🔎 Mercury 40 (2 CYL. PRODUCT OF USA) Reference Library — Exploded parts diagrams (16 diagrams), specifications, common issues, and maintenance checklist.
The Mercury 40 (2 CYL. PRODUCT OF USA) 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 (2 CYL. PRODUCT OF USA):
-
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 (2 CYL. PRODUCT OF USA).
▶BOTTOM COWL (31 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-77586A78 |
GASKET SET |
| 1 |
2154-7603 |
BOTTOM COWL |
| 2 |
714933 |
MOLDING, BOTTOM COWL (2"-6 1/2" -15") |
| 3 |
70455 |
COVER, BOTTOM COWL |
| 4 |
10-69079 |
SCREW, (#10-16 x .440), COVER TO BOTTOM COWL |
| 5 |
86055T |
HANDLE, SHIFT |
| 6 |
86056A1 |
SHAFT, SHIFT |
| 7 |
10-69560 |
SCREW, (.190-32 x 1.250), SHIFT HANDLE TO SHAFT |
| 8 |
10,13-26996 |
LOCKWASHER, Stainless Steel, SHIFT HANDLE SCREW |
| 9 |
66414 |
CAM, SHIFT DETENT |
| 10 |
17-25905 |
PIN, CAM TO SHIFT SHAFT |
| 11 |
23-26856 |
BUSHING, SHIFT SHAFT |
| 12 |
25-16524 |
O-RING, SHIFT SHAFT |
| 13 |
72733 |
ARM, SHIFT |
| 14 |
10-72734 |
SET SCREW, (#10-32 x .310), SHIFT ARM |
| 15 |
18-210711 |
COTTER PIN, SHIFT SHAFT |
| 16 |
24-39627 |
SPRING, DETENT |
| 17 |
39601 |
PLATE, DETENT SPRING |
| 18 |
10-25764 |
SCREW, (.190-32 x .50), DETENT SPRING TO BOTTOM COWL |
| 19 |
27-92874 |
GASKET, DRIVESHAFT HSG./BOTTOM COWL Comment: SN# US-5805431/Belgium-9294811/Canada-7166328 & Up |
| 20 |
53-72168 |
RING, RETAINER |
| 21 |
70393 |
RETAINER, STARTER ROPE Comment: SN# US-5805431/Belgium-9294811/Canada-7166328 & Up |
| 22 |
19-74258 |
PLUG, BOTTOM COWL - FUEL ADAPTOR |
| 23 |
70462 |
ARM, LATCH CRANK |
| 24 |
24-70459 |
SPRING, LATCH CRANK |
| 25 |
75263 |
CRANK, FRONT LATCH |
| 26 |
13-34632 |
WASHER, LATCH HANDLE |
| 27 |
92798 |
HANDLE, LATCH BOTTOM COWL Comment: SN# US-5805431/Belgium-9294811/Canada-7166328 & Up |
| 28 |
17-38489 |
PIN, Roll, LATCH HANDLE TO CRANK |
| 29 |
74802 |
STOP, SHIFT ARM |
| 30 |
23-93171 |
BUSHING, BOTTOM COWL |
▶CARBURETOR ASSEMBLY (24 parts)
| Ref |
OEM Part # |
Part Name |
| - |
1395-8672 |
REPAIR PARTS KIT Comment: (LMO-4) |
| -- |
NSS |
NOT SOLD SEPARATE, CAP PLUG, CARBURETOR |
| 1 |
1377-8402 |
CARBURETOR Comment: (LMO-4) |
| 2 |
1395-6043 |
RETAINER, JET (.041) |
| 3 |
NSS |
NOT SOLD SEPARATE, GASKET, JET RETAINER |
| 4 |
1395-8155 |
BOWL, Fuel |
