🔎 Mercury 4 (2-STROKE) Reference Library — Exploded parts diagrams (16 diagrams), specifications, common issues, and maintenance checklist.
The Mercury 4 (2-STROKE) is a 4-Stroke, 1-Cylinder outboard motor. Designed for dinghies, inflatable boats, and small tenders where lightweight portability is essential.
Quick Reference Specifications
| Specification |
Value |
| Engine Type |
4-Stroke, 1-Cylinder |
| Horsepower |
4 HP |
| Displacement |
123 cc |
| Bore x Stroke |
59 mm x 45 mm |
| Spark Plug (Type & Gap) |
NGK DPR6EA-9 |
| Engine Oil Capacity |
0.45 L (15 fl oz) |
| Recommended Engine Oil |
TC-W3 Certified 2-Stroke Oil |
| Gear Case Oil Capacity |
189 mL (6 fl oz) |
| Idle Speed (in gear) |
1100 RPM (in gear) |
| Full Throttle RPM Range |
4500-5500 |
| 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 4 (2-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
-
Fuel System Issues / Hard Starting: Stale fuel and ethanol-related deposits are common in 2-stroke carbureted engines. Clean or rebuild carburetors and replace fuel lines if deteriorated. → Recommended: Carburetor Repair Kit, Fuel Line Assembly
-
Spark Plug Fouling: 2-stroke engines are prone to spark plug fouling from oil residue, especially at low RPM. Replace plugs at each annual service. → Recommended: OEM Spark Plugs
-
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
-
Thermostat Failure: A stuck thermostat can cause overheating or poor warm-up. Replace if operating temperature is inconsistent. → Recommended: Thermostat Assembly
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 4 (2-STROKE).
▶Accessories (22 parts)
| Ref |
OEM Part # |
Part Name |
| - |
16838A4 |
CHARGING KIT, Battery (RECTIFIER) Comment: (6 AMP) |
| 0 |
82776 |
ATTACHING KIT, Cable And Pulley |
| 1 |
16837A2 |
ALTERNATOR KIT |
| 2 |
16074T |
ALTERNATOR |
| 3 |
10-16059 |
SCREW |
| 4 |
54-16060 |
CLAMP |
| 5 |
10-16821 |
SCREW |
| 6 |
16076A1 |
RECTIFIER KIT Comment: (Use with 25MM Screw) |
| 7 |
89-16077 |
FUSE |
| 8 |
10-16078 |
SCREW Comment: (20MM) |
| 9 |
13-16079 |
LOCKWASHER |
| 10 |
12-8M0108373 |
WASHER, Stainless Steel |
| 11 |
54-813275 |
CLAMP |
| 12 |
11-16081 |
NUT, Stainless Steel |
| 13 |
84-16082 |
CABLE, Battery |
| 14 |
16839A4 |
GUIDE KIT, Vertical Rope |
| 15 |
16113 |
PLATE, Seal |
| 16 |
10-17173 |
SCREW |
| 17 |
16841Q02 |
FLUSHING ATTACHMENT |
| 18 |
84-17175 |
HARNESS ASSEMBLY |
| 19 |
8538281 |
HANDLE, (1.0 Meters) Comment: (1.0M) |
| 20 |
803799A1 |
IGNITION CHECKER |
▶Carburetor (45 parts)
| Ref |
OEM Part # |
Part Name |
| - |
16115A03 |
GASKET SET, Powerhead |
| 1 |
3303-812648T |
