Mercury 40 (2 CYL.) (0T980000 THRU 0T999999) Parts & Diagrams

🔎 Mercury 40 (2 CYL.) Reference Library — Exploded parts diagrams (32 diagrams), specifications, common issues, and maintenance checklist.

The Mercury 40 (2 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 (2 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 (2 CYL.).

▶Accessories (1 parts)

Ref	OEM Part #	Part Name
-	821455T8	TILLER HANDLE KIT

▶Bottom Cowl (74 parts)

Ref	OEM Part #	Part Name
1	24-824992	SPRING, Detent
2	24-824993	SPRING, Backing
3	824994	SPRING, Plate
4	10-82191916	SCREW, (M5 x 14)
5	8280471	STRAP
6	10-4006731	SCREW, (M6 x 16) Stainless Steel
7	8M0039049	CLAMP, Horizontal Shift Shaft
8	10-40011130	SCREW, (M6 x 30) Stainless Steel
9	8M0036802	CAP, Intermediate Lever
10	10-4006731	SCREW, (M6 x 16)
11	23-26954	BUSHING
12	8M0041741	LEVER, Intermediate
13	42927	INSERT
14	17-8224561	PIN
15	23-26954	BUSHING
16	23-48475	BUSHING
17	822459	RETAINER, Cable
18	12-69056	WASHER, (.255 x .620 x .030) Stainless Steel
19	11-401386	NUT, (M6) Stainless Steel
20	11-401386	NUT, (M6) Stainless Steel
21	12-69056	WASHER, (.255 x .620 x .030) Stainless Steel
22	822470	SHIFT LINK
23	23-48475	BUSHING
24	821483A6	SHIFT SHAFT, Horizontal
25	821487	LEVER, Interlock Actuating
26	18-26811	COTTER PIN
27	10-878607	SCREW, (#10-16 x .375), Self Tap
28	84-88807A28	CABLE ASSEMBLY, Black (7.50 Inch)
29	8M0037997	SHIFT ROD
30	18-210711	COTTER PIN
31	17-8251851	PIN, Shift Rod
32	13-827418	LOCKWASHER
33	822011	LEVER, Shift
34	13-825273	WAVE WASHER
35	10-40011107	SCREW, (M5 x 16) Stainless Steel
36	98889	LATCH
37	39519	CUP
38	10-42975	DRIVE SCREW
39	822423002	SEAL
40	25-828249	GROMMET Comment: (Export -Greenland)
41	19-17230	PLUG, Stop Switch
42	8M0032846	RETAINER, Brass, Switch
43	87-11083A31	SWITCH, Stop
44	15920Q54	LANYARD ASSEMBLY, Stop Switch
45	25-16226	GROMMET
46	822424001	SEAL, Throttle Cable
47	19-823874001	PLUG
48	4010-821511T1	BOTTOM COWL
49	19-824076001	PLUG, Shift Lever
50	821490T	SHIFT HANDLE
51	25-19565002	GROMMET Comment: (Split-Power Trim)
52	19-824473	PLUG, Warning Alarm
53	823572001	SEAL, Warning Horn
54	84-8M0210763	ALARM ASSEMBLY, Audio Warning
55	12-8M0214930	WASHER
56	10-82239312	SCREW, (M5 x 12)
57	87-8M0042301	SWITCH ASSEMBLY Comment: (Power Trim)
58	13541	PLUG, Male
59	812830T01	PLUG, Trim Switch
60	8M0032848	RETAINER
61	10-878608	SCREW, (#10-16 x .500)
62	10-40011107	SCREW, (M5 x 16) Stainless Steel, Interlock Cable
63	10-1993716	SCREW, (M6 x 16)
64	822425	CAM, Latch
65	13-12134	WASHER, Wave
66	23-812707	BUSHING
67	22-813613	FITTING
68	54-816311T	TIE STRAP, (8.00 Inches)
69	32-7568058	HOSE, (15.00 Inches)
70	23-812707	BUSHING
71	823573F1	LEVER, Cowl Latch
72	10-40011129	SCREW, (M6 x 25) Stainless Steel
73	23-822003	BUSHING
74	25-822002	GROMMET

