🔎 Mercury 4 (4-STROKE) Reference Library — Exploded parts diagrams (27 diagrams), specifications, common issues, and maintenance checklist.
The Mercury 4 (4-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 |
SAE 10W-30 Mercury 4-Stroke Outboard 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 (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 4 (4-STROKE).
▶Accessories (1 parts)
| Ref |
OEM Part # |
Part Name |
| - |
16839A4 |
GUIDE KIT, Vertical Rope |
▶Accessory Parts (22 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
16074T05 |
ALTERNATOR KIT |
| 2 |
8M0056334 |
ALTERNATOR |
| 3 |
10-16123 |
SCREW, (25 mm) |
| 4 |
12-8M0108373 |
WASHER, Stainless Steel |
| 5 |
54-16060 |
CLAMP |
| 6 |
10-16821 |
SCREW |
| 7 |
262-803557T02 |
FLYWHEEL |
| 8 |
84-17175 |
HARNESS ASSEMBLY |
| 9 |
16838A4 |
CHARGING KIT, Battery, Rectifier - 6 AMP |
| 10 |
16076A1 |
RECTIFIER KIT |
| 11 |
89-16077 |
FUSE |
| 12 |
10-16123 |
SCREW, (25 mm) |
| 13 |
13-16079 |
LOCKWASHER |
| 14 |
12-8M0108373 |
WASHER, Stainless Steel |
| 15 |
54-813275 |
CLAMP |
| 16 |
11-16081 |
NUT, Stainless Steel |
| 17 |
84-16082 |
CABLE, Battery |
| 18 |
16839A4 |
GUIDE KIT, Vertical Rope |
| 19 |
NSS |
NOT SOLD SEPARATE, Guide |
| 20 |
16113 |
PLATE, Seal |
| 21 |
10-17173 |
SCREW |
| 22 |
8538281 |
HANDLE, (1.0 Meters) |
▶Carburetor (18 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-8M0152380 |
GASKET SET, Powerhead |
| 1 |
3303-804766A05 |
CARBURETOR Comment: 6 Horsepower EU SN# 0R162801 & Up |
| 2 |
10-8035095 |
SCREW |
| 3 |
24-803554 |
SPRING |
| 4 |
38,8035243 |
JET, Pilot Comment: 5/6 Horsepower |
| 5 |
10-803509019 |
SCREW ASSEMBLY, Pilot Comment: USA |
| 6 |
812650017 |
MAIN NOZZLE Comment: 6 Horsepower EU SN# 0R162801 & Up |
| 7 |
58,16250012 |
JET, Main Comment: All EU SN# 0R162801 & Up |
| 8 |
162543 |
FLOAT VALVE, Brass |
| 9 |
54-803525 |
CLIP, Stainless Steel |
| 10 |
17-162562 |
PIN, Float - Stainless Steel |
| 11 |
162533 |
FLOAT |
| 12 |
27-8035084 |
GASKET, Rubber |
| 13 |
16258T5 |
FLOAT BOWL |
| 14 |
10-16260 |
SCREW, (M4 x 12) |
| 15 |
10-8035093 |
SCREW, Drain (M5 x 6) |
| 16 |
25-8035131 |
O-RING, Rubber |
| 17 |
10-803509020 |
SCREW ASSEMBLY, Pilot Comment: EU |
▶Clamp Brackets (37 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
3406-9622T6 |
CLAMP BRACKET, Starboard |
| 2 |
3406-96231 |
CLAMP BRACKET, Port |
| 3 |
10-898101337 |
BOLT |
| 4 |
12-95375 |
WASHER |
| 5 |
12-16192 |
WASHER |
| 6 |
11-95374 |
NUT, (M8) |
| 7 |
161931 |
DISTANCE PLATE |
| 8 |
10-16194 |
SCREW |
| 9 |
24-16212 |
SPRING |
| 10 |
8M0045584 |
STOPPER ASSEMBLY, Tilt |
| 11 |
8M0090337 |
GRIP |
| 12 |
10-8230427 |
BOLT |
| 13 |
16210002 |
SET PLATE |
| 14 |
825113 |
BUSHING |
| 15 |
10-16200 |
CLAMP SCREW ASSEMBLY |
| 16 |
12-95379 |
PAD |
| 17 |
16198004 |
THRUST ROD |
| 18 |
24-8150931 |
SPRING |
| 19 |
24-161951 |
SPRING |
| 20 |
12-16197 |
WASHER |
| 21 |
10-16196 |
