Mercury 200 (1866496 THRU 2296266) Parts & Diagrams

🔎 Mercury 200 Reference Library — Exploded parts diagrams (18 diagrams), specifications, common issues, and maintenance checklist.

The Mercury 200 is a 4-Stroke, V6 64-degree, DOHC, 24-valve outboard motor. A popular choice for small fishing boats, inflatable RIBs, and sailboat auxiliaries.

Quick Reference Specifications

Specification	Value
Engine Type	4-Stroke, V6 64-degree, DOHC, 24-valve
Horsepower	20 HP
Displacement	3400 cc (3.4L / 209 CID)
Bore x Stroke	93.3 mm x 83.3 mm
Spark Plug (Type & Gap)	NGK LKAR7C-9
Engine Oil Capacity	6.6 L (7.0 qt)
Recommended Engine Oil	Mercury FourStroke Oil 25W-40
Gear Case Oil Capacity	26 oz
Idle Speed (in gear)	600 ± 50 RPM (in gear)
Full Throttle RPM Range	5500-6000
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 200:

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 200.

▶BOTTOM COWL ASSEMBLY (31 parts)

Ref	OEM Part #	Part Name
1	58978A2	PLATE ASSEMBLY, MOUNTING
2	23-86215	WASHER, NYLON - WATER INLET TUBE
3	26-25329	SEAL, RUBBER - WATER INLET TUBE
4	33513	RETAINER, WATER INLET TUBE SEAL
5	10-20540	SCREW, RETAINER TO MOUNTING PLATE (5/8")
6	27-39401	GASKET, POWERHEAD TO MOUNTING PLATE
7	39622	SEAL, MOUNTING PLATE TO BOTTOM COWL
8	27-39402	GASKET, MOUNTING PLATE TO DRIVE SHAFT HOUSING
9	2129-3956A2	COWL, BOTTOM
10	46266A2	COVER PLATE ASSEMBLY, BOTTOM COWL
11	39591	PAD, SOUND - COVER PLATE
12	10-62568	SCREW, COVER PLATE TO BOTTOM COWL (3/8")
13	39630	CUSHION, RUBBER - BOTTOM COWL
14	60886	BOOT, THROTTLE CABLE - BOTTOM COWL
15	39778	BOOT, FUEL ADAPTOR - BOTTOM COWL
16	39780	BOOT, SHIFT CABLE - BOTTOM COWL
17	39058	SEAL, SHIFT HANDLE - BOTTOM COWL
18	32-8M0108355	HOSE, TELL TALE - COWL TO EXHAUST COVER (16 1/2")
19	22-996642	ELBOW, TELL TALE HOSE TO EXHAUST COVER
20	33474A1	STOP SWITCH ASSEMBLY
21	33474	HARNESS, STOP SWITCH
22	30859	INSULATOR, SLEEVE - INNER SWITCH TERMINALS
23	24-30858A1	SPRING AND CONTACT ASSEMBLY
24	38950A1	COVER ASSEMBLY, STOP SWITCH
25	12-38949	WASHER, SEALING - STOP SWITCH
26	13-21972	LOCKWASHER, STOP SWITCH CONNECTOR
27	11-21971	NUT, STOP SWITCH TO BOTTOM COWL
28	10-62568	SCREW, STOP SWITCH LEAD TO BOTTOM COWL
29	54-26550	CLIP, STOP SWITCH LEADS FASTENING
30	10-62568	SCREW, STOP SWITCH LEADS CLIP
31	8M0084613	"D" WASHER, STOP SWITCH LEADS CLIP SCREW

▶CARBURETOR ASSEMBLY (38 parts)

Ref	OEM Part #	Part Name
1	1343-3568	CARBURETOR ASSEMBLY, COMPLETE (KA-22B)
2	1395-8673	FLOAT ASSEMBLY
3	17-20853	PIN, FLOAT LEVER PINION
4	1399-102	LEVER, FLOAT (LOWER)
5	1399-101	LEVER, FLOAT (UPPER)
6	1395-92581	INLET NEEDLE, SEAT AND GASKET
7	27-25033	GASKET, INLET SEAT
8	1399-99	GASKET, FLOAT BOWL COVER
9	1399-1133	COVER, FLOAT BOWL
10	10-22625	SCREW, FLOAT BOWL COVER (SHORT)
11	10-25850	SCREW, FLOAT BOWL COVER (LONG)
12	27-25851	GASKET, STRAINER COVER (LARGE)
13	1399-3938	SCREEN, FILTER
14	27-25849	GASKET, STRAINER COVER (SMALL)
15	1399-1135	COVER, STRAINER
16	27-25848	GASKET, STRAINER COVER SCREW
17	10-25822	SCREW, STRAINER COVER
18	1395-6027	SCREW, THROTTLE STOP LEVER OR THROTTLE CLUSTER
19	8146791	LEVER, THROTTLE STOP
19A	46387	CLUSTER, THROTTLE
20	1399-2012	SHAFT, THROTTLE
21	1399-3031	TUBE, IDLE
22	27-23180	GASKET, IDLE TUBE
23	10-20858	SCREW AND LOCKWASHER, THROTTLE SHUTTER
24	1399-3032	SHUTTER, THROTTLE
25	19-20011	WELCH PLUG, BODY CHANNEL
26	24-20869	SPRING, THROTTLE SHAFT RETURN
27	10-28845	SCREW, PLUG - BODY CHANNEL
28	1399-2226	MAIN NOZZLE
29	10-23178	SCREW, PLUG - MAIN NOZZLE
30	1399-1653	JET, MAIN FUEL (.053)
31	27-28409	GASKET, MAIN FUEL JET
32	27-28406	GASKET, JET CHANNEL PLUG SCREW
33	10-28405	SCREW, PLUG - MAIN FUEL JET CHANNEL
34	1399-1713	SCREW, IDLE ADJUSTMENT
35	1399-3033	REPAIR PARTS KIT
36	27-757911	GASKET, CARBURETOR FLANGE
37	11-22053	NUT, CARBURETOR MOUNTING STUDS

