Mercury 40 (1 CYL.) (2498136 THRU 3296136) Parts & Diagrams

🔎 Mercury 40 (1 CYL.) Reference Library — Exploded parts diagrams (23 diagrams), specifications, common issues, and maintenance checklist.

The Mercury 40 (1 CYL.) is a 4-Stroke, Inline 4-Cylinder, EFI, SOHC outboard motor. Commonly used on jon boats, pontoons, and mid-size utility craft.

Quick Reference Specifications

Specification	Value
Engine Type	4-Stroke, Inline 4-Cylinder, EFI, SOHC
Horsepower	40 HP
Displacement	995 cc
Bore x Stroke	65 mm x 75 mm
Spark Plug (Type & Gap)	NGK IZFR6F-11
Engine Oil Capacity	3.0 L (3.17 quart)
Recommended Engine Oil	SAE 25W-40 Mercury FourStroke Oil
Gear Case Oil Capacity	440 mL (14.9 fl oz)
Idle Speed (in gear)	700 ± 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 40 (1 CYL.):

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 40 (1 CYL.).

▶BOTTOM COWL ASSEMBLY (19 parts)

Ref	OEM Part #	Part Name
1	NLA	BOTTOM COWL
2	19-35827	PLUG 39
3	53-55891	FASTENER 39
4	36187A1	LEVER (PORT)
5	36188A1	LEVER (STARBOARD)
6	23-26819	BUSHING (NYLON)
7	23-31293	BUSHING (RUBBER)
8	NLA	WASHER (39) Comment: SERIAL 01738941-01865632
9	53-55891	FASTENER
10	17-58997	ROLL PIN (40) Comment: SERIAL 03028361-09999999
11	10-79953Q04	SCREW
12	12-191833	WASHER
13	27-89937	GASKET (39)(40) Comment: SERIAL 02098037-09999999
14	27-55847	GASKET (40) Comment: SERIAL 03028361-09999999
15	55936	COVER
16	10-69079	SCREW
17	56712	TELL TALE NOZZLE 40 Comment: SERIAL 03028361-09999999
18	10-35519	SCREW Comment: SERIAL 03028361-09999999
19	32-8M0108355	HOSE Comment: SERIAL 03028361-09999999

▶CARBURETOR ASSEMBLY (39) (29 parts)

Ref	OEM Part #	Part Name
-	1395-92621	REPAIR KIT (40)
1	1341-8740A1	CARBURETOR(40)
2	1395-8673	FLOAT
6	1395-92581	INLET NEEDLE & SEAT
9	1399-1133	COVER
10	10-52195	SCREW(SHORT)
11	10-52196	SCREW(LONG)
12	13-26995	LOCKWASHER
14	1399-3938	SCREEN
15	27-25849	GASKET(SMALL)
16	1399-1135	COVER
17	27-25848	GASKET
18	10-25822	SCREW
19	1395-6027	SCREW
20	8146791	LEVER,THROTTLE STOP
21	1399-1716	THROTTLE SHAFT
22	NLA	IDLE TUBE(40)
25	1399-3739	THROTTLE SHUTTER(40)
26	19-20011	WELCH PLUG
28	10-28845	SCREW
29	NLA	MAIN NOZZLE(40)
30	NLA	SCREW
31	1399-3252	JET,MAIN FUEL(.032)
34	NLA	SCREW
35	1399-3740	SCREW(40)
36	24-27160	SPRING
37	27-63309	GASKET
38	12-20583	WASHER
39	11-8M0207775	NUT

▶CARBURETOR CHOKE LINKAGE (39) (10 parts)

Ref	OEM Part #	Part Name
1	59000	THROTTLE LEVER ASSEMBLY
2	10-20597	SCREW, THROTTLE LEVER TO CARBURETOR
3	NLA	SHUTTER, CHOKE - CARBURETOR
4	24-20579	SPRING, CHOKE SHUTTER TO LEVER
5	NLA	SCREW, CHOKE SHUTTER TO CARBURETOR
6	NLA	LEVER ASSEMBLY, CHOKE SHUTTER
7	NLA	SHAFT, CHOKE LEVER TO CHOKE KNOB
8	24-30947	SPRING, TENSION - CHOKE KNOB
9	NLA	CHOKE KNOB
10	17-22896	ROLL PIN, CHOKE KNOB TO SHAFT

▶CARBURETOR CHOKE LINKAGE (40) (10 parts)