▶Carburetor (40 parts)

Ref	OEM Part #	Part Name
-	61-8M0063311	POWERHEAD ASSEMBLY Comment: 40 HP
1	3301-821383T18	CARBURETOR, (WME 99) Comment: (Electric 40)
2	NSS	NOT SOLD SEPARATE, Retaining Ring
3	1395-8113521	LEVER, Oil Pump Comment: (Electric)
4	1395-8086121	SCREW, Lever Retainer
5	1395-8236371	VALVE, Throttle
6	NSS	NOT SOLD SEPARATE, Screw-Throttle Valve
7	27-8144461	GASKET, Flange
8	NSS	NOT SOLD SEPARATE, Gasket-Cover Plate
9	1395-811221	COVER PLATE
10	1395-811220	SCREW, Cover Plate
11	NSS	NOT SOLD SEPARATE, Spring-Idle Needle
12	NSS	NOT SOLD SEPARATE, Idle Needle
13	1395-808746	LEVER
14	1395-8087431	BUSHING, Throttle Shaft
15	NSS	NOT SOLD SEPARATE, Spring-Throttle Return
16	1395-8236331	SHAFT, Throttle Comment: (Electric)
17	1395-8236323	SHAFT, Throttle Comment: (Manual)
18	1395-823634	SCREW
19	1395-8087392	SCREW, Idle Speed
20	NSS	NOT SOLD SEPARATE, Fitting Comment: (Electric)
21	NSS	NOT SOLD SEPARATE, Fitting Comment: (Manual)
22	10-95951	VALVE, Inlet Needle
23	1395-808738	GASKET
24	NSS	NOT SOLD SEPARATE, Float Shaft
25	1395-9594	FLOAT
26	NSS	NOT SOLD SEPARATE, Gasket-Fuel Bowl
27	1395-811693	BOWL, Fuel Comment: (Electric)
28	NSS	NOT SOLD SEPARATE, Fitting (Part of 1395-811695) Comment: (Manual)
29	1395-808612	SCREW AND WASHER, (#8-32 x .750)
30	1399-5225	JET, Main (.054) Comment: (WME-64/97)
31	1395-811694	PLUG KIT
32	1395-802731	SEAL Comment: (Consists of 4 Seals)
33	10-814776	SCREW, Adjusting (M6 x 55)
34	823587T02	COVER, Carburetor
35	19-815784	CAP
36	10-4000363	SCREW, (M8 x 100)
37	8235862	PLATE, Carburetor
38	67748	ROLLER
39	NSS	NOT SOLD SEPARATE, Decal-Caution-Airbox

▶Choke Kit (8 parts)

Ref	OEM Part #	Part Name
-	856116A1	CHOKE KIT
1	856116	CHOKE
2	856766	PLATE
3	10-824459120	SCREW, (M8 x 120) Stainless Steel
4	856155	CABLE, Choke
5	10-823042067	SCREW (10-16 X .625)
6	12-89302	WASHER, (.203 x .406 x .040)
7	8M0032846	RETAINER, Brass, Switch

▶Clamp Bracket (41 parts)