CARBURETOR Comment: (5 H.P.) |
| 2 |
812650 |
MAIN NOZZLE |
| 3 |
80,19249 |
JET, Main |
| 4 |
52,16251 |
JET, Pilot Comment: (5 H.P.) |
| 5 |
16252 |
CAP |
| 6 |
16254 |
FLOAT VALVE |
| 7 |
54-16255 |
CLIP |
| 8 |
16253 |
FLOAT |
| 9 |
17-16256 |
PIN |
| 10 |
10-16257 |
SCREW |
| 11 |
16258 |
FLOAT BOWL |
| 12 |
25-16259 |
O-RING |
| 13 |
10-16260 |
SCREW, (M4 x 12) |
| 14 |
10-16261 |
SCREW, Drain |
| 15 |
27-16262 |
GASKET |
| 16 |
27-16326 |
GASKET |
| 17 |
16325 |
DIAPHRAGM |
| 18 |
16268 |
BODY, Pump |
| 19 |
21-16269 |
CHECK VALVE |
| 20 |
10-16270 |
SCREW |
| 21 |
11-16271 |
NUT |
| 22 |
16275 |
DIAPHRAGM |
| 23 |
27-16274 |
GASKET |
| 24 |
16272 |
COVER, Pump |
| 25 |
855540 |
COVER, Carburetor |
| 26 |
27-855541 |
GASKET |
| 27 |
27-8555411 |
GASKET |
| 28 |
10-855542 |
SCREW |
| 29 |
10-162606 |
SCREW Comment: SN# 0T707899/0P268000 & Up |
| 30 |
10-812935 |
SCREW, Adjusting Comment: (5 H.P.) |
| 31 |
24-16266 |
SPRING |
| 32 |
10-16263 |
SCREW |
| 33 |
24-16264 |
SPRING |
| 34 |
27-16327 |
GASKET |
| 35 |
8M0207654 |
BRACKET |
| 36 |
10-855809003 |
BOLT Comment: SN# 0T707899/0P268000 & Up |
| 37 |
13-16818 |
LOCKWASHER |
| 38 |
812936 |
PLATE, Baffle |
| 39 |
10-16334 |
SCREW |
| 40 |
12-16335 |
WASHER |
| 41 |
8M0155123 |
ROD, Choke |
| 42 |
827662 |
LINK, Choke |
| 43 |
25-163321 |
GROMMET |
| 44 |
16333 |
ROD, Snap |
▶Clamp and Swivel Brackets (36 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
3406-9622T6 |
CLAMP BRACKET, Starboard Comment: (STARBOARD) |
| 2 |
3406-96231 |
CLAMP BRACKET, Port Comment: (PORT) |
| 3 |
10-898101337 |
BOLT |
| 4 |
12-95375 |
WASHER |
| 5 |
12-16192 |
WASHER |
| 6 |
11-95374 |
NUT, (M8) |
| 7 |
16193 |
DISTANCE PLATE |
| 8 |
10-16194 |
SCREW |
| 9 |
24-161951 |
SPRING |
| 10 |
10-16196 |
SCREW |
| 11 |
12-16197 |
WASHER |
| 12 |
16198004 |
THRUST ROD |
| 13 |
24-8150931 |
SPRING |
| 14 |
10-16200 |
CLAMP SCREW ASSEMBLY |
| 15 |
12-95379 |
PAD |
| 16 |
3407-813029T1 |
SWIVEL BRACKET |
| 17 |
22-824969 |
FITTING, Grease |
| 18 |
808599 |
CAP Comment: (Use where Applicable) |
| 19 |
10-8M0147119 |
BOLT |
| 20 |
23-8M0057473 |
BUSHING (UPPER) |
| 21 |
23-8M0057474 |
BUSHING (LOWER) |
| 22 |
16204 |
THRUST PLATE |
| 23 |
10-162061 |
SCREW, Adjusting |
| 24 |
24-953838 |
SPRING |
| 25 |
12-16826 |
WASHER, Stainless Steel |
| 26 |
162051 |
FRICTION PLATE |
| 27 |
8M0045584 |
STOP ASSEMBLY, Tilt |
| 28 |
8M0090337 |
GRIP |
| 29 |
825113 |
BUSHING |
| 30 |
16210002 |
SET PLATE |
| 31 |
10-8230427 |
BOLT |
| 32 |
24-16212 |
SPRING |
| 33 |
16213 |
ARM, Reverse Lock |
| 34 |
24-16215 |
SPRING Comment: (RIGHT) |
| 35 |
24-16216 |