| 5 |
NSS |
NOT SOLD SEPARATE, GASKET, FUEL BOWL |
| 6 |
1395-5898 |
FLOAT |
| 7 |
1395-5904 |
SPRING, FLOAT |
| 8 |
NSS |
NOT SOLD SEPARATE, FLOAT PIN |
| 9 |
1395-4805 |
SCREEN, FILTER |
| 10 |
1395-8671 |
NOZZLE Comment: (LMO-4) |
| 11 |
NSS |
NOT SOLD SEPARATE, INLET NEEDLE, SEAT AND GASKET |
| 12 |
NSS |
NOT SOLD SEPARATE, GASKET, INLET NEEDLE AND SEAT |
| 14 |
1395-5896 |
SHAFT, CHOKE |
| 15 |
1395-5905 |
SPRING, CHOKE RETURN |
| 16 |
1395-5897 |
VALVE, CHOKE |
| 17 |
1395-5902 |
SCREW, (#6-32 x .187), VALVE |
| 18 |
1395-5894 |
SHAFT, THROTTLE |
| 19 |
1395-5903 |
SPRING, THROTTLE RETURN |
| 20 |
1395-8670 |
VALVE, THROTTLE Comment: (LMO-4) |
| 21 |
NSS |
NOT SOLD SEPARATE, IDLE NNEDLE |
| 22 |
1395-6103 |
SPRING, IDLE NEEDLE |
| 23 |
NSS |
NOT SOLD SEPARATE, WLECH PLUG, CARBURETOR (5/16") |
▶CLAMP AND SWIVEL BRACKET ASSEMBLY (28 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-77586A78 |
GASKET SET |
| 1 |
1479-7291A1 |
CLAMP BRACKET (PORT) |
| 2 |
1478-7289A1 |
CLAMP BRACKET (STARBOARD) |
| 3 |
10-77190A4 |
THUMB SCREW ASSEMBLY |
| 4 |
78971 |
HANDLE, THUMB SCREW |
| 5 |
17-78970 |
PIN, Groove, THUMB SCREW |
| 6 |
12-73719 |
WASHER, THUMB SCREW |
| 6A |
10-768042 |
SCREW, THUMB SCREW WASHER |
| 7 |
10-96917 |
SCREW, CLAMP BRACKET |
| 8 |
12-34931 |
WASHER, (.406 x .734 x .063) Stainless Steel, CLAMP BRACKET SCREW |
| 9 |
11-8M0204726 |
NUT, (.375-24), CLAMP BRACKET SCREW |
| 10 |
16-68925 |
STUD, CLAMP BRACKET |
| 11 |
13-26992 |
LOCKWASHER, (.250) Stainless Steel, CLAMP BRACKET STUD |
| 12 |
11-29598 |
NUT, (.250-28) Stainless Steel, CLAM BRACKET STUD |
| 13 |
17-68929A2 |
PIN ASSEMBLY, Tilt |
| 14 |
24-62143 |
SPRING, TILT PIN |
| 15 |
1477-7400A2 |
SWIVEL BRACKET ASSEMBLY |
| 16 |
10-69067 |
SCREW, (.250-20 x 1.375), SWIVEL BRACKET |
| 16A |
22-8M0169589 |
FITTING, SWIVEL BRACKET |
| 17 |
76110A1 |
LEVER ASSEMBLY, Tilt |
| 18 |
24-68932 |
SPRING, TORSION - PORT |
| 19 |
68968 |
ROD, REVERSE LOCK |
| 20 |
18-25191 |
COTTER PIN, REVERSE LOCK ROD |
| 21 |
68972 |
LEVER, REVERSE LOCK |
| 22 |
24-73124 |
SPRING, TORSION - STARBOARD |
| 23 |
22-8M0169589 |
FITTING |
| 24 |
79793A1 |
SCREW ASSEBMLY, Adjustment |
| 25 |
25-20385 |
O-RING, (.239 x .070), CO-PILOT SCREW |
▶CRANKSHAFT, PISTON AND CONNECTING ROD (21 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-77586A78 |