Ref	OEM Part #	Part Name
1	3411-821773T1	CLAMP BRACKET Comment: (Port Long)(3 Lower Mounting Holes)
2	3412-821774T8	CLAMP BRACKET Comment: (Starboard Long)
3	10-818883A1	THUMB SCREW ASSEMBLY Comment: (Manual)
4	NSS	NOT SOLD SEPARATE, Handle-Manual
5	NSS	NOT SOLD SEPARATE, Rivet-Manual
6	12-818884	WASHER Comment: (Manual)
7	10-768042	SHOULDER SCREW, Hex Comment: (Manual)
8	8224011	CAP
9	17-25810	PIN
10	23-86637	BEARING
11	17-8224002	PIN
12	11-40140	NUT, (M10)
13	12-4002319	WASHER
14	97-8252711	ANODE
15	12-8M0204649	WASHER, (.281 x .500 x .060) Stainless Steel
16	10-8M0204707	SCREW, (M6 x 25)
17	16-8M0034459	STUD, (M10 x 277)
18	23-824952	SPACER
19	11-4013710	NUT, (M10) (M10 x 1.5) Comment: (Short-Bottom)
20	12-4002319	WASHER Comment: (Short-Bottom)
21	10-826110	SCREW Comment: (Short-Bottom)
22	19624A1	SEAL KIT
23	25-29619	O-RING, (.583 x .103)
24	23-78861	SPACER
25	11-40140	NUT, (M10)
26	12-4002319	WASHER
27	17-8M0026103	PIN ASSEMBLY, Tilt Lock Comment: (Work)
28	17-853923A1	PIN Comment: (Manual Trim)
29	24-821461	SPRING
30	822409	LEVER, Shallow Water Drive
31	17-25319	PIN, (.125 x 0.75 Inches)
32	23-824858	BUSHING, PLASTIC
33	878580	ROD, Plastic, Shallow Water Drive
34	23-824858	BUSHING, Plastic
35	23-823812	BUSHING
36	822411	ARM
37	878563	LINK ROD
38	24-832085A1	SPRING
39	37-830253	DECAL, Tilt Lock
40	NSS	NOT SOLD SEPARATE, Warning Decal
41	NSS	NOT SOLD SEPARATE, Shallow Water Drive Decal

▶Clamp Bracket(Gas Assist Trim) (37 parts)

Ref	OEM Part #	Part Name
1	3411-821773T1	CLAMP BRACKET Comment: (Port)
2	3412-821774T8	CLAMP BRACKET Comment: (Storboard)
3	10-818883A1	THUMB SCREW ASSEMBLY Comment: (Manual)
4	NSS	NOT SOLD SEPARATE, Handle-Manual
5	NSS	NOT SOLD SEPARATE, Rivet-Manual
6	12-818884	WASHER Comment: (Manual)
7	10-768042	SHOULDER SCREW, Hex Comment: (Manual)
8	8224011	CAP
9	17-25810	PIN
10	23-86637	BEARING
11	17-8224002	PIN, Tilt Stop
12	97-8252711	ANODE
13	12-8M0204649	WASHER, (.281 x .500 x .060) Stainless Steel
14	10-8M0204707	SCREW, (M6 x 25)
15	11-82671117	NUT, (.500-20)
16	12-8M0204648	WASHER, (1.5 x 3.05 x 0.13) Stainless Steel
17	10-814259	SCREW, (.500-20 x 4.00)
18	37-830253	DECAL, Tilt Lock
19	NSS	NOT SOLD SEPARATE, Decal-Warning
20	828533T1	TRIM, Hydraulic Assist Comment: (Gas Assist Trim)
21	88238A11	CABLE ASSEMBLY Comment: (Gas Assist Trim)
22	828924	LEVER, Tilt Comment: (Gas Assist Trim)
23	8M0007469	TILT KNOB Comment: (Gas Assist Trim)
24	828930	ARM, Lever Comment: (Gas Assist Trim)
25	13-31030	WAVE WASHER Comment: (Gas Assist Trim)
26	17-25319	PIN, (.125 x 0.75 Inches) Comment: (Gas Assist Trim)
27	8289961	LINK Comment: (Gas Assist Trim)
28	10-32,11-8M0204718	NUT, Stainless Steel Comment: (Gas Assist Trim)
29	17-822481001	PIN, (14 mm) Comment: (Gas Assist/Power Trim)
30	23-822482	BUSHING Comment: (Gas Assist/Power Trim)
31	23-822484	BUSHING Comment: (Gas Assist/Power Trim)
32	12-825190	WASHER Comment: (Gas Assist/Power Trim)
33	11-826712	NUT Comment: (Gas Assist/Power Trim)
34	10-4009040	SCREW, (M10 x 40) Stainless Steel Comment: (Gas Assist/Power Trim)
35	12-4002319	WASHER Comment: (Gas Assist/Power Trim)
36	11-40140	NUT, (M10) Comment: (Gas Assist/Power Trim)
37	NSS	NOT SOLD SEPARATE, Decal-Shallow Water Drive