SCREW |
| 22 |
3407-813029T9 |
SWIVEL BRACKET, Front |
| 23 |
3407-883300T |
SWIVEL BRACKET, Rear |
| 24 |
23-8035674 |
BUSHING, Lower |
| 25 |
8M0124744 |
FRICTION BAND |
| 26 |
11-883302 |
WING NUT |
| 27 |
12-953921 |
WASHER, Stainless Steel |
| 28 |
24-953839 |
SPRING |
| 29 |
803582 |
THRUST PLATE |
| 30 |
23-8035672 |
BUSHING, Upper |
| 31 |
8035821 |
THRUST PLATE |
| 32 |
10-8M0102279 |
BOLT, Stainless Steel |
| 33 |
22-824969 |
FITTING, Grease |
| 34 |
162133 |
ARM, Reverse Lock |
| 35 |
10-82304223 |
BOLT |
| 36 |
24-16216 |
SPRING |
| 37 |
24-16215 |
SPRING |
▶Cowling (29 parts)
| Ref |
OEM Part # |
Part Name |
| - |
37-8M0157275 |
DECAL, Notice-This Side Up |
| 1 |
114-803580T5 |
TOP COWL ASSEMBLY Comment: Silver - Use With Integral Fuel Tank |
| 2 |
8107512 |
SEAL |
| 3 |
25-162282 |
SEAL, Rubber |
| 4 |
4000-803578T02 |
BOTTOM COWL |
| 5 |
815037 |
PLUG |
| 6 |
37-879706 |
DECAL, Fuel Lever Comment: Use With Integral Fuel Tank |
| 7 |
25-16226 |
GROMMET |
| 8 |
25-16225 |
GROMMET |
| 9 |
25-16231 |
GROMMET |
| 10 |
10-16832 |
BOLT, (M6 x 16) |
| 11 |
12-16826 |
WASHER, Stainless Steel |
| 12 |
25-953871 |
GROMMET |
| 13 |
803579 |
COVER HOOK |
| 14 |
10-8230427 |
BOLT |
| 15 |
12-953921 |
WASHER, Stainless Steel |
| 16 |
13-16221 |
WAVE WASHER |
| 17 |
23-16220 |
BUSHING |
| 18 |
26-16219 |
SEAL |
| 19 |
162181 |
HOOK LEVER |
| 20 |
16841Q02 |
FLUSHING ATTACHMENT |
| 21 |
91-803581 |
TOOL KIT |
| 22 |
50-16230 |
SAFETY ROPE |
| 23 |
NSS |
NOT SOLD SEPARATE, DECAL, EPA (2009 & Up) Comment: Contact Mercury Marine Warranty Administration for Replacement (Service Bulletin 2009-18) |
| 24 |
54-813275 |
CLAMP |
| 25 |
10-8230427 |
BOLT, (M6 x 12) |
| 26 |
37-8240877 |
DECAL, Fuel Lever |
| 27 |
25-885154001 |
GROMMET |
| 28 |
37-8156931 |
DECAL, Fuel Lever, Remote Fuel Shut-Off Comment: Use With Integral Fuel Tank |
▶Crankshaft, Piston and Connecting Rods (12 parts)
| Ref |
OEM Part # |
Part Name |
| - |
804797T61 |
POWERHEAD ASSEMBLY |
| 1 |
474-803515T |
CRANKSHAFT |
| 2 |
12-803516 |
WASHER |
| 3 |
28-16053 |
KEY |
| 4 |
600-8M0124936 |
CONNECTING ROD |
| 5 |
10-8035092 |
BOLT |
| 6 |
39-8M0094922 |
PISTON ASSEMBLY Comment: .5 MM Oversize |
| 7 |
53-160573 |
E RING |
| 8 |
41-898103113 |
PIN, Piston |
| 9 |
39-803518T02 |
RING SET, Piston Comment: .5 MM Oversize |
| 10 |
NSS |
NOT SOLD SEPARATE, Piston Ring-Second |
| 11 |
NSS |
NOT SOLD SEPARATE, Oil Ring |
▶Cylinder Block (28 parts)
| Ref |
OEM Part # |
Part Name |
| - |
804797T61 |
POWERHEAD ASSEMBLY |
| 1 |
878-815013T10 |
CYLINDER BLOCK ASSEMBLY |
| 2 |
22-8M0071347 |
FITTING |
| 3 |
26-898101285 |
SEAL, Oil |
| 4 |
30-161324 |
BEARING, Ball |
| 5 |
803512 |
CAP, Filler |
| 6 |
25-803513 |
O-RING |
| 7 |
803511002 |
COVER, Breather |
| 8 |
27-803508021 |
GASKET |
| 9 |
10-8230319 |
BOLT |
| 10 |
17-804369 |
BREATHER TUBE |
| 11 |
12-804370 |
WASHER |
| 12 |
32-952235 |
TUBING |
| 13 |
54-952245 |