GASKET SET |
| 1 |
458-5549 |
CRANKSHAFT |
| 2 |
626-5547A5 |
CONNECTING ROD ASSEMBLY |
| 3 |
10-72455 |
SCREW, CONNECTING ROD |
| 4 |
14-72454 |
TAB WASHER, CONNECTING ROD SCREW |
| 5 |
29-68944 |
BEARING, Needle, CONNECTING ROD |
| 6 |
68953A1 |
LINER ASSEMBLY, CRANKPIN |
| 8 |
31-68949 |
BEARING, Roller, CONNECTING ROD - PISTON PIN |
| 9 |
758-8076A2 |
PISTON ASSEMBLY Comment: SN# US-5805431/Belgium-9294811/Canada-7166328 & Up |
| 10 |
40-68950 |
LOCK RING, PISTON |
| 11 |
39-70175A12 |
RING SET, Piston |
| 12 |
26-30530 |
SEAL, Oil, CRANKSHAFT - UPPER |
| 13 |
31-78099 |
BEARING, Roller, CRANKSHAFT - UPPER |
| 14 |
71841 |
RING, CRANKSHAFT |
| 15 |
30-69389 |
BEARING, Ball, CRANKSHAFT - LOWER |
| 16 |
53-68952 |
RING, Retaining, BALL BEARING -LARGE |
| 17 |
53-27275 |
RING, Retaining, BALL BEARING - SMALL |
| 18 |
26-77494 |
SEAL, Oil, CRANKSHAFT |
| 19 |
25-62706 |
O-RING, (.426 x .070), CRANKSHAFT |
| 20 |
70786A1 |
COUPLING ASSEMBLY, CRANKSHAFT |
| 21 |
26-76266 |
SEAL, COUPLING |
▶CYLINDER BLOCK AND CRANKCASE ASSEMBLY (32 parts)
| Ref |
OEM Part # |
Part Name |
| - |
72530A78 |
POWERHEAD ASSEMBLY |
| 1 |
862-7713A2 |
CYLINDER BLOCK ASSEMBLY |
| 2 |
16-728091 |
STUD, (.250-20/.250-28 x 1.620), POWERHEAD |
| 3 |
17-8M0084726 |
PIN, Dowel (.187 x .530), CYLINDER BLOCK |
| 5 |
16-20353 |
STUD, (.250-28 x 1.750), REED BLOCK AND CARBURETOR |
| 6 |
22-56800 |
PLUG, Pipe (.0625-27), CYLINDER BLOCK |
| 7 |
10-70732 |
SCREW, (.250-20 x 2.00), CRANKCASE TO CYLINDER BLOCK |
| 8 |
10-28635 |
SCREW, (.250-20 x .620) Stainless Steel, CRANKCASE TO CYLINDER BLOCK |
| 9 |
10-28667 |
SCREW, (.250-20 x 1.00) Stainless Steel, CRANKCASE TO CYLINDER BLOCK |
| 10 |
68953A1 |
LINER ASSEMBLY, CYLINDER BLOCK |
| 12 |
29-71840 |
BEARING, Needle, CENTER MAIN |
| 13 |
77585 |
COVER, EXHAUST MANIFOLD |
| 14 |
27-77586 |
GASKET, EXHAUST MANIFOLD COVER |
| 15 |
10-32228 |
SCREW, (#10-32 x .625), EXHAUST MANIFOLD COVER |
| 16 |
1027-5546 |
COVER, CYLINDER BLOCK |
| 17 |
27-68942 |
GASKET, CYLINDER BLOCK COVER |
| 18 |
10-32228 |
SCREW, (#10-32 x .625), CYLINDER BLOCK COVER |
| 19 |
27-68941 |
GASKET, BLOCK TO BOTTOM COWL |
| 20 |
11-24652 |
NUT, (.250-28), POWERHEAD STUDS |
| 22 |
32-9938779 |
TUBE, BLEED |
| 23 |
22-56759 |
CONNECTOR, ADAPTOR |
| 24 |