▶CARBURETOR CHOKE LINKAGE (18 parts)

Ref	OEM Part #	Part Name
1	20596A3	THROTTLE LEVER ASSEMBLY
2	10-29239	SCREW, THROTTLE LEVER TO CARBURETOR (1/2")
3	23-35040	BUSHING, NYLON - THROTTLE LEVER
4	39769	EYELET, THROTTLE LEVER
5	17-23757	PIN, ROLL - THROTTLE LEVER
6	28087	SHUTTER, CHOKE - CARBURETOR
7	10-20578	SCREW, CHOKE SHUTTER TO CARBURETOR
8	24-20579	SPRING, CHOKE SHUTTER TO LEVER
9	39489	LEVER, CHOKE SHUTTER
10	16-20581	STUD, CHOKE SHUTTER LEVER TO CARBURETOR
11	13-29402	WASHER, WAVE - CHOKE SHUTTER LEVER STUD
12	11-8267089	NUT, CHOKE SHUTTER LEVER STUD
13	39600	SHAFT, CHOKE
14	26852	CAP, NYLON - CHOKE SHAFT
15	24-30947	SPRING, TENSION - CHOKE SHAFT
16	12-39595	WASHER, NYLON - CHOKE SHAFT
17	39055	KNOB, CHOKE
18	17-22896	PIN, ROLL - CHOKE KNOB TO CHOKE SHAFT

▶CLAMP AND SWIVEL BRACKET ASSEMBLY (37 parts)

Ref	OEM Part #	Part Name
1	1427-5632A3	CLAMP BRACKET ASSEMBLY
2	22477A4	THUMB SCREW ASSEMBLY
3	12-26227	WASHER, THUMB SCREW
4	74249	TILT TUBE, CLAMP BRACKET TO SWIVEL BRACKET
5	12-52864	SHIM, CLAMP BRACKET TILT TUBE
6	11-858869	NUT, TILT TUBE FASTENING
7	17-56373A2	TILT LOCK PIN ASSEMBLY
8	16-59620	STUD, CLAMP BRACKET
9	23-59621T	SPACER, CLAMP BRACKET STUD
10	12-24812	WASHER, CLAMP BRACKET STUD
11	13-8M0204647	LOCKWASHER, CLAMP BRACKET STUD
12	11-22053	NUT, CLAMP BRACKET STUD
13	17-39585	SWIVEL PIN
14	33423	CO-PILOT DISC
15	10-53460	SCREW, CO-PILOT DISC TO SADDLE
16	11-29250	NUT, CO-PILOT DISC TO SADDLE SCREW
17	1461-6667A1	SWIVEL BRACKET ASSEMBLY
18	25-8M0204650	"O" RING, SWIVEL BRACKET
19	22-8M0169589	FITTING, GREASE - SWIVEL BRACKET
20	19-77633Q	LUCRICAP, SWIVEL BRACKET GREASE FITTING
21	39307	PLATE, CLAMP - CO-PILOT
22	20203	DISC, FRICTION - CLAMP PLATE AND SWIVEL BRACKET
23	10-29201	SCREW, CLAMP PLATE TO SWIVEL BRACKET
24	38-39666	SERIAL PLATE
25	10-28642	SCREW, DRIVE - SERIAL PLATE TO SWIVEL BRACKET
26	33512	LEVER, TILT STOP
27	10-29237	SCREW, RETAINING - LEVER TO SWIVEL BRACKET
28	13-36076	WASHER, WAVE - TILT STOP LEVER SCREW
29	15-37711	SHIM, RETAINING SCREW
30	11-8M0207775	NUT, TILT STOP LEVER SCREW
31	10-20217	SCREW, ANCHOR - TILT STOP LEVER
32	23-20216	SPACER, TILT STOP LEVER SCREW
33	33417A1	REVERSE LOCK LEVER ASSEMBLY
34	26092	ROD, REVERSE LOCK LEVER
35	23-26841	BUSHING, NYLON - REVERSE LOCK LEVER ROD
36	18-45882	COTTER PIN, REVERSE LOCK LEVER TO ROD
37	24-33418	SPRING, REVERSE LOCK LEVER

▶CRANKSHAFT AND CENTER MAIN BEARING ASSEMBLY (14 parts)

Ref	OEM Part #	Part Name
1	415-2295	CRANKSHAFT
2	30-63326T	BEARING, BALL - CRANKCASE(LOWER)
3	26-16977	OIL SEAL, CRANKCASE (LOWER)
4	23-33736	SPACER, PROTECTOR - CRANKSHAFT
5	534-3267T25	CENTER MAIN BEARING ASSEMBLY
6	17-20032	DOWEL PIN, CENTER MAIN BEARING
7	10-25313	SCREW, CENTER MAIN BEARING CLAMPING
8	11-29469	NUT, CENTER MAIN BEARING CLAMPING SCREW
9	34-88498A1	REED SET, CENTER MAIN BEARING (MATCHED)
10	34-64632	REED STOP, MAIN BEARING REED VALVES
11	10-77280	SCREW, REED STOP MOUNTING
12	11-29469	NUT, REED STOP MOUNTING SCREW
13	17-20032	DOWEL PIN, MAIN BEARING TO CYLINDER BLOCK
14	28-20094	KEY, FLYWHEEL

▶CYLINDER BLOCK AND CRANKCASE ASSEMBLY (51 parts)