CLAMP |
| 14 |
900-8M0119549 |
CYLINDER HEAD |
| 15 |
27-803508 |
GASKET |
| 16 |
17-16119 |
PIN, Dowel |
| 17 |
27-803508012 |
GASKET |
| 18 |
853705006 |
CAP, Thermostat |
| 19 |
27-8M0214960 |
GASKET |
| 20 |
8M0228409 |
THERMOSTAT, 126 Degrees Fehrenheit/52 Degrees Celsius |
| 21 |
10-803509 |
BOLT, (M8 x 90) |
| 22 |
10-855677002 |
BOLT, (M8 x 60) |
| 23 |
33-8M0204682 |
SPARK PLUG, NGK#DCPR6E |
| 24 |
803510 |
COVER |
| 25 |
27-8035082 |
GASKET |
| 26 |
10-166954 |
BOLT |
| 27 |
12-953921 |
WASHER, Stainless Steel |
▶Driveshaft Housing (15 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-8M0152380 |
GASKET SET, Powerhead |
| 1 |
1599-803591T2 |
HOUSING, Driveshaft Comment: Long |
| 2 |
23-16114 |
BUSHING |
| 3 |
19-803593 |
PLUG |
| 4 |
27-803508016 |
GASKET, Driveshaft Housing |
| 5 |
17-16119 |
PIN, Dowel |
| 6 |
10-879194264 |
BOLT |
| 7 |
19-879194296 |
FLUSH PLUG |
| 8 |
27-95220 |
GASKET |
| 9 |
25-161181 |
GROMMET |
| 10 |
25-16117 |
GROMMET |
| 11 |
827663A1 |
HOUSING ASSEMBLY |
| 12 |
23-811214 |
BUSHING Comment: Long |
| 13 |
16121 |
RETAINER |
| 14 |
10-16123 |
SCREW, (25 mm) Comment: Long |
▶Electrical Components (16 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
262-803557T02 |
FLYWHEEL Comment: Sailpower/Sailmate |
| 2 |
339-803559T07 |
IGNITER ASSEMBLY |
| 3 |
10-879194264 |
BOLT |
| 4 |
85-803560001 |
BOOT |
| 5 |
85-803560003 |
PROTECTOR |
| 6 |
10-16123 |
SCREW, (25 mm) |
| 7 |
12-8M0108373 |
WASHER, Stainless Steel |
| 8 |
54-16060 |
CLAMP |
| 9 |
10-16821 |
SCREW |
| 10 |
8M0056334 |
ALTERNATOR Comment: Sailpower/Sailmate-Standard |
| 11 |
54-8M0130961 |
CLAMP |
| 12 |
10-8230427 |
BOLT, (M6 x 12) |
| 13 |
54-953951 |
CLAMP |
| 14 |
10-8230427 |
BOLT, (M6 x 12) |
| 15 |
803562 |
WARNING LAMP |
| 16 |
87-823037A06 |
SWITCH ASSEMBLY, Stop - Lanyard |
▶Engine Gasket Set Components (1 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-803508016 |
GASKET, Driveshaft Housing |
▶Fuel System (34 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-8M0152380 |
GASKET SET, Powerhead |
| 1 |
803530 |
MANIFOLD, Inlet |
| 2 |
25-8035133 |
O-RING |
| 3 |
10-8150684 |
BOLT, (M6 x 25) |
| 4 |
27-80350810 |
GASKET, Insulator |
| 5 |
27-803508013 |
GASKET |
| 6 |
32-8M0057113 |
LINE, Fuel (1000 mm), To Carburetor |
| 7 |
54-95395 |
CLIP, Stainless Steel |
| 8 |
803529T06 |
PUMP, Fuel Comment: SN# 0R129315 & Up |
| 9 |
25-803513 |
O-RING |
| 10 |
10-8555448 |
SCREW, (M6 x 30) |
| 11 |
8M0155131 |
ROD, Choke |
| 12 |
23-8M0047187 |
BUSHING |
| 13 |
10-16223 |
BOLT, (M6 x 14) |
| 14 |
12-161404 |
WASHER |
| 15 |
54-953951 |
CLAMP |
| 16 |
8276225 |
LINK WIRE, Choke |
| 17 |
10-16832 |
BOLT, (M6 x 16) |
| 18 |
803528 |
BRACKET |
| 19 |
23-804371001 |
COLLAR |
| 20 |
23-952868 |
COLLAR |
| 21 |
11-400212 |
NUT, (M6) Stainless Steel |
| 22 |
803526T |
SILENCER, Air |
| 23 |
803527 |
FLAME TRAP |
| 24 |
10-855809003 |
BOLT |
| 25 |