21-64871A2 |
CHECK VALVE, CRANKCASE |
| 25 |
69498 |
REED BLOCK |
| 26 |
27-70415 |
GASKET, CRANKCASE TO REED BLOCK |
| 27 |
34-69499A1 |
REED ASSEMBLY |
| 28 |
34-69500 |
STOP, Reed |
| 29 |
10-28430 |
SCREW, (#6-32 x .25), REED AND REED STOP |
| 30 |
27-70416 |
GASKET, REED BLOCK TO ADAPTOR |
| 31 |
70420 |
ADAPTOR, CARBURETOR TO REED BLOCK |
| 32 |
79746 |
BRACKET, CABLE MOUNTING |
| 33 |
10-69022 |
SCREW, (#10-32 x .500) Stainless Steel, BRACKET TO ADAPTOR |
| 34 |
10-20055 |
SCREW, (#10-32 x .375), CABLE MOUNTING BRACKET |
▶DRIVESHAFT HOUSING ASSEMBLY (14 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-77586A78 |
GASKET SET |
| 1 |
1580-6673A2 |
HOUSING ASSEMBLY, Driveshaft |
| 2 |
16-75321 |
STUD, DRIVE SHAFT HOUSING Comment: (LONG SHAFT) |
| 3 |
10-79953Q04 |
SCREW, (.375-16 x .250), GREASE FILTER |
| 4 |
12-191833 |
WASHER, GREAST FILLER SCREW |
| 5 |
32-75308 |
TUBE, Water Comment: (LONG SHAFT) |
| 6 |
26-36556 |
SEAL, (.500 Inch Outside Diameter), WATER TUBE |
| 7 |
23-13127 |
BEARING, WATER TUBE SEAL |
| 8 |
54-79791 |
CLAMP, CO-PILOT |
| 9 |
88669 |
MOUNT, RUBBER (TOP AND BOTTOM) Comment: SN# US-5805431/Belgium-9294811/Canada-7166328 & Up |
| 10 |
23-74308 |
BUSHING, RUBBER MOUNT |
| 11 |
98496A1 |
BRACKET ASSEMBLY, STEERING ARM |
| 12 |
10-75840 |
SCREW, (#10-24 x .880), STEERING ARM BRACKET |
| 13 |
11-82670911 |
NUT, (.312-24) Stainless Steel, GEAR HOUSING STUD |
▶FLYWHEEL AND STATOR (30 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
247-7933A2 |
FLYWHEEL ASSEMBLY |
| 2 |
28-20094 |
KEY, Woodruff, FLYWHEEL RIVE |
| 3 |
12-20553 |
WASHER, FLYWHEEL |
| 4 |
11-8M0204726 |
NUT, FLYWHEEL |
| 5 |
339-5566A5 |
STATOR ASSEMBLY |
| 6 |
10-66707 |
SCREW, STATOR TO MOUNTING BRACKET (7/8") |
| 7 |
339-5590A1 |
COIL ASSEMBLY (3 3/8" AND 4 3/8" LEADS) |
| 8 |
54-59538 |
CLIP, COIL RETAINING |
| 9 |
54-65927 |
CLIP, COIL RETAINING |
| 10 |
86-69348 |
TERMINAL BLOCK, STATOR |
| 10A |
10,13-58308 |
LOCKWASHER, Internal , TERMINAL BLOCK |
| 11 |
10-22654 |
SCREW, (.190-32 x .38), LEADS TO TERMINAL BLOCK |
| 12 |
10-69347 |
SCREW, TERMINAL BLOCK TO STATOR (5/8") |
| 13 |
10-32,11-46438 |
NUT, , TERMINAL BLOCK SCREW |
| 14 |
70426A3 |
TRIGGER ASSEMBLY |
| 17 |
70414 |
LINK ROD, TRIGGER TO SPARK LEVER |
| 18 |
10-32,11-68219 |
NUT, Stainless Steel, ADJUSTING LINK ROD |