Ref	OEM Part #	Part Name
1	59000	THROTTLE LEVER ASSEMBLY
2	10-20597	SCREW, THROTTLE LEVER TO CARBURETOR
3	79092	SHUTTER AND SCREEN
4	24-53193	SPRING, CHOKE SHUTTER TO LEVER
5	10-55298	SCREW Comment: SERIAL 00000000-02687542
6	24-55299A1	SPRING ASSEMBLY Comment: SERIAL 02687543-09999999
7	10-55298	SCREW
8	53187	CHOKE LEVER
9	24-53190	SPRING
10	53189	CHOKE KNOB

▶CLAMP & SWIVEL BRACKET ASSEMBLY (61 parts)

Ref	OEM Part #	Part Name
1	1468-5570A3	CLAMP BRACKET (PORT)(40) Comment: SERIAL 03028361-09999999
1/2	1467-5406A2	CL/BRKT.(PORT/STBD)(39)(40) Comment: SERIAL 00000000-03028360
2	1467-5571A3	CLAMP BRACKET (STBD.)(40) Comment: SERIAL 03028361-09999999
3	59170A3	THUMB SCREW
4	12-26227	WASHER
5	12-52864	WASHER
6	45757	TILT TUBE
7	54-8M0085928	CLIP
8	11-858869	NUT
9	16-59622	STUD
10	11-29598	NUT (40) Comment: SERIAL 03028361-09999999
11	17-55952A1	TILT LOCK PIN
12	23-30813	SPACER
13	23-26856	BUSHING (NYLON)
14	56663	ROD
15	18-56206	COTTER PIN
16	30815	LINK
17	53267A1	REVERSE LOCK LEVER (40)
18	53435	BRACKET (40)
19	24-53456	SPRING (40)
20	NLA	SPRING
21	62257A2	LINK ROD (40 Comment: SERIAL 03028361-09999999
22	32351T	CONTROL LEVER 39 40 Comment: SERIAL 00000000-02771621
23	17-25905	ROLL PIN 39 40 Comment: SERIAL 00000000-02771621
24	10-28789	SCREW (39)(40) Comment: SERIAL 01738941-09999999
25	12-8M0204666	WASHER (39) Comment: SERIAL 01738941-09999999
26	23-31309	SPACER 39 40 Comment: SERIAL 00000000-02771621
27	13-34632	WAVE WASHER 39 40 Comment: SERIAL 00000000-02771621
28	12-24812	WASHER 39 40 Comment: SERIAL 00000000-02771621
29	62024T	CONTROL LEVER 40 Comment: SERIAL 03028361-09999999
30	62257A2	LINK ASSEMBLY 40 Comment: SERIAL 03028361-09999999
31	17-25905	ROLL PIN 40 Comment: SERIAL 03028361-09999999
32	23-31309	SPACER 40 Comment: SERIAL 03028361-09999999
33	10-852368	SCREW 40 Comment: SERIAL 02771622-09999999
34	12-8M0204666	WASHER 40 Comment: SERIAL 02771622-09999999
35	13-34632	WAVE WASHER 40 Comment: SERIAL 02771622-09999999
36	12-24812	WASHER 40 Comment: SERIAL 02771622-09999999
37	20203	DISC
38	NLA	PLATE
39	NLA	SCREW
40	NLA	SPACER 40 Comment: SERIAL 03028361-09999999
41	NLA	WAVE WASHER 40 Comment: SERIAL 03028361-09999999
42	19-77633Q	CAPLUG
43	22-8M0169589	GREASE FITTING
44	1451-1788	SWIVEL BRACKET
45	25-25439	O-RING
46	NLA	SERIAL PLATE
47	10-28642	DRIVE SCREW
48	63310A1	TILT STOP LEVER
49	10-29237	SCREW
50	11-8M0207775	NUT
51	10-27791	SCREW
52	13-20846	WAVE WASHER
53	11-8M0207775	NUT
54	17-30688	SWIVEL PIN
55	77334	CO-PILOT DISC
56	10-30679	SCREW
57	11-8M0207775	NUT
58	10-67982	BOLT 40
59	12-67983	WASHER 40
60	11-8267098	NUT 40

▶CRANKSHAFT, PISTON AND CONNECTING ROD (10 parts)