12-16826 |
WASHER, Stainless Steel |
| 26 |
54-95395 |
CLIP, Stainless Steel |
| 27 |
32-8M0079503 |
TUBING, (170 mm) |
| 28 |
35-8M0157133 |
FILTER, Fuel |
| 29 |
32-878054 |
TUBING |
| 30 |
22-8M0182334 |
CONNECTOR, Fuel - Brass |
| 31 |
10-4000333 |
SCREW, (M6 x 40) |
| 32 |
12-16826 |
WASHER, Stainless Steel |
| 33 |
878311 |
CAP |
▶Gear Housing, Driveshaft (42 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-8M0188431 |
SEAL KIT, Gear Housing |
| 1 |
1668-9621T6 |
GEAR HOUSING ASSEMBLY, Basic Comment: Sailpower/Sailmate |
| 2 |
23-16124 |
BUSHING |
| 3 |
22-8M0229353 |
PLUG |
| 4 |
27-95220 |
GASKET |
| 5 |
10-8M0063198 |
BOLT |
| 6 |
12-16826 |
WASHER, Stainless Steel |
| 7 |
43-16138 |
GEAR |
| 8 |
16133 |
STRAINER, Water |
| 9 |
10-16134 |
SCREW |
| 10 |
10-16126 |
BOLT |
| 11 |
12-16192 |
WASHER |
| 12 |
45-8M0076368 |
DRIVESHAFT Comment: Long |
| 13 |
30-95347 |
BEARING |
| 14 |
28-16155 |
KEY |
| 15 |
27-16164003 |
GASKET |
| 16 |
15-8132761 |
SHIM, (0.15) |
| 17 |
26-16162 |
SEAL, Oil |
| 18 |
46-826053T |
HOUSING |
| 19 |
27-16160004 |
GASKET |
| 20 |
16159 |
PLATE |
| 21 |
27-8M0155369 |
GASKET |
| 22 |
47-8M0204676 |
IMPELLER |
| 23 |
16157 |
LINER |
| 24 |
46-16156 |
HOUSING, Upper Water Pump |
| 25 |
26-16168 |
SEAL |
| 26 |
32-16167 |
HOSE |
| 27 |
10-8M0063198 |
BOLT |
| 28 |
12-16826 |
WASHER, Stainless Steel |
| 29 |
26-16171 |
SEAL |
| 30 |
32-16169 |
TUBE, Water Comment: Short |
| 31 |
32-16170 |
TUBE, Water Comment: Long |
| 32 |
25-18876 |
GROMMET |
| 33 |
8M0058365 |
CAM ROD Comment: Long |
| 34 |
17-16179 |
PIN |
| 35 |
16165 |
RETAINER |
| 36 |
10-823042 |
BOLT |
| 37 |
25-161771 |
O-RING |
| 38 |
23-16176 |
BUSHING |
| 39 |
25-16178 |
O-RING |
| 40 |
8M0090459 |
CAM |
| 41 |
17-16175 |
PIN |
▶Gear Housing, Propeller Shaft (25 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-8M0188431 |
SEAL KIT, Gear Housing |
| 1 |
1668-9621T6 |
GEAR HOUSING ASSEMBLY, Basic Comment: Sailpower/Sailmate |
| 42 |
30-16128 |
BEARING, Ball |
| 43 |
15-813277 |
SHIM, (0.15) |
| 44 |
43-812944 |
GEAR |
| 45 |
16152 |
FOLLOWER, Cam |
| 46 |
16153 |
RETAINER |
| 47 |
52-812946 |
CLUTCH |
| 48 |
17-16150 |
PIN, Clutch |
| 49 |
24-17667 |
SPRING |
| 50 |
44-195133 |
PROPELLER SHAFT |
| 51 |
12-16140 |
WASHER |
| 52 |
43-8129451 |
GEAR, Reverse |
| 53 |
30-16132 |
BEARING, Ball |
| 54 |
26-16130 |
SEAL, Oil |
| 55 |
25-16131 |
O-RING |
| 56 |
825118T |
HOUSING |
| 57 |
10-167051 |
BOLT |
| 58 |
16145Q01 |
THRUST WASHER |
| 59 |
48-812950A03 |
PROPELLER Comment: 9 Pitch |
| 60 |
12-16146 |
WASHER |
| 61 |
11-16147 |
PROP NUT |
| 62 |
18-815026 |
COTTER PIN |
| 63 |
10-16832 |
BOLT, (M6 x 16) |
| 64 |
97-875208 |
ANODE |
▶Intake/Exhaust Valves (15 parts)
| Ref |
OEM Part # |
Part Name |
| - |
804797T61 |
POWERHEAD ASSEMBLY |
| 1 |
400-8M0147019 |
CAMSHAFT |
| 2 |
803546 |
LIFTER |
| 3 |
803547 |
PUSH ROD |
| 4 |
803548 |
PLATE |
| 5 |
10-8035097 |
BOLT |