| 19 |
33973 |
SWIVEL, LINK ROD |
| 20 |
70428 |
BRACKET, STATOR MOUNTING |
| 21 |
10-25764 |
SCREW, STATOR MOUNTING BRACKET (7/16") |
| 22 |
70422 |
LEVER, SPARK |
| 23 |
10-62802 |
SCREW, ADJUSTNG - SPARK LEVER (1 1/8") |
| 24 |
11-21923T |
NUT, ( 8-32), ADJUSTING SCREW |
| 25 |
24-70418 |
SPRING, THROTTLE LEVER |
| 26 |
70424 |
LEVER, Throttle |
| 27 |
70429 |
CAM, Throttle |
| 28 |
10-38055 |
SCREW, (.190-32 x .620), THROTTLE CAM TO THROTTLE LEVER |
| 29 |
12-8M0204666 |
WASHER, (.203 x .500 x .032), THROTTLE CAM SCREW |
| 30 |
10-38515 |
SCREW, SHOULDER (7/8") |
| 31 |
12-69056 |
WASHER, (.255 x .625 x .0312), SHOULDER SCREW |
▶FUEL PUMP AND FUEL LINES (8 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
89977A1 |
PUMP ASSEMBLY, Fuel |
| 2 |
32-8M0108355 |
LINE, (57.00 Inches Bulk) (4-1/2" AND 1-3/4") |
| 3 |
54-68424 |
CLAMP, FUEL LINE |
| 4 |
22-19688 |
FITTING, FUEL LINE TO CARBURETOR |
| 5 |
22-63981 |
FITTING, FUEL LINE TO ADAPTOR |
| 6 |
32-9912878 |
TUBING, FUEL PUMP TO BLOCK (1 INCH) |
| 7 |
22-61544 |
ELBOW, HOSE TO CYLINDER BLOCK (45 DEGREE) |
| 8 |
54-68424 |
CLAMP, FUEL PUMP HOSE TO ELBOWS |
▶FUEL TANK, FUEL LINES AND CARBURETOR (37 parts)
| Ref |
OEM Part # |
Part Name |
| - |
22-93588 |
ELBOW, FUEL TANK - W/ FILTER SCREEN |
| -- |
76623 |
BRACKET, FUEL TANK Comment: (LONG SHAFT) |
| 1 |
1248-8083A2 |
TANK ASSEMBLY, Fuel |
| 2 |
36-78573A1 |
CAP, FUEL |
| 3 |
10-70298 |
SCREW, VENT - FUEL CAP |
| 4 |
12-8M0204663 |
WASHER, (.187 x .500 x .062) Neoprene, VENT SCREW |
| 5 |
27-78577 |
GASKET, FUEL CAP |
| 6 |
12-38255 |
WASHER, FUEL CAP |
| 7 |
24-22227 |
SPRING, FUEL CAP |
| 8 |
12-71055 |
WASHER, FUEL CAP |
| 9 |
18-210711 |
COTTER PIN, FUEL CAP |
| 10 |
752373 |
CHAIN, FUEL CAP |
| 11 |
24-85767 |
SPRING, FUEL CAP - RETAINING |
| 12 |
27-78578 |
GASKET, FUEL TANK TO COWL |
| 13 |
78579 |
BRACKET, FUEL TANK AND IGNITION COIL |
| 14 |
10-37571 |
SCREW, (.190-32 x .500), BRACKET TO CYLINDER BLOCK |
| 15 |
10-32,11-859124 |
NUT, Stainless Steel, BRACKET SCREW |
| 16 |
75689A1 |
STRAP ASSEMBLY, FUEL TANK ATTACHING |
| 17 |
10-26668 |
SCREW, STRAP ASSEMBLY TO FUEL TANK BRACKET |
| 18 |
32-8M0108355 |
LINE, Fuel, FUEL TANK TO VALVE (8") |
| 19 |
54-68424 |
CLAMP, FUEL LINE ATTACHING |
| 20 |
20-89398 |
VALVE, FUEL SHUT OFF |