SPRING Comment: (LEFT) |
| 36 |
10-82304223 |
BOLT |
▶Cowling (23 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
2189-815038A2 |
TOP COWL ASSEMBLY Comment: (SILVER) |
| 2 |
25-162282 |
SEAL, Rubber |
| 3 |
8M0130233 |
SEAL, Rubber |
| 4 |
810780 |
BAFFLE, Sound |
| 5 |
12-16826 |
WASHER, Stainless Steel |
| 6 |
162181 |
HOOK LEVER |
| 7 |
26-16219 |
SEAL |
| 8 |
23-16220 |
BUSHING |
| 9 |
16222 |
COVER HOOK |
| 10 |
10-8230427 |
BOLT |
| 11 |
12-953921 |
WASHER, Stainless Steel |
| 12 |
13-16221 |
WAVE WASHER |
| 13 |
25-16231 |
GROMMET |
| 14 |
25-16225 |
GROMMET |
| 15 |
25-16226 |
GROMMET |
| 16 |
91-16229 |
TOOL KIT |
| 17 |
50-16230 |
SAFETY ROPE |
| 18 |
19-18670 |
PLUG |
| 19 |
815037 |
PLUG |
| 20 |
2189-825984A2 |
BOTTOM COWL |
| 21 |
10-16832 |
BOLT, (M6 x 16) |
| 22 |
37-804661A05 |
DECAL, EPA Label Information Comment: (2005) |
| 23 |
37-16227 |
DECAL, Fuel Cock |
▶Cylinder Block/Crankshaft/Piston (39 parts)
| Ref |
OEM Part # |
Part Name |
| - |
8M0145945 |
POWERHEAD ASSEMBLY Comment: (5 HP)(Without Re-Circulation System) |
| 1 |
878-815013A5 |
CYLINDER BLOCK Comment: (Without Re-Circulation System) |
| 2 |
17-16119 |
PIN, Dowel |
| 3 |
10-16695 |
BOLT |
| 4 |
10-815063 |
SCREW |
| 5 |
13-16818 |
LOCKWASHER |
| 6 |
979-96301 |
CYLINDER HEAD |
| 7 |
27-812939015 |
GASKET |
| 8 |
10-16126 |
BOLT Comment: SN# 0T707899/0P268000 & Up |
| 9 |
12-4002217 |
WASHER |
| 10 |
33-8M0114744 |
SPARK PLUG, (NGK#BP7HS-10) Comment: (Without Resistance) |
| 11 |
34-16706 |
REED VALVE |
| 12 |
34-17666 |
STOP Comment: (5 HP) |
| 13 |
10-16820 |
SCREW |
| 14 |
8150162 |
HOUSING |
| 15 |
23-815017 |
BUSHING |
| 16 |
26-8M0101649 |
SEAL, Oil |
| 17 |
27-8M0152378 |
GASKET |
| 18 |
10-167051 |
BOLT |
| 19 |
31-16052 |
BEARING, Roller |
| 20 |
28-16053 |
KEY |
| 21 |
30-16049 |
BEARING, Ball |
| 22 |
8537122 |
THRUST PLATE |
| 23 |
26-16051 |
SEAL, Oil |
| 24 |
779-9616T |
PISTON Comment: (.5MM Oversize) |
| 25 |
53-16057 |
CLIP |
| 26 |
39-8M0080356 |
RING, Piston Comment: (.5MM Oversize) |
| 27 |
41-898101918 |
PIN, Piston |
| 28 |
474-879147T15 |
CRANKSHAFT ASSEMBLY |
| 29 |
NSS |
NOT SOLD SEPARATE, Crankshaft |
| 30 |
NSS |
NOT SOLD SEPARATE, Crankshaft |
| 31 |
813046 |
PIN, Crank |
| 32 |
629-813047 |
CONNECTING ROD |
| 33 |
31-813048 |
BEARING |
| 34 |
23-815018 |
SPACER |
| 35 |
32-823976 |
HOSE, Tell-Tale |
| 36 |
32-8M0057112 |
HOSE, Rubber (1 Meter) Comment: (Use with Re-Circulation System) |
| 37 |
21-42657A3 |
CHECK VALVE Comment: (Use with Re-Circulation System) |
| 38 |
54-95224 |
CLIP Comment: (Use with Re-Circulation System) |