| 6 |
8M0056319 |
ROCKER ARM |
| 7 |
803550 |
PIVOT |
| 8 |
11-803551 |
NUT |
| 9 |
8M0056316 |
VALVE, Exhaust |
| 10 |
8M0056312 |
VALVE, Intake |
| 11 |
8M0158660 |
SEAT |
| 12 |
24-898101214 |
SPRING |
| 13 |
803555 |
RETAINER |
| 14 |
28-803556 |
KEEPER, Valve |
▶Integral Fuel Tank, 4 Horsepower (38 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
1265-889246T45 |
TANK ASSEMBLY, Fuel Comment: Design II |
| 2 |
1258-878355A2 |
TANK ASSEMBLY, Fuel Comment: Bodensee |
| 3 |
36-8M0058610 |
CAP ASSEMBLY, Fuel Comment: Bodensee |
| 4 |
27-878353 |
GASKET |
| 5 |
10-8M0204707 |
SCREW, (M6 x 25) |
| 6 |
12-161404 |
WASHER |
| 7 |
23-8537437 |
MOUNT, Rubber |
| 8 |
23-853715007 |
SPACER |
| 9 |
10-16705 |
BOLT |
| 10 |
10-8M0051381 |
SCREW, Stainless Steel |
| 11 |
54-813275 |
CLAMP |
| 12 |
25-881305 |
MOUNT, Rubber |
| 13 |
11-400212 |
NUT, (M6) Stainless Steel |
| 14 |
878350 |
BRACKET |
| 15 |
10-823042060 |
BOLT |
| 16 |
32-8M0057113 |
LINE, Fuel (1000 mm), Cut to 9.875 Inches |
| 17 |
54-95395 |
CLIP, Stainless Steel |
| 18 |
32-8M0057113 |
LINE, Fuel (1000 mm), Cut to 14.00 Inches |
| 19 |
22-878387 |
FUEL COCK ASSEMBLY |
| 20 |
10-815046 |
SCREW, Stainless Steel |
| 21 |
32-8M0057113 |
LINE, Fuel (1000 mm), Cut to 1.375 Inches |
| 22 |
32-8M0057113 |
LINE, Fuel (1000 mm), Cut to 8.50 Inches |
| 23 |
22-73318 |
TEE, Plastic |
| 24 |
32-8M0057113 |
LINE, Fuel (1000 mm), Cut to 5.25 Inches |
| 25 |
54-816311T |
TIE STRAP, (8.00 Inches) |
| 26 |
22-815048 |
CONNECTOR, Plastic |
| 27 |
32-8M0168427 |
HOSE, Rubber, 1.75 Inch |
| 28 |
22-8M0182334 |
CONNECTOR, Fuel - Brass |
| 29 |
10-4000333 |
SCREW, (M6 x 40) |
| 30 |
12-16826 |
WASHER, Stainless Steel |
| 31 |
878311 |
CAP |
| 32 |
35-8M0157133 |
FILTER, Fuel |
| 33 |
32-17668 |
HOSE, 7.125 Inch |
| 34 |
23-8797051 |
SLEEVE |
| 35 |
10-82304235 |
BOLT, (M6 x 45) (M6 x 45) |
| 36 |
881306 |
PLATE |
| 37 |
23-881307001 |
SPACER |
| 38 |
26-878354 |
SEAL |
▶Lube Chart (0 parts)
▶Oil Pan (41 parts)
| Ref |
OEM Part # |
Part Name |
| - |
804797T61 |
POWERHEAD ASSEMBLY |
| 1 |
10-82303110 |
SCREW, (M5 x 16) |
| 2 |
54-803543 |
STOPPER |
| 3 |
32-952237 |
TUBING |
| 4 |
26-8035202 |
SEAL |
| 5 |
10-855558 |
SCREW, (M5 x 16) |
| 6 |
12-160721 |
WASHER |
| 7 |
803540 |
HOUSING, Strainer |
| 8 |
803542 |
STRAINER |
| 9 |
803541 |
CUP |
| 10 |
17-16119 |
PIN, Dowel |
| 11 |
84-803539 |
LEAD WIRE |
| 12 |
87-8M0163139 |
SWITCH |
| 13 |
25-8035135 |
GROMMET |
| 14 |
10-810755007 |
BOLT, (M6 x 20) |
| 15 |
803532001 |
PLATE, Exhaust |
| 16 |
27-803508015 |
GASKET |
| 17 |
803531T |
PAN, Oil |
| 18 |
10-168306 |
BOLT, (M6 x 40) |
| 19 |
8035331 |
ROTOR, Outer |
| 20 |
17-162563 |
PIN |
| 21 |
803533 |
ROTOR, Inner |
| 22 |
25-803513010 |
O-RING |
| 23 |
803534 |
COVER |
| 24 |
10-168287 |
BOLT, (M6 x 16) |
| 25 |
10-167051 |
BOLT, (M6 x 20) |
| 26 |
8150162 |
HOUSING |
| 27 |
26-8M0101649 |
SEAL, Oil |
| 28 |
23-815018 |