Ref	OEM Part #	Part Name
1	1123-3017A2	CRANKCASE TOP ASSEMBLY
2	25-20081	"O" RING, CRANKCASE TOP Comment: SERIAL 02031774-09999999
3	15-20514A1	SHIM, BALL BEARING TO CRANKCASE TOP (.002-3-5-10)
4	30-63326T	BEARING, BALL - CRANKCASE TOP (UPPER)
5	31-20594	BEARING, ROLLER - CRANKCASE TOP (UPPER)
6	26-66300	OIL SEAL, CRANKCASE TOP (UPPER)
7	10-25299	SCREW, CRANKCASE TOP TY CYLINDER BLOCK AND CRANKCASE (3/4")
8	14-20747	TAB WASHER, CRANKCASE TOP SCREW
9	54-34598	CLIP, HOLD DOWN RING - CRANKCASE TOP
10	10-36205	SCREW, RING CLIP TO CRANKCASE TOP
11	24-34731	SPRING, TENSION - HOLD DOWN RING CLIP
12	830-2753A3	CYLINDER BLOCK AND CRANKCASE ASSEMBLY
13	22-328022	PLUG, PIPE - CYLINDER BLOCK (TOP)
14	17-23784	PIN, DOWEL - CRANKCASE TO CYLINDER BLOCK
15	16-65866	STUD, CRANKCASE TO CYLINDER BLOCK (1 5/16")
16	11-29250	NUT, CRANKCASE STUD
17	16-65868	STUD, CYLINDER BLOCK TO DRIVE SHAFT HOUSING (2 1/8")
18	16-68165	STUD, CYLINDER BLOCK TO DRIVE SHAFT HOUSING (1 5/8")
19	19-20011	WELCH PLUG, CRANKCASE CHECK VALVE
20	21-27146A1	CHECK VALVE ASSEMBLY, CRANKCASE
21	16-68165	STUD, CRANKCASE TO DRIVE SHAFT HOUSING (1 5/8")
22	16-65865	STUD, CARBURETOR TO CRANKCASE
23	10-26066	SCREW, CRANKCASE TO CYLINDER BLOCK (1 1/4")
24	10-21449	SCREW, CRANKCASE TO CYLINDER BLOCK (2")
25	10-26123	SCREW, CRANKCASE TO CYLINDER BLOCK )2 1/2")
26	11-29250	NUT, CRANKCASE SCEW
27	25-25429	"O" RING, CRANKCASE SCREW
28	10-98260	SCREW, LOCK - CENTER MAIN BEARING (5/8")
29	14-20091	TAB WASHER, CENTER MAIN BEARING LOCK SCREW
30	10-22960	SCREW, THROTTLE LIMIT - CRANKCASE
31	11-20013	NUT, JAM - THROTTLE LIMIT SCREW
32	26852	CAP, NYLON - THROTTLE LIMIT SCREW
33	26174	COVER, TRANSFER PORT
34	27-26175	GASKET, TRANSFER PORT COVER
35	10-28635	SCREW, TRANSFER PORT COVER TO CYLINDER BLOCK
36	39956	CLIP, TRANSFER PORT COVER SCRWE
37	1020-2757	COVER, CYLINDER BLOCK
38	27-26173	GASKET, CYLINDER BLOCK COVER
39	10-24644	SCREW, COVER TO CYLINDER BLOCK (1 3/8")
40	10-21091	SCREW, COVER TO CYLINDER BLOCK (1")
41	11-8M0207775	NUT, CYLINDER BLOCK COVER SCREW
42	27-78411	GASKET, CYLINDER BLOCK TO BAFFLE PLATE
43	39308	PLATE, BAFFLE - EXHAUST MANIFOLD
44	27-78409	GASKET, BAFFLE PLATE TO MANIFOLD COVER
45	88797	COVER, EXHAUST MANIFOLD
46	10-37562	SCREW, MANIFOLD COVER TO CYLINDER BLOCK (1")
46&47	10-28782	SCREW, MANIFOLD COVER TO CYLINDER BLOCK (7/8")
47	10-39349	SCREW, MANIFOLD COVER TO CYLINDER BLOCK_ LOWER CENTER (3/4")
48	30-63326T	BEARING, BALL - CRANKCASE (LOWER)
49	26-16977	OIL SEAL, CRANKCASE(LOWER)
50	23-33736	SPACER, PROTECTOR - CRANKSHAFT

▶DRIVE SHAFT HOUSING ASSEMBLY (38 parts)

Ref	OEM Part #	Part Name
1	1560-2671A2	DRIVE SHAFT HOUSING ASSEMBLY (LONG SHAFT)
2	16-34378	STUD, DRIVE SHAFT HSG. TO GEAR HSG. (2 5/16")
3	16-33470	STUD, DRIVE SHAFT HSG. TO GEAR HSG. (3 15/16")
4	19-32298	PLUG, DRIVE SHAFT HOUSING
5	11-82670911	NUT, DRIVE SHAFT HOUSING STUD
6	11-8M0204726	NUT, GEAR HOUSING TO DRIVE SAHFT HOUSING STUD
7	32-39587	TUBE, WATER OUTLET (LONG SHAFT)
8	39301	COVER, TRIM - DRIVE SHAFT HOUSING
9	10-35012	SCREW, TRIM COVER TO BOTTOM COWL (5/8")
10	39353	SEAL, RUBBER - TRIM COVER
11	27-39402	GASKET, MOUNTING PLATE TO DRIVE SHAFT HOUSING
12	39492	PLATE, IDLE RELIEF
13	10-35519	SCREW, IDLE RELIEF PLATE TO DRIVE SHAFT HOUSING
14	32-45054	TUBE, NYLON - IDLE RELIEF PLATE
15	25-201951	"O" RING, IDLE RELIEF TUBE
16	11-29250	NUT, POWERHEAD STUDS
17	33420	BUMPER, RUBBER - SADDLE
18	10-31716	SCREW, RUBBER BUMPER TO SADDLE (5/8")
19	13-26992	LOCKWASHER, RUBBER BUMPER SCREW
20	1562-7098A1	SADDLE
21	85002	MOUNT, RUBBER - UPPER (LONG SHAFT)
22	53-23720	RING, RETAINING - UPPER MOUNT
23	39481	COVER, UPPER MOUNT
24	10-39669	SCREW, UPPER MOUNT COVER FASTENING
25	79947A1	MOUNT, RUBBER - LOWER (LONG SHAFT)
26	53-8M0051043	RING, RETAINING - LOWER MOUNT
27	23-31270	SPACER, LOWER MOUNT COVER
28	47943	COVER, LOWER MOUNT
29	10-33726	SCREW, LOWER MOUNT COVER FASTENING
30	33495	LINK ROD, REVERSE LOCK
31	24-33413	SPRING, TENSION - REVERSE LOCK LINK ROD
32	11-57146	NUT, REVERSE LOCK LINK ROD
33	39241A1	CAM COUPLING ASSEMBLY, SHIFT SHAFT
34	35653	RETAINER, REVERSE LOCK CAM
35	10-20540	SCREW, CAM RETAINER TO DRIVE SHAFT HOUSING
36	13-26992	LOCKWASHER, CAM RETAINER SCREW
37	33407	LEVER, REVERSE LOCK CAM
38	17-58998	PIN, TOLL - CAM LEVER TO RETAINER