▶Driveshaft Housing/Gear Housing (31 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-8M0188431 |
SEAL KIT, Gear Housing |
| 1 |
1500-8M0089106 |
HOUSING ASSEMBLY, Driveshaft Comment: (LONG) |
| 2 |
23-16114 |
BUSHING |
| 3 |
10-879194264 |
BOLT |
| 4 |
19-879194296 |
FLUSH PLUG Comment: SN# 0T707899/0P268000 & Up |
| 5 |
27-95220 |
GASKET |
| 6 |
27-812947001 |
GASKET |
| 7 |
17-16119 |
PIN, Dowel |
| 8 |
25-161181 |
GROMMET |
| 9 |
25-16117 |
GROMMET |
| 10 |
827663A1 |
HOUSING ASSEMBLY |
| 11 |
16121 |
RETAINER |
| 12 |
10-16123 |
SCREW, (25 mm) Comment: (LONG) |
| 13 |
1668-9621T6 |
GEAR HOUSING ASSEMBLY Comment: (BASIC-SAILPOWER/SAILMATE) |
| 14 |
23-16124 |
BUSHING |
| 15 |
97-875208 |
ANODE Comment: (SQUARE) |
| 16 |
10-16832 |
BOLT, (M6 x 16) |
| 17 |
22-8M0229353 |
PLUG |
| 18 |
27-95220 |
GASKET |
| 19 |
10-8M0063198 |
BOLT (FRONT) |
| 20 |
12-16826 |
WASHER, Stainless Steel |
| 21 |
10-16126 |
BOLT (REAR) |
| 22 |
12-16192 |
WASHER |
| 23 |
16133 |
STRAINER, Water |
| 24 |
10-16134 |
SCREW |
| 25 |
30-16128 |
BEARING, Ball |
| 26 |
30-16132 |
BEARING, Ball |
| 27 |
26-16130 |
SEAL, Oil |
| 28 |
25-16131 |
O-RING |
| 29 |
825118T |
HOUSING |
| 30 |
10-8248324 |
BOLT |
▶Engine Gasket Set Components (2 parts)
| Ref |
OEM Part # |
Part Name |
| - |
16115A03 |
GASKET SET, Powerhead |
| 0 |
27-812947001 |
GASKET, Driveshaft Housing |
▶Fuel Tank (33 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
1258-824964A03 |
TANK ASSEMBLY, Fuel |
| 2 |
36-8M0060029 |
CAP |
| 3 |
26-8M0099393 |
SEAL |
| 4 |
16236 |
MOUNT |
| 5 |
12-953921 |
WASHER, Stainless Steel |
| 6 |
13-400256 |
LOCKWASHER, (M6) |
| 7 |
11-400212 |
NUT, (M6) Stainless Steel |
| 8 |
12-898101937 |
WASHER |
| 9 |
8M0046049 |
BRACKET |
| 10 |
10-16832 |
BOLT, (M6 x 16) |
| 11 |
13-400256 |
LOCKWASHER, (M6) |
| 12 |
22-815043 |
REDUCER ELBOW Comment: (5 H.P.) |
| 13 |
22-815045 |
FUEL COCK ASSEMBLY Comment: (5 H.P.) |
| 14 |
10-815046 |
SCREW, Stainless Steel Comment: (5 H.P.) |
| 15 |
56762 |
CLAMP, Plastic Comment: (5 H.P.) |
| 16 |
32-8M0057113 |
LINE, Fuel (1000 mm) Comment: (5 H.P.) |
| 17 |
35-8M0157133 |
FILTER, Fuel Comment: (5 H.P.) |
| 18 |
54-95395 |
CLIP, Stainless Steel Comment: (5 H.P.) |
| 19 |
22-73318 |
TEE, Plastic Comment: (5 H.P.) |
| 20 |
32-8M0168427 |
HOSE, Rubber Comment: (5 H.P.) |
| 21 |
22-815048 |
CONNECTOR, Plastic Comment: (5 H.P.) |
| 22 |
32-851848032 |
HOSE, Rubber (110 mm) Comment: (5 H.P.) |
| 23 |
22-8M0182334 |
CONNECTOR, Fuel - Brass Comment: (5 H.P.) |
| 24 |
10-4000333 |
SCREW, (M6 x 40) Comment: (5 H.P.) |
| 25 |
12-16826 |
WASHER, Stainless Steel Comment: (5 H.P.) |