SPACER |
| 29 |
27-8M0152378 |
GASKET |
| 30 |
26-8M0056308 |
SEAL, Oil |
| 31 |
10-803509021 |
BOLT |
| 32 |
12-8035161 |
WASHER |
| 33 |
10-8150685 |
BOLT, (M8 x 40) |
| 34 |
27-803508014 |
GASKET |
| 35 |
803535 |
CONTROL PLUNGER |
| 36 |
24-8035541 |
SPRING |
| 37 |
25-168231 |
O-RING |
| 38 |
803536 |
SEAT |
| 39 |
803537 |
COVER |
| 40 |
10-168287 |
BOLT, (M6 x 16) |
▶Recoil Starter (28 parts)
| Ref |
OEM Part # |
Part Name |
| - |
37-898103193 |
DECAL, Interferance |
| 1 |
8M0227442 |
HOUSING, Starter |
| 2 |
24-812645T10 |
SPRING SET, Starter |
| 3 |
812633002 |
SHEEVE, Starter |
| 4 |
24-812634003 |
SPRING, Return |
| 5 |
24-812636001 |
SPRING |
| 6 |
812635002 |
RATCHET |
| 7 |
812638001 |
FRICTION PLATE |
| 8 |
10-812637001 |
BOLT |
| 9 |
16110004 |
PLATE, Seal |
| 10 |
50-12066Q10 |
ROPE |
| 11 |
804363001 |
HANDLE, Starter |
| 12 |
8M0084137 |
ROPE ANCHOR |
| 13 |
54-8M0130961 |
CLAMP |
| 14 |
17643002 |
SNAP, Link Rod |
| 15 |
8M0169412 |
SNAP, Link Rod |
| 16 |
803577 |
LOCK ROD, Starter |
| 17 |
812643002 |
CAM, Starter Lock |
| 18 |
10-855544 |
SCREW |
| 19 |
23-855545001 |
COLLAR |
| 20 |
12-16826 |
WASHER, Stainless Steel |
| 21 |
24-804366001 |
SPRING, Starter Lock Cam |
| 22 |
17634001 |
LOCK, Starter |
| 23 |
10-8555449 |
SCREW |
| 24 |
24-812645007 |
SPRING |
| 25 |
23-895130 |
COLLAR |
| 26 |
10-810755 |
SCREW |
| 27 |
13-400256 |
LOCKWASHER, (M6) |
▶Remote Control 4000 Side Mount (57 parts)
| Ref |
OEM Part # |
Part Name |
| - |
8M0178530 |
REMOTE CONTROL, Manual Start - Non Power Trim Comment: No Ignition Switch |
| 1 |
NSS |
NOT SOLD SEPARATE, Housing-Front |
| 2 |
NSS |
NOT SOLD SEPARATE, Decal-F-N-R |
| 3 |
NSS |
NOT SOLD SEPARATE, Decal-Throttle Friction |
| 4 |
NSS |
NOT SOLD SEPARATE, Decal-Run/Off |
| 5 |
19-89774 |
PLUG, Key Switch Hole |
| 6 |
17192 |
PLUG, Stop Switch Hole |
| 7 |
17191 |
PLUG, Wire Harness Hole |
| 8 |
10-4005685 |
SCREW, (M4 x 10) |
| 9 |
16921 |
BRACKET, Lock Bar Support |
| 10 |
10-87775510 |
SCREW, (M4 x 10) |
| 11 |
8M0207317 |
LOCK BAR, Red |
| 12 |
24-16924 |
SPRING |
| 13 |
8M0205858 |
HANDLE KIT |
| 14 |
8811411 |
GRIP |
| 15 |
881146 |
PLUG |
| 16 |
881137A1 |
CAP/DECAL ASSEMBLY |
| 17 |
10-40118107 |
SCREW, (M5 x 18) |
| 18 |
13-16923 |
LOCKWASHER, External |
| 19 |
16899T |
HOLDER, Neutral Lock |
| 20 |
16917 |
COVER |
| 21 |
10-40116110T |
SCREW, (M6 x 110) |
| 22 |
881145 |
KNOB, Throttle Friction |
| 23 |
12-16896 |
WASHER |
| 24 |
53-13194 |
RING, Retaining |
| 25 |
16895 |
ARM ASSEMBLY, Brake |
| 26 |
23-16875 |
BEARING, (1.750 Inside Diameter) |
| 27 |
12-16874 |
WASHER |
| 28 |
11-401385 |
NUT, (M5) Stainless Steel |
| 29 |
54-85899A1 |
CLIP ASSEMBLY |
| 30 |
NSS |
NOT SOLD SEPARATE, Gear Shift Assembly |
| 31 |
23-16868 |
BEARING, (.750 Inside Diameter) |
| 32 |
12-16870 |
WASHER |
| 33 |
16873 |
ROLLER, Cam |
| 34 |
NSS |
NOT SOLD SEPARATE, Drive Gear |
| 35 |
NSS |