| 21 |
32-8M0108355 |
LINE, Fuel, VALVE TO CARBURETOR (4") |
| 22 |
22-96858 |
FITTING, CARBURETOR Comment: 37 Degree - With Fuel Pump |
| 23 |
1377-8402 |
CARBURETOR Comment: (LMO-4) |
| 24 |
27-70417 |
GASKET, CARBURETOR MOUNTING |
| 25 |
70557 |
CABLE, Choke |
| 26 |
11-78045 |
NUT, LOCKING - CHOKE CABLE |
| 27 |
86874 |
BUTTON, CHOKE CABLE |
| 28 |
12-8M0204649 |
WASHER, (.281 x .500 x .060) Stainless Steel, CARBURETOR STUD |
| 29 |
11-36069 |
NUT, CARBURETOR STUD |
| 30 |
78049 |
LEVER, IDLE ADJUSTMENT |
| 31 |
78046 |
LINK, IDLE ADJUSTMENT |
| 32 |
78048 |
SHAFT, IDLE ADJUSTMENT |
| 33 |
23-78047 |
SLEEVE, IDLE ADJUSTMENT |
| 34 |
11-78045 |
NUT, CHOKE KNOB |
| 35 |
92434A2 |
KNOB, CHOKE |
▶GEAR HOUSING ASSEMBLY(DRIVESHAFT) (32 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-77586A78 |
GASKET SET |
| 1 |
1648-7811A9 |
GEAR HOUSING ASSEMBLY, BASIC |
| 2 |
16-75321 |
STUD, GEAR HOUSING (7 1/4") Comment: (LONG SHAFT) |
| 3 |
16-68928 |
STUD, WATER PUMP (2 1/8") |
| 4 |
16-70741 |
STUD, WATER PUMP (1 1/8") |
| 5 |
23-77428 |
BEARING, GEAR HOUSING |
| 6 |
23-90770 |
BUSHING, FLANGES -GEAR HOUSING |
| 7 |
43-90796 |
GEAR, Pinion |
| 9 |
11-20922 |
NUT, PINION GEAR |
| 10 |
45-77433 |
DRIVESHAFT Comment: (LONG SHAFT) |
| 11 |
28-8M0032835 |
KEY, IMPELLER DRIVE |
| 12 |
27-68939 |
GASKET, WATER PUMP - LOWER |
| 13 |
46-90844A1 |
HOUSING ASSEMBLY, Water Pump |
| 14 |
26-897153 |
SEAL, Oil, WATER PUMP |
| 15 |
70977T |
INSERT, WATER PUMP |
| 16 |
12-8M0204666 |
WASHER, (.203 x .500 x .032), WATER PUMP |
| 17 |
25-74138 |
O-RING, WATER PUMP |
| 18 |
47-89980 |
IMPELLER |
| 19 |
68955 |
FACE PLATE, WATER PUMP |
| 20 |
46-95965A2 |
COVER ASSEMBLY, Water Pump |
| 21 |
26-30913 |
SEAL, Oil, WATER PUMP COVER |
| 22 |
23-13127 |
BEARING, WATER TUBE SEAL |
| 23 |
26-36558 |
SEAL, WATER TUBE |
| 24 |
23-31792T |
SLEEVE, WATER TUBE GUIDE |
| 25 |
25-30526 |
RING, RUBBER - DRIVESHAFT |
| 26 |
12-30164 |
WASHER, (.192 x .375 x .0312) Stainless Steel, WATER PUMP STUDS |
| 27 |
10-32,11-859124 |
NUT, Stainless Steel, WATER PUMP STUDS |
| 28 |
10-28653 |
SCREW, (#10-32 x 0.25), VENT - GEAR HOUSING |
| 29 |
19643 |
WASHER, VENT SCREW |
| 30 |
10-79953Q04 |
SCREW, (.375-16 x .250), GREASE FILLER |
| 31 |
12-191833 |
WASHER, GREASE FILLER SCREW |
| 32 |
75307 |