▶FLYWHEEL ASSEMBLY AND THROTTLE CONTROL LINKAGE (36 parts)

Ref	OEM Part #	Part Name
1	11-8M0214915	NUT, FLYWHEEL
2	12-36281	WASHER, FLYWHEEL NUT
3	25-37340	"O" RING, FLYWHEEL HUB
4	28-20094	KEY, FLYWHEEL DRIVE
5	221-2297A1	FLYWHEEL ASSEMBLY, COMPLETE
6	10-35563	SCREW, FLEXIBLE PLATE TO FLYWHEEL
7	50-33000A1	RATCHET ASSEMBLY, FLYWHEEL
8	10-32417	SCREW, RATCHET TO FLYWHEEL
9	10-34290	SCREW, RATCHET TO FLYWHEEL
10	13-26992	LOCKWASHER, RATCHET TO FLYWHEEL SCREW
11	398-3297A1	STATOR PLATE ASSEMBLY, COMPLETE (SEE NOTE BELOW)
12	35599A1	SHIELD ASSEMBLY, LEAD WIRE - STATOR PLATE
13	10-45742	SCREW, LEAD WIRE SHIELD TO STATOR PLATE
14	13-26996	LOCKWASHER, SHIELD SCREW
15	34601	RING, HOLD DOWN - STATOR PLATE
16	10-35400	SCREW, HOLD DOWN RING TO STATOR PLATE
17	15-33910015	SHIM, STATOR PLATE TO CRANKCASE TOP
18	39296	CAM, THROTTLE CONTROL - STATOR PLATE
19	10-29722	SCREW, THROTTLE CONTROL CAM TO STATOR PLATE
20	46097	SWIVEL, CONTROL LINK TO THROTTLE CONTROL CAM
21	39596	LINK, THROTTLE CONTROL
22	13-27071	WASHER, WAVE - THROTTLE CONTROL LINK
23	12-26013	WASHER, THROTTLE CONTROL LINK
24	11-20110	NUT, THROTTLE CONTROL LINK TO THROTTLE LEVER
25	46381	BRACKET, STATOR PLATE
26	10-29722	SCREW, BRACKET TO STATOR PLATE
27	46407	LONK ROD, THROTTLE CONTROL
28	12-30164	WASHER, LINK ROD SWIVEL TO THROTTLE LEVER
29	33973	SWIVEL, LINK ROD TO THROTTLE LEVER
30	11-859124	NUT, THROTTLE CONTROL LINK ROD
31	30212	TERMINAL BLOCK, STATOR PLATE GROUND LEADS
32	10-72169	SCREW,TERMINAL BLOCK TO REAR MOUNTING BRACKET
33	10-62568	SCREW, GROUND LEADS TO TERMINAL BLOCK
34	54-22875	CLIP, STATOR LEADS FASTENING
35	10-62568	SCREW, STATOR LEADS FASTENING CLIP
36	8M0084613	"D" WASHER, STATOR LEADS FASTENING CLIP SCREW

▶FUEL PUMP AND FUEL LINE ASSEMBLY (21 parts)

Ref	OEM Part #	Part Name
1	39654A2	FUEL PUMP ASSEMBLY
2	21-30430A1	CHECK VALVE ASSEMBLY
3	23014A1	DIAPHRAGM KIT
6	23004	RETAINER, CHECK VALVE
7	10-43725	SCREW, RETAINER TO HOUSING
8	10-29246	SCREW, FUEL PUMP TO CYLINDER BLOCK (1 5/8")
9	10-28712	SCREW, FUEL PUMP TO CYLINDER BLOCK (1 5/8")
10	22-59351	FITTING, FUEL PUMP OUTLET
11	32-30040	FUEL LINE, FUEL PUMP TO CARBURETOR (5 1/4")
12	22-45089	ADAPTOR, FUEL PUMP INLET
13	22-22995	FITTING, FUEL PUMP INLET ADAPTOR TO FUEL LINE
14	22-22946	SLEEVE, RUBBER - FUEL PUMP INLET FITTING
15	22-22948	NUT, FUEL PUMP INLET FITTING
16	32-33475	FUEL LINE, FUEL PUMP TO ADAPTOR (22 1/2")
17	30188	CUP WASHER, ADAPTOR
18	24-23067T	SPRING, ADAPTOR STEM
19	25-16524	"O" RING, ADAPTOR STEM
20	23069	STEM, CHECK UNIT ADAPTOR
21	22833	ADAPTOR, CHECK UNIT
22	10-20784	SCREW, CHECK UNIT ADAPTOR TO BOTTOM COWL (1 1/2")
23	11-8267089	NUT, CHECK UNIT ADAPTOR SCREW

