TOP COWL ASSEMBLY Comment: (Silver)
2	821256T2	INLET, Air - Silver Comment: (Silver)
3	10-82130016	SCREW, (M6 x 16)
4	859356A02	SOUND BLANKET KIT Comment: (Top)
5	NSS	NOT SOLD SEPARATE, Sound Blanket Comment: (Port)
6	NSS	NOT SOLD SEPARATE, Sound Blanket Comment: (Starboard)
7	NSS	NOT SOLD SEPARATE, Sound Blanket Comment: (Back)
8	19-823865	CAP PLUG
9	831207A16	HANDLE
10	23-812707	BUSHING
11	23-831214	SPACER
12	13-12134	WASHER, Wave
13	8M0001081	CAM, Latch Shaft
14	12-8M0214930	WASHER
15	10-1993716	SCREW, (M6 x 16)
16	8M0036792	BRACKET, Front
17	815477	BUMPER, Latch
18	12-8M0204649	WASHER, (.281 x .500 x .060) Stainless Steel
19	11-401366	NUT, (M6) Stainless Steel
20	53-8237951	RING, Retaining
21	8M0207770	ROLLER
22	8155381	PIN, Roll
23	12-8M0204649	WASHER, (.281 x .500 x .060) Stainless Steel
24	11-401366	NUT, (M6) Stainless Steel
25	47341A11	ROPE AND HANDLE KIT, Manual Starting
26	50-12066Q10	ROPE

▶Transom Bracket (26 parts)

Ref	OEM Part #	Part Name
1	3426-828334T02	BRACKET, Transom Comment: (Starboard)
2	3425-828333T07	BRACKET ASSEMBLY, Transom Comment: (Port)
3	22-8M0169588	FITTING, Grease Comment: (Port)
4	826125A1	TILT TUBE Comment: (Saltwater)
5	11-826135	NUT, (1.00-14) Nylon Insert Comment: (Saltwater)
6	25-45711	O-RING, (.612 x .103)
7	13-88750	WASHER
8	11-826164	NUT, (.875-14) Comment: (Saltwater)
9	10-8M0149747	SCREW, (.500-20 x 4.500)
10	12-8M0204665	WASHER, (.530 x .870 x .105) Stainless Steel
11	12-8M0204648	WASHER, (1.5 x 3.05 x 0.13) Stainless Steel
12	11-82671117	NUT, (.500-20)
13	24-830899	SPRING, Tension
14	8M0109798	LEVER ASSEMBLY, Tilt Lock
15	23-65830	NYLINER
16	24-830900	SPRING, Compression
17	99633	KNOB
18	17-99615	PIN, Groove
19	17-893709	PIN
20	8M0086406	BRACKET, Anchor
21	10-858771	SCREW, (M10 x 30)
22	12-4002319	WASHER
23	11-40114	NUT, (M10 x 1.5)
24	97-818298Q1	ANODE KIT
25	10-8M0204707	SCREW, (M6 x 25)
26	12-8M0204649	WASHER, (.281 x .500 x .060) Stainless Steel

100-Hour / Annual Service Checklist

Regular maintenance keeps your Mercury 115 EFI (4-STROKE) running reliably season after season. Most of these tasks can be performed with basic tools and the factory service manual.

Replace water pump impeller and inspect wear plate
Change engine oil and oil filter (check drain plug washer)
Replace spark plugs and check ignition timing
Drain and refill lower unit gear oil; inspect for water contamination
Inspect fuel lines, primer bulb, and fuel filter for deterioration
Check and replace sacrificial anodes (zinc or aluminum)
Inspect propeller for damage; check shaft seal and cotter pin
Check valve clearance (refer to service manual for specifications)
Lubricate all grease points (steering, tilt tube, shift linkage)
Inspect control cables and throttle/shift linkage for smooth operation

Pro Tip: Always flush the engine with fresh water after saltwater use — even a quick 10-minute flush significantly extends component life.
Pro Tip: Use fuel stabilizer in the tank before winter storage, and fog the cylinders to prevent internal corrosion during extended periods of non-use.

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Mercury 115 EFI (4-STROKE) (0T178500 THRU 0T800999) Parts & Diagrams

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