Ref	OEM Part #	Part Name
1	427-3513	CRANKSHAFT (39-SEE BLOCK COMMENTS)(40)
2	608-7395A2	CONNECTING ROD (39)(40) Comment: SERIAL 02098037-09999999
3	10-87374	SCREW (39)(40) Comment: SERIAL 02098037-09999999
4	29-26815	NEEDLE BEARING
5	11-20061	NUT
6	12-31433	WASHER
7	29-31505	NEEDLE BEARING
8	719-7391T3	PISTON AND PISTON PIN ASSEMBLY
9	40-21666	LOCK RING
10	39-21665A12	PISTON RING

▶CYLINDER BLOCK AND CRANKCASE ASSEMBLY (44 parts)

Ref	OEM Part #	Part Name
1	843-8694A3	CYLINDER BLOCK (39)(40) Comment: SERIAL 02098037-09999999
2	21-28481A1	CHECK VALVE 40 Comment: SERIAL 02771622-09999999
3	NLA	WELCH PLUG Comment: SERIAL 02771622-09999999
4	16-66021	STUD
5	16-46431	STUD
6	17-8M0084726	DOWEL PIN
7	22-996642	ELBOW (90 )(40-SER.33028361 & UP)
8	NLA	SCREW (1-3/4")
9	10-64278	SCREW (1")
10	11-8M0207775	NUT
11	70726	REED BLOCK
12	34-35836	REED, INLET VALVE
13	34-22215	RETAINER
14	10-28430	SCREW
15	27-357391	GASKET
16	30-72961	BALL BEARING
17	26-56397	OIL SEAL (40) Comment: SERIAL 32771622-09999999
18	15-31412A1	SHIM ASSEMBLY
19	NLA	BEARING HOUSING ASSEMBLY
20	30-72961	BALL BEARING
21	31-31410	ROLLER BEARING
22	26-31411	OIL SEAL
23	25-20863	O-RING
24	10-39002	SCREW (39)(40)(#12-24 X 1/2")
25	54-34598	CLAMP 39 40 Comment: SERIAL 00000000-02693114
26	10-36205	SCREW Comment: SERIAL 00000000-02693114
27	24-34731	SPRING Comment: SERIAL 00000000-02693114
28	35658	TRANSFER PORT COVER
29	27-35657	GASKET
30	10-20720	SCREW 40 Comment: SERIAL 02923727-09999999
31	NLA	CLAMP Comment: SERIAL 02923727-09999999
32	31014	MOUNT
33	13-26992	LOCKWASHER)
34	11-20088	NUT
35	1016-7070A1	COVER, CYLINDER BLOCK (40) Comment: SERIAL 03028361-09999999
36	22-328022	PIPE PLUG (40)
37	27-416151	GASKET
38	10-21091	SCREW (39)(40) Comment: SERIAL 02098037-09999999
39	11-8M0207775	NUT
40	27-416141	GASKET
41	46234	BAFFLE PLATE
42	27-416141	GASKET
43	46171	COVER, EXHAUST MANIFOLD
44	10-28636	SCREW

▶DRIVE SHAFT HOUSING ASSEMBLY (16 parts)

Ref	OEM Part #	Part Name
1	NLA	DRIVE SHAFT HOUSING (LONG SHAFT)
2	16-66373	STUD (40)
3	11-82670911	NUT
4	11-8M0204726	NUT
5	1539-8450A1	SADDLE
6	79896A1	MOUNT ASSEMBLY (LOWER)
7	79985A1	MOUNT ASSEMBLY (UPPER)(SEE BLOCK COMMENTS)
8	53-26406	RETAINING RING
9	71490	COVER
10	10-45817	SCREW (39)(40) Comment: SERIAL 02278851-09999999
11	55435	BLOCK (LONG SHAFT)(40) Comment: SERIAL 02771622-09999999
12	27-59079	GASKET (40) Comment: SERIAL 03028361-09999999
13	11-24652	NUT(39)(40) Comment: SERIAL 02278851-09999999
14	32-32077	WATER TUBE (LONG SHAFT)
15	26-36556	SEAL (39-)(40) Comment: SERIAL 01697723-09999999
16	23-13127	SPACER

▶FLYWHEEL ASSEMBLY AND THROTTLE CAM LINKAGE (21 parts)