▶GEAR HOUSING ASSEMBLY, COMPLETE (PAGE 1) (50 parts)

Ref	OEM Part #	Part Name
1	1627-2964A1	GEAR HOUSING ASSEMBLY
2	17-20201	PIN, DOWEL - DRIVE SHAFT HOUSING STUD
3	16-30668	STUD, WATER PUMP TO GEAR HOUSING (2 13/16")
4	16-33471	STUD, GEAR HOUSING TO DRIVE SAHFT HOUSING(4 13/16")
5	31-28157	BEARING, ROLLER - DRIVE SHAFT
6	45-93301A1	DRIVE SHAFT (LONG SHAFT)
7	43-45227A3	GEAR, PINION
8	14-20806	TAB WASHER, PINION GEAR SCREW
9	10-20807	SCREW, PINION GEAR TO DRIVE SHAFT
10	10-79953Q04	SCREW, GREASE FILLER
11	12-191833	WASHER, GREASE FILLER SCREW
12	10-29608	SCREW, GEAR HOUSING FLUSHING
13	27-8M0214916	GASKET, GEAR HOUSING FLUSHING SCREW
14	26-8M0214917	SEAL, GEAR HOUSING FLUSHING SCREW
15	10-28653	SCREW, GREASE VENT
16	19643	WASHER, GREASE VENT SCREW
17	56830A1	SHAFT ASSEMBLY, SHIFT - LOWER (LONG SHAFT)
18	25-38933	"O" RING, LOWER SHIFT SHAFT
19	53-30899	RING, RETAINING - SHIFT SHAFT
20	23-30676A1	BUSHING ASSEMBLY, SHIFT SHAFT
21	25-26802	"O" RING, SHIFT SHAFT BUSHING
22	26-30696	OIL SEAL, SHIFT SHAFT BUSHING
23	10-39149	SCREW, SHIFT SHAFT BUSHING RETAINER
24	15-20804A1	SHIM, BALL BEARING TO GEAR HOUSING (.002-3-5-10)
25	30-69389	BEARING, BALL - DRIVE SHAFT
26	53-33463	RING, RETAINING - BALL BEARING
27	15-20804A1	SHIM, GEAR HOUSING TO WATER PUMP BASE(.002-3-5-10)
28	27-39626	GASKET, WATER PUMP BASE TO GEAR HOUSING
29	25-33466	"O" RING, WATER PUMP BASE
30	46-48763A1	WATER PUMP BASE ASSEMBLY
31	26-20070	OIL SEAL, WATER PUMP BASE
32	26-897154	OIL SEAL, WATER PUMP BASE (SPRING LOADED)
33	17-35973	PIN, DOWEL - WATER PUMP BASE TO WATER PUMP BODY
34	27-39625	GASKET, WATER PUMP BASE TO FACE PLATE (LOWER)
35	39624	PLATE, FACE - WATER PUMP BASE TO WATER PUMP BODY
36	27-396231	GASKET, FACE PLATE TO WATER PUMP BODY (UPPER)
37	47-39487	IMPELLER, WATER PUMP
38	28-28784	KEY, IMPELLER DRIVE
39	46-60365A1	WATER PUMP BODY ASSEMBLY
40	39629	INSERT, WATER PUMP BODY
41	26-20070	OIL SEAL, WATER PUMP BODY
42	23-86215	WASHER, NYLON - WATER PUMP BODY
43	26-25329	SEAL, WATER PUMP BODY
44	45010	RETAINER, WATER PUMP BODY SEAL Comment: SERIAL 02032081-09999999
45	10-455611	SCREW, SEAL RETAINER TO WATER PUMP BODY (1 1/8") Comment: SERIAL 02032081-09999999
46	23-45170	SLEEVE, GUIDE - WATER INLET TUBE
47	13-8M0204647	LOCKWASHER, WATER PUMP STUDS
48	11-28770	NUT, WATER PUMP STUDS
49	12-20684	RING, RUBBER - CENTRIFUGAL SLINGER (DRIVE SHAFT)
50	25-26802	"O" RING, UPPER - DRIVE SHAFT

▶GEAR HOUSING ASSEMBLY, COMPLETE (PAGE 2) (30 parts)

Ref	OEM Part #	Part Name
1	1627-2964A1	GEAR HOUSING ASSEMBLY SEE PAGE 26 FOR PARTS BREAKDOWN
51	33436	CAM, SHIFT
52	33438	FOLLOWER, CAM
53	24-88435	SPRING, CAM FOLLOWER
54	97-47820A1	PLATE, ANODIC - GEAR HOUSING
55	10-29081	SCREW, ANODIC PLATE TO GEAR HOUSING (1 1/4")
56	43-33447A1	FORWARD GEAR ASSEMBLY, COMPLETE
57	30-25398	BEARING, BALL - FORWARD GEAR
58	43-33447A1	FORWARD GEAR ASSEMBLY
59	31-28157	BEARING, ROLLER - FORWARD GEAR
60	52-33443	RATCHET, SLIDING CLUTCH
61	17-33433	PIN, CROSS - RATCHET TO PROPELLER SHAFT
62	53-33430	RING, RETAINING - CROSS PIN
63	43-33444A1	REVERSE GEAR ASSEMBLY, COMPLETE
64	43-33444A1	REVERSE GEAR ASSEMBLY
65	30-25398	BEARING, BALL - REVERSE GEAR
66	12-33434	WASHER, THRUST - REVERSE GEAR
67	15-33431A1	SHIM, THRUST WASHER TO GEAR HOUSING (.00A2-3-5-10)
68	25-8M0214925	"O" RING, BEARING CARRIER
69	33402T4	BEARING CARRIER ASSEMBLY
70	31-28157	BEARING, ROLLER - BEARING CARRIER
71	26-27163	OIL SEAL, BEARING CARRIER (SPRING LOADED)
72	26-26805	OIL SEAL, BEARING CARRIER
73	12-33432	WASHER, GEAR HOUSING COVER
74	33410	COVER, GEAR HOUSING
75	23-85964A1	COLLAR, GUIDE - PROPELLER SHAFT
76	48-37316A1	PROPELLER ASSEMBLY (3 BLADE - ALUMINUM - 7" PITCH)
77	11-64075A1	SPACER, SPLINE - PROPELLER SHAFT
78	12-27025	WASHER, PROPELLER NUT
79	11-8M0204653	NUT, PROPELLER RETAINING