NOT SOLD SEPARATE, Plate/Stud Assembly |
| 36 |
12-8M0207778 |
WASHER |
| 37 |
10-4007154 |
SCREW, (M8 x 30) |
| 38 |
10-4005683 |
SCREW, (M4 x 6) |
| 39 |
16886 |
CLIP |
| 40 |
24-16888 |
SPRING |
| 41 |
16884 |
ROLLER |
| 42 |
16883 |
DRUM ASSEMBLY |
| 43 |
13-16922 |
WAVE WASHER |
| 44 |
NSS |
NOT SOLD SEPARATE, Cover-Bottom |
| 45 |
NSS |
NOT SOLD SEPARATE, Cover-Top |
| 46 |
23-16887 |
BEARING, (.810 Inside Diameter) |
| 47 |
10-40118106 |
SCREW, (M5 x 12) |
| 48 |
16919A1 |
LEVER ASSEMBLY |
| 49 |
NSS |
NOT SOLD SEPARATE, Decal-Lift for Fast Idle |
| 50 |
12-35280 |
WASHER, (.255 x .620 x .030) Stainless Steel |
| 51 |
11-401196 |
NUT, (M6) |
| 52 |
17063T |
SPACER |
| 53 |
23-71942 |
BUSHING |
| 54 |
16879 |
ROLLER, Detent |
| 55 |
16880 |
CLIP, Detent |
| 56 |
24-16882 |
SPRING, Detent |
▶Remote Control Attaching Kit (41 parts)
| Ref |
OEM Part # |
Part Name |
| - |
8M0172938 |
ATTACHING KIT, Remote Control |
| 1 |
8M0062171 |
PLATE, Steering Hook |
| 2 |
10-4000354 |
SCREW, (M8 x 30) |
| 3 |
17023 |
BRACKET |
| 4 |
10-8230421 |
BOLT |
| 5 |
10-162233 |
SCREW |
| 6 |
12-17029 |
WASHER |
| 7 |
24-17028 |
SPRING |
| 8 |
17027 |
CAP |
| 9 |
17026 |
BRACKET |
| 10 |
804357 |
LEVER ASSEMBLY, Throttle |
| 11 |
13-16221 |
WAVE WASHER |
| 12 |
26-16219 |
SEAL |
| 13 |
23-16220 |
BUSHING |
| 14 |
10-162232 |
BOLT |
| 15 |
17-17031 |
PIN, Lock |
| 16 |
17-17033 |
PIN |
| 17 |
24-17032 |
SPRING |
| 18 |
17030 |
SLEEVE |
| 19 |
11-400212 |
NUT, (M6) Stainless Steel |
| 20 |
803584 |
ROD, Throttle Link |
| 21 |
23-16849 |
COLLAR |
| 22 |
803585 |
LEVER, Throttle Link |
| 23 |
11-804993A1 |
NUT KIT |
| 24 |
12-804992 |
WASHER |
| 25 |
11-804993 |
WASHER |
| 26 |
84-17035 |
HARNESS ASSEMBLY |
| 27 |
17-803588 |
PIN |
| 28 |
84-803587 |
CABLE, Throttle |
| 29 |
12-16335 |
WASHER |
| 30 |
18-16189 |
COTTER PIN |
| 31 |
803590 |
BRACKET |
| 32 |
803589 |
LINK, Throttle |
| 33 |
10-16223 |
BOLT, (M6 x 14) |
| 34 |
16333 |
ROD, Snap |
| 35 |
12-16192 |
WASHER |
| 36 |
13-400256 |
LOCKWASHER, (M6) |
| 37 |
11-400213 |
NUT, (M8) Stainless Steel |
| 38 |
25-885154 |
GROMMET |
| 39 |
10-855544 |
SCREW |
| 40 |
84-17162 |
HARNESS ASSEMBLY |
▶Sailpower/Sailmate Components (17 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
8M0056334 |
ALTERNATOR |
| 2 |
10-16123 |
SCREW, (25 mm) |
| 3 |
54-16060 |
CLAMP |
| 4 |
10-16821 |
SCREW |
| 5 |
16076A1 |
RECTIFIER KIT |
| 6 |
89-16077 |
FUSE |
| 7 |
10-16123 |
SCREW, (25 mm) |
| 8 |
13-16079 |
LOCKWASHER |
| 9 |
12-8M0108373 |
WASHER, Stainless Steel |
| 10 |
54-813275 |
CLAMP |
| 11 |
11-16081 |
NUT, Stainless Steel |
| 12 |
84-16822 |
HARNESS, Extension |
| 13 |
25-16823 |
GROMMET |
| 14 |
84-16082 |
CABLE, Battery |
| 15 |
87-823037A04 |
SWITCH ASSEMBLY, Emergency Stop |
| 16 |
823054 |
LANYARD |
| 17 |
12-8M0108373 |
WASHER, Stainless Steel |
▶Service/Support Material (1 parts)
| Ref |
OEM Part # |
Part Name |
| - |
NSS |