Ref	OEM Part #	Part Name
1	11-20696	NUT 39 40 Comment: SERIAL 00000000-02771621
2	12-36245	WASHER Comment: SERIAL 00000000-02771621
3	25-62701	O-RING(39) Comment: SERIAL 00000000-02771621
4	28-20094	KEY Comment: SERIAL 00000000-02771621
5	NLA	PLUG (39) Comment: SERIAL 00000000-02098036
6	NLA	FLYWHEEL ASSEMBLY 39 40 Comment: SERIAL 00000000-02771621
7	13-35629	WAVE WASHER Comment: SERIAL 00000000-02771621
8	NLA	STATOR PLATE (SEE BREAKDOWN BELOW) Comment: SERIAL 00000000-02771621
9	NLA	CAM,BREAKER Comment: SERIAL 00000000-02771621
10	56520	THROTTLE CAM (NOT AS SHOWN) Comment: SERIAL 00000000-02771621
11	10-69054	SCREW Comment: SERIAL 00000000-02771621
12	NLA	RING Comment: SERIAL 00000000-02771621
13	10-35400	SCREW Comment: SERIAL 00000000-02771621
14	15-33910015	SHIM(.015) Comment: SERIAL 00000000-02771621
15	NLA	LINK Comment: SERIAL 00000000-02771621
16	NLA	PIVOT PIN Comment: SERIAL 00000000-02771621
17	13-29720	WAVE WASHER Comment: SERIAL 00000000-02771621
18	10-34696	SCREW Comment: SERIAL 00000000-02771621
19	12-34392	WASHER Comment: SERIAL 00000000-02771621
20	13-29720	WAVE WASHER Comment: SERIAL 00000000-02771621
21	11-28656	NUT Comment: SERIAL 00000000-02771621

▶FLYWHEEL,STATOR AND IGNITION COIL (40) (49 parts)

Ref	OEM Part #	Part Name
1	11-20696	NUT,FLYWHEEL
2	12-36245	WASHER,FLYWHEEL NUT
3	25-62701	"O"RING,FLYWHEEL NUT
4	28-20094	KEY
5	NLA	FLYWHEEL ASSEMBLY
6	13-35629	WAVE WASHER
7	NLA	CAM,BREAKER
8	336-3962A4	STATOR ASSEMBLY
9	10-69560	SCREW,STATOR TO END CAP
10	336-3980A1	HOUSING ASSEMBLY,CONTACT
11	336-4318A2	BREAKER ASSEMBLY
12	10-56266	SCREW
13	56316A1	CABLE ASSEMBLY
14	38938	BOOT
15	336-3989	WICK
16	336-3981	INSULATOR
17	11-56325	NUT
18	336-4429	HOLDER,CONTACT HOUSING
19	NLA	COVER ASSEMBLY
20	NLA	SCREW,COVER
21	12-56077	WASHER
22	NLA	WAVE WASHER
23	54-26550	CLIP
24	10-62568	SCREW,CLIP
25	8M0084613	"C" WASHER,LIP SCREW
26	56520	THROTTLE CAM
27	10-69054	SCREW,THROTTLE CAM
28	12-37998	WASHER,THROTTLE CAM SCREW
29	NLA	THROTTLE LINK
30	10-34696	SCREW,THROTTLE LINK
31	12-34392	WASHER,THROTTLE LINK SCREW
32	13-29720	WAVE WASHER, THROTTLE LINK SCREW
33	11-28656	NUT,THROTTLE LINK SCREW
34	NLA	SCREW,THROTTLE LINK
35	54-24836	CLIP
36	8M0084613	"C" WASHER
37	56757A1	JUMPER WIRE ASSEMBLY
38	10-8M0113176	SCREW,JUMPER WIRE
39	336-4409A4	IGNITION COIL ASSEMBLY
40	13-26996	LOCKWASHER
41	11-45076	NUT
42	NLA	SHIELD Comment: SERIAL 02923122-09999999
43	56188	COVER
44	10-56543	SCREW,COVER
45	11-27164	NUT,COVER SCREW
46	84-813715A1	LEAD WIRE
47	332-2854T01	NIPPLE
48	85-63709A1	PROTECTOR
49	33-896329833	SPARK PLUG

▶FUEL PUMP ASSEMBLY (39) (16 parts)

Ref	OEM Part #	Part Name
1	39082A4	FUEL PUMP ASSEMBLY
2	21-22974A3	CHECK VALVE ASSEMBLY
3	31503A1	DIAPHRAGM KIT
5	NLA	SPACER Comment: SERIAL 01865633-09999999
6	10-68918	SCREW (1") Comment: SERIAL 01865633-09999999
7	11-68219	NUT Comment: SERIAL 00000000-01865632
8	NLA	ELBOW (90 )
9	NLA	ELBOW (45 )
10	32-9912688	HOSE
11	22-33373001	ELBOW (90 )
12	54-20387	CLAMP
13	32-53800	FUELINE
14	32454	ADAPTOR
15	NLA	SCREW
16	24-28357	SPRING
17	11-20110	NUT