▶MISCELLANEOUS PARTS/ACCESSORIES (1 parts)

Ref	OEM Part #	Part Name
-	46-48749A3	HEAVY DUTY WATER PUMP ASSEMBLY

▶PISTON AND CONNECTING ROD ASSEMBLY (9 parts)

Ref	OEM Part #	Part Name
1	600-2748A2	CONNECTING ROD ASSEMBLY
2	10-45379	SCREW, CONNECTING ROD
3	29-20046T	BEARING, NEEDLE - CRANKPIN
4	11-20061	NUT, CONNECTING ROD SCREW
5	12-28121	WASHER, NEEDLE BEARING RETAINING
6	29-20063	BEARING, NEEDLE - PISTON PIN
7	724-2537A2	PISTON AND PISTON PIN ASSEMBLY
8	40-20057	LOCK RING, PISTON PIN
9	39-28616A12	RING, PISTON (.015 OVERSIZE)

▶SHIFT CONTROL LINKAGE (34 parts)

Ref	OEM Part #	Part Name
1	59107	HANDLE, NYLON - SHIFT CONTROL
2	12-8M0204649	WASHER, SHIFT CONTROL HANDLE
3	11-826709109	NUT, SHIFT CONTROL HANDLE TO SHIFT SHAFT
4	64122	BRACKET, MOUNTING - SHIFT SHAFT
5	10-56500	SCREW, MOUNTING BRACKET TO POWERHEAD PLATE (1 1/4")
6	11-8M0207775	NUT, MOUNTING BRACKET SCREW
7	24-39627	SPRING, DETENT - MOUNTING BRACKET
8	39601	PLATE, DETENT SPRING
9	10-69022	SCREW, PLATE AND SPRING TO MOUNTING BRACKET (1/2")
10	23-30678	BUSHING, NYLON - SHIFT SHAFT
11	39588	CAM, DETENT - SHIFT SHAFT
12	17-25905	PIN, RILL - DETENT CAM TO SHIFT SHAFT
13	13-36206	WASHER, WAVE - SHIFT SHAFT
14	12-20553	WASHER, SHIFT SHAFT
15	39415	LEVER, SHIFT CONTROL
16	17-25905	PIN, ROLL - SHIFT CONTROL LEVER TO SHIFT SHAFT
17	39632	SHAFT, SHIFT (HORIZONTAL)
18	15-39952A1	SHIM, SECTOR GEAR TO NYLON BUSHING(.002-10-15)
19	43-30802	GEAR, SECTOR, SHIFT SHAFT
20	12-8M0204649	WASHER, SHIFT SHAFT
21	11-8267089	NUT, SECTOR GEAR TO SHIFT SHAFT
22	61009A2	SHIFT CONTROL SHAFT ASSEMBLY, VERTICAL
23	43-39477	GEAR, SECTOR - SHIFT CONTROL SHAFT
24	25-38933	"O" RING, SHIFT CONTROL SHAFT
25	23-30677	BUSHING, NYLON - SHIFT CONTROL SHAFT
26	58979	FOLLOWER, NEUTRAL SPEED LIMITER Comment: SERIAL 02189601-09999999
27	10-24644	SCREW, FOLLOWER TO POWERHEAD MOUNTING PLATE (1 3/8")
28	15-28212	SHIM, LIMITER FOLLOWER SCREW
29	11-8M0207775	NUT, LIMITER FOLLOWER SCREW
30	24-39675	SPRING, NEUTRAL SPEED LIMITER FOLLOWER
31	10-62568	SCREW, SPRING TO LIMITER FOLLOWER
32	72857	STOP, OVER-SPEED LIMITER Comment: SERIAL 02189601-09999999
33	12-24676	WASHER, LIMITER STOP SCREW Comment: SERIAL 02189601-09999999
34	10-35400	SCREW, LIMITER STOP TO FOLLOWER (7/16") Comment: SERIAL 02189601-09999999

▶STATOR PLATE ASSEMBLY (34 parts)