| 26 |
22-8M0182334 |
CONNECTOR, Fuel - Brass Comment: (5 H.P.) |
| 27 |
10-4000333 |
SCREW, (M6 x 40) Comment: (5 H.P.) |
| 28 |
12-16826 |
WASHER, Stainless Steel Comment: (5 H.P.) |
| 29 |
54-95395 |
CLIP, Stainless Steel Comment: (5 H.P.) |
| 30 |
32-17668 |
HOSE Comment: (5 H.P.) |
| 31 |
54-813275 |
CLAMP Comment: (5 H.P.) |
| 32 |
35-8M0157133 |
FILTER, Fuel Comment: (5 H.P.) |
| 33 |
32-17669 |
HOSE Comment: (5 H.P.) |
▶Gear Housing Components (39 parts)
| Ref |
OEM Part # |
Part Name |
| - |
8M0155395 |
REPAIR KIT, Water Pump |
| 1 |
45-8M0076368 |
DRIVESHAFT Comment: (LONG) |
| 2 |
30-95347 |
BEARING |
| 3 |
28-16155 |
KEY |
| 4 |
43-16138 |
GEAR |
| 5 |
27-16164003 |
GASKET Comment: SN# 0T707899/0P268000 & Up |
| 6 |
15-8132761 |
SHIM, (0.15) Comment: (0.15) |
| 7 |
26-16162 |
SEAL, Oil |
| 8 |
46-826053T |
HOUSING (LOWER) |
| 9 |
16165 |
RETAINER |
| 10 |
10-823042 |
BOLT |
| 11 |
27-16160004 |
GASKET Comment: SN# 0T707899/0P268000 & Up |
| 12 |
16159 |
PLATE |
| 13 |
27-8M0155369 |
GASKET Comment: SN# 0T707899/0P268000 & Up |
| 14 |
47-8M0204676 |
IMPELLER |
| 15 |
16157 |
LINER |
| 16 |
46-16156 |
HOUSING, Upper Water Pump (UPPER) |
| 17 |
10-8M0063198 |
BOLT |
| 18 |
12-16826 |
WASHER, Stainless Steel |
| 19 |
26-16168 |
SEAL |
| 20 |
32-16167 |
HOSE |
| 21 |
26-16171 |
SEAL |
| 22 |
32-16170 |
TUBE, Water Comment: (LONG) |
| 23 |
15-813277 |
SHIM, (0.15) |
| 24 |
43-812944 |
GEAR |
| 25 |
16152 |
FOLLOWER, Cam |
| 26 |
16153 |
RETAINER |
| 27 |
52-812946 |
CLUTCH |
| 28 |
17-16150 |
PIN, Clutch |
| 29 |
24-17667 |
SPRING |
| 30 |
44-195133 |
PROPELLER SHAFT |
| 31 |
12-16140 |
WASHER |
| 32 |
43-8129451 |
GEAR, Reverse |
| 33 |
16145Q01 |
THRUST WASHER Comment: SN# 0T707899/0P268000 & Up |
| 34 |
48-812951A02 |
PROPELLER Comment: (6 PITCH - HI-REVERSE THRUST) |
| 35 |
12-16146 |
WASHER |
| 36 |
11-16147 |
PROP NUT |
| 37 |
18-815026 |
COTTER PIN |
| 38 |
810753 |
GUIDE |
▶Magneto and Ignition Components (35 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
200-8M0110989 |
FLYWHEEL |
| 2 |
16058T |
COIL, Exciter |
| 3 |
10-16059 |
SCREW |
| 4 |
54-16060 |
CLAMP |
| 5 |
10-16821 |
SCREW |
| 6 |
11-16071 |
NUT |
| 7 |
12-16072 |
WASHER |
| 8 |
160661 |
COIL, Pulser |
| 9 |
10-16067 |
SCREW |
| 10 |
815113T02 |
COIL ASSEMBLY, Ignition |
| 11 |
85-855543 |
BOOT, With Resistance |
| 12 |
10-167051 |
BOLT, (M6 x 20) |
| 13 |
13-16818 |
LOCKWASHER |
| 14 |
12-809931044 |
WASHER |
| 15 |
25-16068 |
GROMMET |
| 16 |
16061T04 |
CD UNIT Comment: SN# 0T707899/0P268000 & Up |
| 17 |
878061 |
FRONT DAMPER Comment: SN# 0T707899/0P268000 & Up |
| 18 |