SHIFT SHAFT Comment: (LONG SHAFT) |
▶GEAR HOUSING ASSEMBLY(PROPELLER SHAFT) (21 parts)
| Ref |
OEM Part # |
Part Name |
| - |
26-71140A1 |
SEAL KIT, Gear Housing |
| 1 |
1648-7811A9 |
GEAR HOUSING ASSEMBLY, BASIC |
| 31 |
11-20696 |
NUT, PROPELLER SHAFT |
| 32 |
12-73672 |
WASHER, PROPELLER SHAFT |
| 33 |
43-90795A1 |
GEAR, Drive |
| 34 |
14-79603 |
WASHER, SPECIAL - PROPELLER SHAFT |
| 35 |
15-79602A1 |
SHIM SET, PROPELLER SHAFT (.002-3-5-10-20) |
| 36 |
53-79601 |
RING, Retaining |
| 37 |
24-91813 |
SPRING, CLUTCH |
| 39 |
44-93358 |
PROPELLER SHAFT Comment: SN# US-5805431/Belgium-9294811/Canada-7166328 & Up |
| 40 |
77424 |
SPACER, PROPELLER SHAFT |
| 41 |
99210A1 |
CARRIER ASSEMBLY, Bearing |
| 42 |
26-98309 |
SEAL, Oil |
| 43 |
75812 |
COVER, GEAR HOUSING |
| 44 |
25-68935 |
O-RING, (1.799 x .103), BEARING CARRIER |
| 45 |
28-32003 |
KEY, BEARING CARRIER |
| 46 |
70588 |
THRUST HUB, FORWARD |
| 47 |
48-93357A10 |
PROPELLER ASSEMBLY Comment: SN# US-5805431/Belgium-9294811/Canada-7166328 & Up |
| 48 |
93356 |
THRUST HUB, AFT Comment: SN# US-5805431/Belgium-9294811/Canada-7166328 & Up |
| 49 |
11-82670911 |
NUT, (.312-24) Stainless Steel, PROPELLER |
| 50 |
11-82670911 |
NUT, (.312-24) Stainless Steel, DRIVE SHAFT HOUSING STUD |
▶MANUAL STARTER (15 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
75764 |
BRACKET ASSEMBLY, STARTER REWIND |
| 2 |
10-37571 |
SCREW, (.190-32 x .500), BRACKET TO CYLINDER BLOCK |
| 3 |
12-30164 |
WASHER, (.192 x .375 x .0312) Stainless Steel, BRACKET TO CYLINDER BLOCK SCREW |
| 4 |
77568 |
SHEAVE, Starter |
| 5 |
24-70167 |
SPRING, STARTER REWIND |
| 6 |
50-90892A2 |
ROPE ASSEMBLY, Starter (INCLUDES 2 RIVETS) |
| 7 |
70396 |
HANDLE, STARTER ROPE |
| 8 |
70394 |
CAP, STARTER HANDLE |
| 9 |
43-90324 |
GEAR, Pinion, STARTER REWIND |
| 10 |
24-70288 |
SPRING, PINION |
| 11 |
12-90323 |
WASHER, PINION |
| 12 |
90322 |
RETAINER, PINION SPRING |
| 13 |
24-90321 |
SPRING, TORSION - PINION |
| 14 |
10-79644 |
SCREW, (.190-32 x .880), SPRING RETAINER |
| 15 |
17-70180 |
RIVET, STARTER SHEAVE |
▶MISCELLANEOUS PARTS/ACCESSORIES (1 parts)
| Ref |
OEM Part # |
Part Name |
| - |
87905A5 |
PUMP KIT, Fuel (REMOTE FUEL TANK) |
▶STEERING HANDLE ASSEMBLY (20 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
11099A1 |
BOOT ASSEMBLY, HANDLE |
| 2 |
70382 |