NOT SOLD SEPARATE, DECAL, EPA (2009 & Up) Comment: Contact Mercury Marine Warranty Administration for Replacement (Service Bulletin 2009-18) |
▶Shift Components (12 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
803594 |
LEVER, Shift |
| 2 |
30-812937 |
STOPPER |
| 3 |
24-813028 |
SPRING |
| 4 |
25-16181 |
O-RING |
| 5 |
17-16188 |
PIN |
| 6 |
18-16189 |
COTTER PIN |
| 7 |
10-16185 |
BOLT |
| 8 |
16184 |
LEVER |
| 9 |
16187 |
SHIFT ROD Comment: Long |
| 10 |
12-16826 |
WASHER, Stainless Steel |
| 11 |
16190 |
JOINT, Set |
| 12 |
10-8248324 |
SCREW, (M6 x 16) |
▶Special Tools (12 parts)
| Ref |
OEM Part # |
Part Name |
| - |
91-805747A04 |
TOOL, Claws |
| 1 |
NSS |
NOT SOLD SEPARATE, Valve Seat Cutter Kit - Obtain Locally |
| 2 |
FT2997 |
COMPRESSOR TOOL, Piston Ring |
| 3 |
91-24697 |
EXPANDER TOOL, Piston Ring |
| 4 |
91-83164M |
FLYWHEEL PULLER |
| 5 |
91-83165T |
PULLER ASSEMBLY |
| 6 |
91-27780 |
PULLER |
| 7 |
91-83165T |
PULLER ASSEMBLY |
| 8 |
91-883766 |
EMISSION PROBE Comment: International |
| 9 |
91-892647A01 |
MULTI-METER KIT, DMT 2004 |
| 10 |
91-8M0059838 |
HOLDER/PULLER TOOL, Flywheel |
| 11 |
91-37299Q2 |
GREASE GUN |
▶Steering Handle (32 parts)
| Ref |
OEM Part # |
Part Name |
| - |
8M0106934 |
HANDLE KIT, Steering |
| 1 |
803565T |
HANDLE, Steering |
| 2 |
17-16085 |
PIN |
| 3 |
16093 |
SHAFT, Throttle |
| 4 |
16338 |
BRACKET |
| 5 |
10-16827 |
SCREW |
| 6 |
10-16087 |
SCREW, Adjusting |
| 7 |
12-16826 |
WASHER, Stainless Steel |
| 8 |
813026 |
FRICTION PIECE |
| 9 |
11-400212 |
NUT, (M6) Stainless Steel |
| 10 |
10-16094 |
SCREW |
| 11 |
16086 |
GRIP |
| 12 |
803569 |
SHAFT, Rubber |
| 13 |
23-8035671 |
BUSHING |
| 14 |
37-8M0097201 |
DECAL |
| 15 |
16-815028 |
STUD BOLT |
| 16 |
12-804508 |
WASHER |
| 17 |
23-803566 |
SPACER |
| 18 |
23-803567 |
BUSHING |
| 19 |
17-16085 |
PIN |
| 20 |
8035681 |
STOPPER |
| 21 |
13-400256 |
LOCKWASHER, (M6) |
| 22 |
11-400212 |
NUT, (M6) Stainless Steel |
| 23 |
10-82304235 |
BOLT, (M6 x 45) |
| 24 |
853740018 |
PROTECTIVE SLEEVE |
| 25 |
84-803570001 |
WIRE, Throttle |
| 26 |
23-803573 |
COLLAR |
| 27 |
12-953921 |
WASHER, Stainless Steel |
| 28 |
10-82304220 |
BOLT, (M6 x 35) |
| 29 |
803571 |
DRUM, Throttle |
| 30 |
803574 |
ROD, Throttle |
| 31 |
803572 |
OPENER, Throttle |
▶Tank Assembly, Fuel - Plastic - 3.2 Gallon (6 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
1260-859061A1 |
TANK ASSEMBLY, Fuel |
| 2 |
823535 |
GAUGE/CAP ASSEMBLY |
| 3 |
27-8169771 |
GASKET, Fuel Cap |
| 4 |
22-8M0175544 |
CONNECTOR KIT, Fuel |
| 5 |
25-823533 |
O-RING |
| 6 |
35-823534 |
SCREEN |
▶Throttle Shift Cables (2 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
8M0178530 |
REMOTE CONTROL, Manual Start - Non Power Trim |
| 2 |
896143A40 |
CABLE ASSEMBLY, Throttle Shift - 40 Feet |
100-Hour / Annual Service Checklist
Regular maintenance keeps your Mercury 4 (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.