▶FUEL PUMP ASSEMBLY (40) (16 parts)

Ref	OEM Part #	Part Name
1	89977A1	FUEL PUMP ASSEMBLY
2	21-30430A2	CHECK VALVE ASSEMBLY
3	53245A1	DIAPHRAGM KIT
6	53241	BASE
7	53239	COVER
8	10-32627	SCREW (1-1/2")
9	12-847883	WASHER
10	NLA	ELBOW (90 )
11	32-9912688	HOSE
12	22-33373001	ELBOW (90 )
13	54-20387	CLAMP
14	NLA	FUEL LINE (SERIAL#& UP) Comment: SERIAL 03028361-09999999
15	32454	ADAPTOR
16	10-23702	SCREW (1-1/8") Comment: SERIAL 03028361-09999999
17	24-28357	SPRING
18	11-20110	NUT Comment: SERIAL 00000000-02927900

▶GEAR HOUSING (DRIVE SHAFT) (PAGE 1) (24 parts)

Ref	OEM Part #	Part Name
-	23-86215	SPACER (NYLON)(39)(40) Comment: SERIAL 01697723-09999999
1	1622-4408A1	G/HSG.(40) Comment: SERIAL 03028361-09999999
2	16-58138	STUD (3-7/16")
3	16-58136	STUD (2-3/4")
4	31-22756	ROLLER BEARING
5	17-20032	DOWEL PIN
6	26-33613	SEAL (RUBBER)(39)(40) Comment: SERIAL 01697723-09999999
7	35-33425	SCREEN
8	10-28642	SCREW
9	12-191833	WASHER
10	10-79953Q04	SCREW
11	19643	WASHER
12	10-28653	SCREW
13	54641A1	SHIFT SHAFT (LONG)
14	53-22899	RETAINING RING
15	23-30676A1	BUSHING ASSEMBLY
16	25-26802	O-RING
17	26-30696	OIL SEAL
18	10-39149	SCREW
19	43-98696	PINION GEAR (39-3 RAMP RATCHET)(40)
20	14-30377	TAB WASHER
21	10-30376	SCREW
22	45-39077	DRIVE SHAFT (LONG)(39-SEE NOTE IN BLOCK COMMENTS)(40)
23	15-30527A1	SHIM ASSEMBLY

▶GEAR HOUSING (DRIVE SHAFT) (PAGE 2) (22 parts)

Ref	OEM Part #	Part Name
-	23-13127	SPACER(39)(40) Comment: SERIAL 01697723-09999999
1	1622-4408A4	G/HSG. (40) Comment: SERIAL 03028361-09999999
24	30-33076	BALL BEARING
25	53-30523	RETAINING RING
26	15-30527A1	SHIM ASSEMBLY
27	46-46893A3	WATER PUMP HOUSING (40)
28	25-29439	O-RING
29	26-30900T	OIL SEAL
30	26-33613	SEAL
31	32-34293	WATER TUBE
32	70977T	INSERT (39)(40) Comment: SERIAL 02200318-09999999
33	28-8M0032835	KEY(39-)(40) Comment: SERIAL 02278851-09999999
34	47-89981	IMPELLER (39)(40) Comment: SERIAL 02278851-09999999
35	46895	FACE PLATE (39)(40) Comment: SERIAL 02200318-09999999
36	93224A1	WATER PUMP COVER (39-PLASTIC)(40)
37	26-36558	SEAL (39)(40) Comment: SERIAL 01697723-09999999
38	26-30913	OIL SEAL
39	12-20533	WASHER (40)
40	11-826709109	NUT (40)
41	25-30526	RUBBER RING
42	25-48171	O-RING
43	23-31792T	SLEEVE

▶GEAR HOUSING (PROPELLER SHAFT) (28 parts)