878062 |
DAMPER (REAR) |
| 19 |
18-815026 |
COTTER PIN |
| 20 |
16074T |
ALTERNATOR Comment: (SAILPOWER) |
| 21 |
10-16059 |
SCREW Comment: (SAILPOWER) |
| 22 |
54-16060 |
CLAMP Comment: (SAILPOWER) |
| 23 |
10-16821 |
SCREW Comment: (SAILPOWER) |
| 24 |
16076A1 |
RECTIFIER KIT Comment: (SAILPOWER)(Use with 25MM Screw) |
| 25 |
89-16077 |
FUSE Comment: (SAILPOWER) |
| 26 |
10-16078 |
SCREW Comment: (SAILPOWER)(20 MM) |
| 27 |
13-16079 |
LOCKWASHER Comment: (SAILPOWER) |
| 28 |
12-8M0108373 |
WASHER, Stainless Steel Comment: (SAILPOWER) |
| 29 |
54-813275 |
CLAMP Comment: (SAILPOWER) |
| 30 |
11-16081 |
NUT, Stainless Steel Comment: (SAILPOWER) |
| 31 |
84-16822 |
HARNESS, Extension Comment: (SAILPOWER) |
| 32 |
25-16823 |
GROMMET Comment: (SAILPOWER) |
| 33 |
84-16082 |
CABLE, Battery Comment: (SAILPOWER) |
| 34 |
87-823037A04 |
SWITCH ASSEMBLY, Emergency Stop Comment: SN# 0T707899/0P268000 & Up |
| 35 |
823054 |
LANYARD |
▶Recoil Starter (32 parts)
| Ref |
OEM Part # |
Part Name |
| - |
803576T02 |
STARTER ASSEMBLY, Recoil |
| 1 |
8M0227442 |
HOUSING, Starter |
| 2 |
24-812645T |
SPRING SET, Starter |
| 3 |
812633 |
SHEEVE, Starter |
| 4 |
24-812634 |
SPRING, Return |
| 5 |
8M0060217 |
RATCHET |
| 6 |
24-812636 |
SPRING, Friction |
| 7 |
10-8M0060218 |
BOLT |
| 8 |
812638 |
FRICTION PLATE |
| 9 |
161101 |
PLATE, Seal |
| 10 |
50-12066Q10 |
ROPE |
| 11 |
812640 |
HANDLE, Starter Rope |
| 12 |
812641 |
RETAINER |
| 13 |
812642 |
PULLEY, Starter |
| 14 |
10-168281 |
SCREW AND LOCKWASHER |
| 15 |
10-810755 |
SCREW |
| 16 |
17634 |
LOCK, Starter |
| 17 |
23-895130 |
COLLAR |
| 18 |
24-812645007 |
SPRING |
| 19 |
10-8555449 |
SCREW |
| 20 |
8M0169412 |
SNAP, Link Rod |
| 21 |
812643 |
CAM Comment: (DESIGN I) |
| 22 |
10-855544 |
SCREW Comment: (DESIGN I) |
| 23 |
23-855545 |
COLLAR Comment: (DESIGN I) |
| 24 |
13-17641 |
WAVE WASHER Comment: (DESIGN I) |
| 25 |
8126431 |
LOCK CAM, Starter Comment: (DESIGN II) |
| 26 |
10-804364 |
SCREW Comment: (DESIGN II) |
| 27 |
23-804365 |
COLLAR Comment: (DESIGN II) |
| 28 |
24-804366 |
SPRING Comment: (DESIGN II) |
| 29 |
12-16826 |
WASHER, Stainless Steel Comment: (DESIGN II) |
| 30 |
17642001 |
ROD |
| 31 |
13-400256 |
LOCKWASHER, (M6) |
▶Remote Control Attaching Kit (29 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
16840A2 |
ATTACHING KIT, Remote Control |
| 2 |
16848 |
LEVER |
| 3 |
17034 |
WIRE, Throttle |
| 4 |
10-8230427 |
BOLT |
| 5 |
12-953921 |
WASHER, Stainless Steel |
| 6 |
23-16849 |
COLLAR |
| 7 |
84-17035 |
HARNESS ASSEMBLY (DUAL STOP SWITCH) |
| 8 |
17-17031 |
PIN, Lock |
| 9 |
17-17033 |
PIN |
| 10 |