GRIP, HANDLE |
| 3 |
70383 |
ARM, HANDLE |
| 4 |
12-31433 |
WASHER, HANDLE |
| 5 |
53-70384 |
RING, Retaining, HANDLE |
| 6 |
70386 |
PULLEY, STEERING HANDLE |
| 7 |
70385 |
SHAFT, HANDLE |
| 7A |
84-70671A1 |
HARNESS ASSEMBLY, STOP SWITCH |
| 8 |
70389A2 |
BRACKET ASSEMBLY, HANDLE |
| 9 |
10-37978 |
SCREW, (#10-32 x .750) Stainless Steel, HANDLE BRACKET |
| 10 |
70390 |
RETAINER, CABLE |
| 11 |
85-708571 |
INSULATOR, CABLE |
| 12 |
23-70391 |
BUSHING, HANDLE BRACKET |
| 13 |
11-73784 |
NUT, HANDLE BRACKET |
| 14 |
92791 |
CABLE, THROTTLE ADVANCE Comment: SN# US-5805430/Australia-8068064/Belgium-9294810/Canada-7166327 & Below |
| 14&15 |
92791 |
CABLE, THROTTLE ADVANCE/ RETARD Comment: SN# US-5805431/Belgium-9294811/Canada-7166328 & Up |
| 15 |
92791 |
CABLE, THROTTLE RETARD Comment: SN# US-5805430/Australia-8068064/Belgium-9294810/Canada-7166327 & Below |
| 16 |
11-21825 |
NUT, (.250-28), THROTTLE CABLE |
| 17 |
12-37998 |
WASHER, THROTTLE CABLE |
| 18 |
5790811 |
SLEEVE, STOP SWITCH HARNESS |
▶SWITCH BOX AND IGNITION COIL (14 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
339-6222A8 |
SWITCHBOX ASSEMBLY |
| 2 |
10-45218 |
SCREW, (#10-32 x .380), SWITCH BOX GROUND |
| 3 |
10-22523 |
SCREW, (.190-32 x .75), SWITCH BOX |
| 4 |
12-8M0204666 |
WASHER, (.203 x .500 x .032), SWITCH BOX SCREW |
| 6 |
84-813715A1 |
WIRE ASSEMBLY, HIGH TENSION |
| 6A |
85-63709A1 |
BOOT/TERMINAL KIT, SPARK PLUG |
| 7 |
33-8M0114744 |
SPARK PLUG Comment: (USE IN USA) |
| 8 |
300-8M0166172 |
COIL ASSEMBLY, Ignition |
| 10 |
10-32,11-45076 |
NUT, Brass, IGNITION COIL TERMINAL |
| 11 |
76254 |
COVER |
| 12 |
10-76502 |
SCREW, (.190-32 x 1.880), COIL COVER |
| 13 |
61990 |
TIE STRAP, (14.00 Inches), SWITCH BOX LEADS |
| 14 |
5790811 |
SLEEVE, SWITCH BOX LEADS |
| 15 |
12-21273 |
WASHER, COIL COVER SCREW |
▶TOP COWL (6 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
2155-6654 |
TOP COWL ASSEMBLY |
| 2 |
74139 |
HOOK, TOP COWL - REAR |
| 3 |
10-45742 |
SCREW, HOOK TO TOP COWL (3/8") |
| 4 |
11-8M0204718 |
NUT, HOOK SCREW |
| 5 |
70461 |
CATCH, TOP COWL - FRONT |
| 6 |
10-69570 |
SCREW, (#10-16 x .750), CATCH TO TOP COWL |
100-Hour / Annual Service Checklist
Regular maintenance keeps your Mercury 40 (2 CYL. PRODUCT OF USA) 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.