Ref	OEM Part #	Part Name
1	398-2221	STATOR PLATE AND CORE
2	398-2568T1	COIL ASSEMBLY
3	398-2321	CLIP, COIL RETAINING
4	398-2413	CLIP, COIL RETAINING
5	398-2207	FELT, CAM - BREAKER
6	398-732	CLIP, GROUND WIRE LEAD
7	10-21130	SCREW, GROUND TERMINAL
8	398-2203	CONDENSER ASSEMBLY
9	10-38395	SCREW, CONDENSER FASTENING (1 1/4")
10	13-21134	LOCKWASHER, CONDENSER FASTENING SCREW
11	12-21135	WASHER, CONDENSER FASTENING SCREW
12	54-45806	CLAMP, LEAD WIRE
13	12-21135	WASHER, LEAD WIRE CLAMP SCREW
14	13-21134	LOCKWASHER, LEAD WIRE CLAMP SCREW
15	11-21923T	NUT, LEAD WIRE CLAMP SCREW
16	11-21825	NUT, COIL LEAD WIRE CLIP SCRW(SPACER)
17	54-24836	CLIP, NYLON - COIL LEAD WIRE
18	8M0084613	"D" WASHER, COIL ELAD WIRE CLIP
19	13-26995	LOCKWASHER, COIL LEAD WIRE CLIP SCREW
20	11-26419	NUT, COIL LEAD WIRE CLIP SCREW
21	398-2320	BREAKER ASSEMBLY
22	10-33988	SCREW/LOCKWASHER, BREAKER FASTENING
23	12-21135	WASHER, TERMINAL SCREW
24	13-21134	LOCKWASHER, TERMINAL SCREW
25	11-21923T	NUT, TERMINAL SCREW
26	398-2206	GROUND LEAD, STATOR TO TERMINAL BLOCK
27	23-30419	SLEEVE, INSULATION - GROUND LEAD
28	84-821945A46	LEAD WIRE
29	84-821945A46	LEAD WIRE - TOP
30	85-63709A1	PROTECTOR, SPARK PLUG
31	20117	MARKER, "TOP" - LEAD WIRE
32	33-8M0114739	SPARK PLUG, (CHAMPION - L4J)
33	398-2208	COVER, DUST - STATOR PLATE
34	10-36455	SCREW, DUST COVER TO STATOR PLATE

▶STEERING HANDLE ASSEMBLY (25 parts)

Ref	OEM Part #	Part Name
1	27763	GRIP, RUBBER - STEERING HANDLE BODY
2	39352	BODY AND SHAFT, STEERING HANDLE
3	31001	INDICATOR, SPEED AND SHIFT - STEERING HANDLE
4	10-31002	SCREW, SET - SPEED AND SHIFT INDICATOR
5	10-22290	SCREW, DRIVE - INDICATOR TO STEERING HANDLE BODY
6	23-30677	BUSHING, NYLON - STEERING HANDLE TO BODY
7	49557A4	STEERING HANDLE ASSEMBLY
8	23-28100	BUSHING, NYLON - STEERING HANDLE
9	12-30283	WASHER, STEERING HANDLE SHAFT
10	24-26703	SPRING, STEERING HANDLE SHAFT
11	39211	RETAINER, YOKE PIN HOLDING
12	39208	YOKE, STEERING HANDLE SHAFT
13	39210	PLATE, NYLON - THROTTLE CONTROL SHAFT
14	17-26862	PIN, YOKE TO STEERING HANDLE SHAFT
15	39218	PIVOT, STEERING HANDLE TO BRACKET
16	15-26707	SHIM, STEERING HANDLE PIVOT TO BRACKET
17	13-39227	WASHER, WAVE - STEERING HANDLE PIVOT TO BRACKET
18	13-39228	LOCKWASHER, STEERING HANDLE SCREW
19	10-96138	SCREW, STEERING HANDLE TO ARM BRACKET
20	39631A1	THROTTLE CONTROL SHAFT ASSEMBLY
21	10-96138	SCREW, THROTTLE CONTROL SHAFT TO BRACKET (1/2")
22	39185	SHIELD, STEERING HANDLE
23	39302T	BRACKET, STEERING ARM
24	10-53460	SCREW, STEERING ARM BRACKET TO SADDLE
25	11-29250	NUT, STEERING ARM BRACKET FASTENING SCREW

▶THROTTLE CONTROL LINKAGE (31 parts)

Ref	OEM Part #	Part Name
1	43-39478	GEAR, PINION - THROTTLE CONTROL
2	23-31011	BUSHING, NYLON - THROTTLE CONTROL HOUSING
3	45160	HOUSING, THROTTLE CONTROL SEE NOT BELOW
4	43-60863	SHAFT AND GEAR, THROTTLE
5	10-20653	SCREW, THROTTLE CONTROL HOUSING FASTENING (1") - LOWER
6	11-8M0207775	NUT, THROTTLE CONTROL HOUSING SCREW
7	10-32293	SCREW, THROTTLE CONTROL HOUSING FASETNING (1 3/4") - UPPER
8	12-20084	WASHER, THROTTLE CONTROL HOUSING SCREW
9	11-29250	NUT, THROTTLE CONTROL HOUSING SCREW
10	23-33462	BUSHING, NYLON - SHAFT AND GEAR (THROTTLE CONTROL HOUSING)
11	12-20086	WASHER, THROTTLE SHAFT AND GEAR
12	13-36206	WASHER, WAVE - THROTTLE SHAFT AND GEAR Comment: SERIAL 02188145-09999999
13	18-25191	COTTER PIN, THROTTLE SHAFT AND GEAR
14	45152	LEVER, THROTTLE - SHAFT AND GEAR Comment: SERIAL 01973290-09999999
15	10-36137	SCREW, LOCKING - THROTTLE LEVER(1") Comment: SERIAL 02031466-09999999
16	11-30506	NUT, THROTTLE LEVER LOCKING SCREW
17	23-30678	BUSHING, NYLON - THROTTLE LEVER (UPPER)
18	46413	THROTTLE LEVER, VERTICAL SHAFT
19	10-22960	SCREW, VERTICAL SHAFT THROTTLE LEVER
20	11-25168	NUT, VERTICAL SHAFT THROTTLE LEVER SCREW
21	17-24865	PIN, GROOVE - STATOR PLATE LEVER TO VERTICAL SHAFT
22	46919	LEVER, STATOR PLATE - VERTICAL SHAFT Comment: SERIAL 02188146-09999999
23	46408	LEVER, STATOR PLATE CONTROL
24	10-21807	SCREW, STARTER HOUSING TO CRANKCASE (1 3/4")
25	23-46406	BUSHING, STATOR PLATE CONTROL LEVER
26	11-8267089	NUT, STARTER HOUSING TO CRANKCASE SCREW
27	12-24664	WASHER, SHAFT AND GEAR
28	11-826709109	NUT, SHAFT AND GEAR
29	46405	LINK, THROTTLE CLUSTER
30	10-69011	SCREW, THROTTLE CLUSTER LINK
31	11-68219	NUT, JAM - THROTTLE CLUSTER LINK SCREW