Ref	OEM Part #	Part Name
-	NLA	HSG. COMP.(LONG)(39/40)
1	1622-4408A1	G/HSG.(40) Comment: SERIAL 03028361-09999999
44	44434	SHIFT CAM (40) Comment: SERIAL 03028361-09999999
45	31334	CAM FOLLOWER
46	24-31333	SPRING
47	15-30522A1	SHIM ASSEMBLY
48	30-21889	BALL BEARING
49	43-48577A3	FORWARD GEAR (39-3 RAMP RATCHET)(40)
50	31-22458	ROLLER BEARING
51	43-48577A2	RATCHET (39-2 RAMP RATCHET) Comment: 43-48577A2 INCLUDES A FORWARD GEAR, REVERSE GEAR, PINION GEAR, RATCHET AND CROSS PIN.
52	53-32449	RETAINING RING
53	17-30535	CROSS PIN
54	44-47935	PROPELLER SHAFT (39)(40) Comment: SERIAL 02278851-09999999
55	43-48578	REVERSE GEAR (39-3 RAMP RATCHET)(40)
56	12-30531	THRUST WASHER
57	30-21889	BALL BEARING
58	15-30532A1	SHIM ASSEMBLY
59	25-30529	O-RING
60	30541T1	BEARING CARRIER ASSEMBLY
61	31-22458	ROLLER BEARING
62	26-30530	OIL SEAL
63	12-30528	WASHER
64	30537	COVER
65	86665A1	THRUST HUB (39-)(40) Comment: SERIAL 02278851-09999999
67	48-47944A1	PROPELLER (39)(40) Comment: SERIAL 02278851-09999999
68	11-64075A1	SPACER (39)(40) Comment: SERIAL 02278851-09999999
69	12-27025	WASHER (39-/40) Comment: SERIAL 02278851-02927900
70	11-8M0204653	NUT (39)(40) Comment: SERIAL 02278851-09999999

▶MISCELLANEOUS/ACCESSORIES (1 parts)

Ref	OEM Part #	Part Name
-	NLA	DECAL SET (39)

▶SHIFT CONTROL LINKAGE (39) (24 parts)

Ref	OEM Part #	Part Name
1	30747	SHIFT CONTROL HANDLE Comment: SERIAL 00000000-01919629
2	59107	SHIFT CONTROL HANDLE Comment: SERIAL 01919630-09999999
3	12-8M0204649	WASHER Comment: SERIAL 01919630-09999999
4	11-826709109	NUT Comment: SERIAL 01919630-09999999
5	NLA	SHIFT SHAFT Comment: SERIAL 01919630-09999999
6	23-30678	BUSHING
7	NLA	SPRING
8	NLA	DOWEL PIN
9	39588	CAM Comment: SERIAL 02278851-09999999
10	17-25905	PIN Comment: SERIAL 02278851-09999999
11	43-30802	GEAR
12	12-8M0204649	WASHER
13	11-8267089	NUT
14	24-30816	SPRING Comment: SERIAL 00000000-02278850
15	NLA	SCREW Comment: SERIAL 00000000-02278850
16	13-21272	LOCKWASHER Comment: SERIAL 00000000-02278850
17	24-39627	SPRING Comment: SERIAL 02278851-09999999
18	39601	PLATE Comment: SERIAL 02278851-09999999
19	10-25764	SCREW Comment: SERIAL 02278851-09999999
20	23-30677	BUSHING
21	NLA	SHIFT CONTROL SHAFT ASSEMBLY
22	NLA	GEAR
23	25-26630	RING Comment: SERIAL 00000000-01794250
23A	25-38933	O-RING Comment: SERIAL 01794251-09999999

▶SHIFT CONTROL LINKAGE (40) (17 parts)

Ref	OEM Part #	Part Name
1	59107	SHIFT CONTROL HANDLE
2	12-8M0204649	WASHER
3	11-826709109	NUT
4	NLA	SHIFT SHAFT
5	23-30678	BUSHING
6	NLA	SPRING
7	NLA	DOWEL PIN
8	39588	CAM
9	17-25905	PIN
10	43-30802	GEAR
11	12-8M0204649	WASHER
12	11-8267089	NUT
13	24-39627	SPRING
14	39601	PLATE
15	10-25764	SCREW
16	23-30677	BUSHING
17	43-86686A1	SECTOR GEAR Comment: SECTOR GEARS ARE INCLUDED WITH GEAR HOUSING ASSEMBLIES, COMPLETE.