24-17032 |
SPRING |
| 11 |
17030 |
SLEEVE |
| 12 |
12-17029 |
WASHER |
| 13 |
16847 |
LEVER, Throttle |
| 14 |
17026 |
BRACKET |
| 15 |
17027 |
CAP |
| 16 |
24-17028 |
SPRING |
| 17 |
13-16221 |
WAVE WASHER |
| 18 |
26-16219 |
SEAL |
| 19 |
23-16220 |
BUSHING |
| 20 |
17023 |
BRACKET |
| 21 |
10-162233 |
SCREW |
| 22 |
11-400212 |
NUT, (M6) Stainless Steel |
| 23 |
17024 |
PLATE, Steering Hook |
| 24 |
10-4000354 |
SCREW, (M8 x 30) |
| 25 |
12-16192 |
WASHER |
| 26 |
13-17025 |
LOCKWASHER |
| 27 |
11-400213 |
NUT, (M8) Stainless Steel |
| 28 |
84-17162 |
HARNESS ASSEMBLY (5.9M) |
| 29 |
25-16823 |
GROMMET |
▶Service/Support Material (1 parts)
| Ref |
OEM Part # |
Part Name |
| 0 |
37-804661A05 |
DECAL, EPA Label Information Comment: (2005) |
▶Shift Components (20 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-8M0188431 |
SEAL KIT, Gear Housing |
| 1 |
8130275 |
LEVER, Shift |
| 2 |
30-812937 |
STOPPER |
| 3 |
24-813028 |
SPRING |
| 4 |
16184 |
LEVER |
| 5 |
10-16185 |
BOLT |
| 6 |
17-16188 |
PIN |
| 7 |
18-16189 |
COTTER PIN |
| 8 |
25-16181 |
O-RING |
| 9 |
16187 |
SHIFT ROD Comment: (LONG) |
| 10 |
12-16826 |
WASHER, Stainless Steel |
| 11 |
16190 |
JOINT |
| 12 |
10-8248324 |
BOLT |
| 13 |
8M0058365 |
CAM ROD Comment: (LONG) |
| 14 |
17-16179 |
PIN |
| 15 |
25-161771 |
O-RING |
| 16 |
23-16176 |
BUSHING |
| 17 |
25-16178 |
O-RING |
| 18 |
8M0090459 |
CAM |
| 19 |
17-16175 |
PIN |
▶Throttle Components (21 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
16075T4 |
HANDLE, Steering |
| 2 |
37-8M0097201 |
DECAL |
| 3 |
16088 |
WIRE, Throttle |
| 4 |
16093 |
SHAFT, Throttle |
| 5 |
23-16336 |
BUSHING |
| 6 |
23-16191 |
SPACER |
| 7 |
813026 |
FRICTION PIECE |
| 8 |
10-16087 |
SCREW, Adjusting |
| 9 |
12-16826 |
WASHER, Stainless Steel |
| 10 |
11-400212 |
NUT, (M6) Stainless Steel |
| 11 |
16086 |
GRIP |
| 12 |
10-16094 |
SCREW |
| 13 |
16338 |
BRACKET |
| 14 |
10-16827 |
SCREW |
| 15 |
23-16083005 |
BUSHING |
| 16 |
17-16085 |
PIN |
| 17 |
8M0207656 |
RETAINER |
| 18 |
16-815028 |
STUD BOLT |
| 19 |
13-400256 |
LOCKWASHER, (M6) |
| 20 |
16089 |
BRACKET |
| 21 |
10-168281 |
SCREW AND LOCKWASHER (WITH LOCKWASHER) |
▶Tools (1 parts)
| Ref |
OEM Part # |
Part Name |
| 0 |
91-37241 |
PULLER PLATE |
100-Hour / Annual Service Checklist
Regular maintenance keeps your Mercury 4 (2-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
- Inspect and clean carburetor(s); check fuel mixture settings
- 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
- Decarbonize exhaust ports and piston crown if needed
- 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.