▶TOP COWL AND STARTER ASSEMBLY (65 parts)

Ref	OEM Part #	Part Name
1	2130-2677A2	TOP COWL ASSEMBLY
2	39664	INSERT, ROPE GUIDE - TOP COWL
3	16-21553	STUD, TOP COWL TO MOUNTING BRACKETS(1 1/2")
4	12-30283	WASHER, TOP COWL STUD
5	11-82670911	NUT, TOP COWL STUD
6	39400	SHIELD, REAR - TOP COWL
7	10-38055	SCREW, REAR SHIELD TO TOP COWL (5/8")
8	2133-2706A5	WRAP AROUND COWL ASSEMBLY
9	39606	BLANKET, SOUND ABSORBING - WRAP AROUND COWL
10	30413	HOOK, COWL LATCH FASTENING
11	46785A1	HANDLE, COWL LATCH Comment: SERIAL 00000000-02249145
12	46785A1	SWIVEL, COWL LATCH Comment: SERIAL 00000000-02249145
13	17-21057	PIN, HINGE - COWL LATCH HANDLE Comment: SERIAL 00000000-02249145
14	53-21058	"E" RING, COWL LATCH HINGE PIN Comment: SERIAL 00000000-02249145
15	46785A1	COWL LATCH ASSEMBLY Comment: SERIAL 02249146-09999999
16	39628	BUTTON, FRONT COVER RELEASE - TOP COWL
17	24-20099	SPRING, COMPRESSION - FRONT COVER RELEASE BUTTON
18	12-8M0204649	WASHER, FRONT COVER RELEASE BUTTON
19	60865	CATCH, FRONT COVER - TOP COWL
20	10-22523	SCREW, FRONT COVER LATCH TO TOP COWL (3/4")
21	2127-5669A2	FRONT COVER ASSEMBLY, COMPLETE
22	60867A1	BASE, FRONT COVER LATCH
23	10-26500	SCREW, LATCH BASE TO FRONT COVER (9/16")
24	12-26014	WASHER, LATCH BASE SCREW
25	60866	HOOK, FRONT COVER LATCH
26	24-39598	SPRING, TORSION - FRONT COVER LATCH HOOK
27	17-39599	PIN, PIVOT - FRONT COVER LATCH HOOK
28	39936	BLANKET, SOUND ABSORBING - FRONT COVER
29	2131-3020	HOUSING, STARTER
30	10-37562	SCREW, STARTER HOUSING TO CYLINDER BLOCK (1")
31	13-8M0204647	LOCKWASHER, STARTER HOUSING TO CYLINDER BLOCK SCREW
32	10-21807	SCREW, STARTER HOUSING TO CRANKCASE (1 3/4")
33	11-8267089	NUT, STARTER HOUSING TO CRANKCASE SCREW
34	55860	PULLEY, STARTER CABLE
35	10-37892	SCREW, PULLEY TO STARTER HOUSING (1")
36	12-22887	WASHER, PULLEY SCREW
37	23-309772	SPACER, PULLEY SCREW
38	11-20110	NUT, PULLEY SCREW
39	25-39597	GROMMET, STARTER HOUSING
40	14-20165	TAB WASHER, SHEAVE SHAFT NUT
41	11-20166	NUT, SHEAVE SHAFT (LEFT HAND THREAD)
42	20155	RETAINER, STARTER SPRING
43	24-29340T02	SPRING, STARTER REWIND
44	23-20159	BUSHING, SPRING GUIDE
45	50-64008A1	STARTER SHEAVE ASSEMBLY Comment: SERIAL 02091156-09999999
46	13-29720	WASHER, WAVE - STARTER PAWL
47	20162	PAWL, STARTER
48	23-65720	SPACER, SHEAVE SHAFT Comment: SERIAL 02091156-09999999
49	26179	RETAINER, STARTER SHEAVE TO PLATE
50	12-35559	WASHER, STARTER SHEAVE RETAINER Comment: SERIAL 02091156-09999999
51	13-20160	WASHER, WAVE - STARTER SHEAVE TENSION
52	20164	PLATE, RETAINER - STARTER PAWL
53	24-45823	SPRING, PAWL RETAINER PLATE Comment: SERIAL 02091156-09999999
54	65869A1	SHAFT, SHEAVE Comment: SERIAL 02091156-09999999
55	39298	BRACKET, MOUNTING - TOP COWL (REAR)
56	10-37562	SCREW, REAR MOUNTING BRACKET TO BOTTOM COWL (1")
57	90435	MOUNT, RUBBER - REAR MOUNTING BRACKET TO CYLINDER BLOCK
58	11-8267089	NUT, RUBBER MOUNT TO BRACKET AND CYLINDER BLOCK
59	39300	BRACKET, MOUNTING - TOP COWL (FRONT)
60	10-37562	SCREW, FRONT MOUNTING BRACKET TO BOTTOM COWL (1")
61	90435	MOUNT, RUBBER - FRONT MOUNTING BRACKET TO CRANKCASE
62	11-8267089	NUT, RUBBER MOUNT TO BRACKET AND CRANKCASE
63	50-12066Q10	STARTER CABLE ASSEMBLY
64	30782	HANDLE, STARTER CABLE
65	79470A1	RETAINER, STARTER CABLE AND HANDLE

100-Hour / Annual Service Checklist

Regular maintenance keeps your Mercury 200 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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