▶STATOR PLATE ASSEMBLY (25 parts)

Ref	OEM Part #	Part Name
-	NLA	STATOR PLATE ASSEMBLY,COMPLETE 39 40-SER.#& BELOW Comment: SERIAL 00000000-02771621
1	NLA	STATOR PLATE AND CORE Comment: SERIAL 00000000-02771621
2	398-2568T1	COIL ASSEMBLY Comment: SERIAL 00000000-02771621
3	NLA	CLIP(SIDE) Comment: SERIAL 00000000-02771621
4	NLA	CLIP Comment: SERIAL 00000000-02771621
5	NLA	SCREW Comment: SERIAL 00000000-02771621
6	398-2207	FELT Comment: SERIAL 00000000-02771621
7	398-2203	CONDENSER Comment: SERIAL 00000000-02771621
8	NLA	SCREW Comment: SERIAL 00000000-02771621
9	NLA	LOCKWASHER Comment: SERIAL 00000000-02771621
10	NLA	WASHER Comment: SERIAL 00000000-02771621
11	54-24836	CLAMP Comment: SERIAL 00000000-02771621
12	8M0084613	'C" WASHER Comment: SERIAL 00000000-02771621
13	NLA	LOCKWASHER Comment: SERIAL 00000000-02771621
14	11-21923T	NUT Comment: SERIAL 00000000-02771621
15	398-2202	BREAKER ASSEMBLY Comment: SERIAL 00000000-02771621
16	NLA	SCREW Comment: SERIAL 00000000-02771621
17	NLA	WASHER Comment: SERIAL 00000000-02771621
18	NLA	LOCKWASHER Comment: SERIAL 00000000-02771621
19	11-21923T	NUT Comment: SERIAL 00000000-02771621
20	84-813715A1	LEAD WIRE Comment: SERIAL 00000000-02771621
21	85-63709A1	PROTECTOR Comment: SERIAL 00000000-02771621
22	33-8M0114737	SPARK PLUG (39)(40) Comment: SERIAL 02098037-09999999
23	NLA	DUST COVER Comment: SERIAL 00000000-02771621
24	NLA	SCREW Comment: SERIAL 00000000-02771621

▶STEERING HANDLE ASSEMBLY (43 parts)

Ref	OEM Part #	Part Name
-	60850A6	STEERING HANDLE (39)(40) Comment: SERIAL 02278851-09999999
1	27763	GRIP
2	NLA	BODY AND SHAFT
3	NLA	INDICATOR
4	NLA	SET SCREW
5	NLA	DRIVE SCREW
6	23-30677	BUSHING
7	NLA	STEERING HANDLE(39) Comment: SERIAL 00000000-02440975
7A	NLA	STEERING HANDLE 39- 40 Comment: SERIAL 02440976-09999999
7B	NLA	KNUCKLE Comment: SERIAL 02440976-09999999
7C	NLA	BUSHING Comment: SERIAL 02440976-09999999
8	23-28100	BUSHING
9	12-20084	WASHER (39-) Comment: SERIAL 00000000-01865632
10	NLA	SPRING (39) Comment: SERIAL 00000000-02278850
11	14-26706	TAB WASHER (39) Comment: SERIAL 00000000-01865632
11A	NLA	RETAINER (39--) Comment: SERIAL 01865633-02278850
12	NLA	YOKE (39) Comment: SERIAL 01865633-02278850
13	17-26862	PIN (39) Comment: SERIAL 00000000-02278850
14	43-53205	BALL GEAR (40)
15	17-26862	PIN (39)(40) Comment: SERIAL 02278851-09999999
16	NLA	RING (39)(40) Comment: SERIAL 02278851-09999999
17	48003	PIVOT (39)(40) Comment: SERIAL 02278851-09999999
18	15-48002015	SHIM (39-(40) Comment: SERIAL 02278851-09999999
19	13-39227	WAVE WASHER (39) Comment: SERIAL 01865633-02278850
20	NLA	LOCKWASHER (39) Comment: SERIAL 01865633-02278850
21	10-64074	SCREW (39)(40) Comment: SERIAL 02278851-09999999
22	NLA	CONTROL SHAFT (39) Comment: SERIAL 00000000-02278850
22A	NLA	UNIVERSAL JOINT (39)(40) Comment: SERIAL 02278851-09999999
23	23-48005	SLEEVE (39)(40) Comment: SERIAL 02278851-09999999
24	43-53205	BALL GEAR (40)
25	17-26862	PIN (39)(40) Comment: SERIAL 02278851-09999999
26	NLA	RING (39-)(40) Comment: SERIAL 02278851-09999999
27	10-96138	SCREW (39) Comment: SERIAL 00000000-02278850
28	39210	PLATE (39) Comment: SERIAL 01865633-02278850
29	39185	SHIELD (39) Comment: SERIAL 01865633-02278850
30	47680T	BRACKET (39)(40) Comment: SERIAL 02278851-09999999
31	NLA	BOOT (39)(40) Comment: SERIAL 02278851-09999999
32	23-47818	BUSHING, (39)(40) Comment: SERIAL 02278851-09999999
33	24-72847	SPRING (39)(40) Comment: SERIAL 02278851-09999999
34	10-37655	SCREW (39)(40) Comment: SERIAL 02278851-09999999
35	NLA	BOOT
36	10-30679	SCREW
37	11-8M0207775	NUT

▶THROTTLE CONTROL LINKAGE (39) (15 parts)

Ref	OEM Part #	Part Name
1	NLA	SOCKET
2	23-31011	BUSHING
3	NLA	GEAR
4	17-22896	ROLL PIN
5	NLA	BUSHING
6	12-26702	WASHER Comment: SERIAL 01738941-09999999
7	13-34632	WAVE WASHER Comment: SERIAL 01738941-09999999
8	NLA	GEAR AND SHAFT
9	NLA	BUSHING
10	NLA	BRACKET
11	NLA	SCREW
12	NLA	LEVER ASSEMBLY
13	17-22896	ROLL PIN
14	NLA	SCREW
15	11-30968	NUT

▶THROTTLE CONTROL LINKAGE (40) (15 parts)

Ref	OEM Part #	Part Name
1	NLA	SOCKET
2	23-31011	BUSHING
3	NLA	GEAR
4	17-22896	ROLL PIN
5	NLA	BUSHING
6	12-26702	WASHER
7	13-34632	WAVE WASHER
8	NLA	GEAR AND SHAFT
9	NLA	BUSHING
10	NLA	BRACKET
11	NLA	SCREW
12	NLA	LEVER ASSEMBLY
13	17-22896	ROLL PIN
14	NLA	SCREW
15	11-30968	NUT

▶TOP COWL AND STARTER ASSEMBLY (43 parts)

Ref	OEM Part #	Part Name
1	191-7668A2	TOP COWL (39)(40) Comment: SERIAL 01865633-09999999
2	39538	STRIP, REAR(39)(40) Comment: SERIAL 01865633-09999999
3	39537	STRIP,FORWARD(39)(40) Comment: SERIAL 01865633-09999999
4	NLA	SOUND BLANKET (STARBOARD)
5	NLA	SOUND BLANKET (PORT)
6	NLA	SOUND BLANKET (REAR)
7	89096	TRIM COVER
8	10-23618	SCREW
9	14-20165	TAB WASHER
10	11-20166	NUT
11	NLA	SCREEN
12	10-62568	SCREW
13	30834	BRACKET (STARBOARD) 39 Comment: SERIAL 00000000-01865632
14	10-37655	SCREW 39 Comment: SERIAL 00000000-01865632
15	11-27164	NUT 39 Comment: SERIAL 00000000-01865632
16	39258	BRACKET (STARBOARD) 39- 40 Comment: SERIAL 01865633-09999999
17	10-39514	SCREW 39- 40 Comment: SERIAL 01865633-09999999
18	12-37998	WASHER 39- 40 Comment: SERIAL 01865633-09999999
19/20	12-8M0204649	WASHER 39- 40 Comment: SERIAL 01865633-09999999
21	12-21273	WASHER (39) Comment: SERIAL 00000000-01738940
22	20155	RETAINER
23	24-29340T02	SPRING ASSEMBLY
24	23-28912	BUSHING
25	50-93696A2	STARTER SHEEVE
26	17-22896	PIN
27	30596	STARTER PAWL
28	13-36206	WAVE WASHER
29	23-28919	BUSHING
30	23-61005	SPACER (39)(40) Comment: SERIAL 01697723-09999999
31	26179	RETAINER
32	12-35559	WASHER (39)(40) Comment: SERIAL 01697723-09999999
33	13-20160	WAVE WASHER
34	30595	PLATE
35	35558	SHAFT (39)(40) Comment: SERIAL 01697723-09999999
36	53472	MOUNT
37	12-26907	WASHER (39) Comment: SERIAL 00000000-01738940
38	55860	PULLEY
39	23-309772	SPACER
40	12-22887	WASHER
41	10-28789	SCREW
42	50-12066Q10	STARTER ROPE
43	30782	HANDLE
44	79470A1	RETAINER ASSEMBLY

100-Hour / Annual Service Checklist

Regular maintenance keeps your Mercury 40 (1 CYL.) 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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