▶Crankshaft/Piston/Flywheel (23 parts)

Ref	OEM Part #	Part Name
-	61-8M0063311	POWERHEAD ASSEMBLY Comment: 40 HP
1	11-42979	NUT, (M16)
2	12-33001	WASHER, (.641 x 1.250 x .190)
3	261-859233T23	FLYWHEEL Comment: (Electric)
4	261-859233T24	FLYWHEEL Comment: (Manual)
5	493-821369T01	CRANKSHAFT ASSEMBLY
6	43-43019A2	GEAR ASSEMBLY, Driver
7	28-91800	KEY, Woodruff
8	30-63742T	BEARING, Ball
9	53-812877	RING, Retaining
10	31-818889A1	BEARING ASSEMBLY, Roller
11	26-8173971	SEAL, Oil
12	827955A2	BEARING ASSEMBLY, Center Main
13	NSS	NOT SOLD SEPARATE, Roller
14	NSS	NOT SOLD SEPARATE, Ring-Seal
15	640-9612A6	CONNECTING ROD ASSEMBLY Comment: (With Plastic Bearings)
16	10-91012	SCREW, (.250-28 Special)
17	8M0234886	BEARING KIT Comment: (Plastic)
18	29-8M0214934	BEARING
19	12-8M0012298	WASHER
20	705-850026T2	PISTON Comment: (.015 Oversize)
21	53-857196	LOCK RING
22	39-821695A1	RING SET, Piston Comment: (.015 Oversize)

▶Cylinder Block (48 parts)

Ref	OEM Part #	Part Name
-	61-8M0063311	POWERHEAD ASSEMBLY Comment: 40 HP
1	890-821358T5	CYLINDER BLOCK
2	22-328022	PLUG, Pipe (.125-27) Brass
3	10-81742780	SCREW, (M8 x 80)
4	812888A2	CARRIER ASSEMBLY
5	21-42657A4	CHECK VALVE Comment: SN# 1B859740 & Up
6	21-8282182	CHECK VALVE
7	22-56759	FITTING, Barbed, Barbed Comment: (Electric)
8	10-81742740	SCREW, (M8 x 40)
9	22-85439001	CONNECTOR, Male
10	17-8M0084653	PIN, Center Main
11	17-43044	PIN, Dowel - Without Hole (.375 x .625)
12	22-390721	PLUG, Pipe (.125-27) Brass
13	22-185981	PLUG, Pipe (.375-18)
14	22-15133	FITTING
15	1171-9812A8	END CAP ASSEMBLY
16	26-828932	SEAL, Oil
17	26-41953	SEAL
18	25-8M0142854	O-RING, (2.175 x .175)
19	10-81742720	SCREW, (M8 x 20)
20	25-48462	O-RING, (.614 x .070), Included With Reference 1 Comment: (Manual)
21	8129962	COVER Comment: (Manual)
22	10-40011108	SCREW, (M5 x 20) Stainless Steel Comment: (Manual)
23	27-8M0000822	GASKET, Included With Reference 1
24	32-892024122	TUBING, (20.00 Feet Bulk) (Cut to 1.50 Inch Length)
25	21-149126	CHECK VALVE, Double End
26	32-892024122	TUBING, (240.00 Inches Bulk) (Cut to 5.50 Inch Length)
27	22-996642	FITTING, Elbow 90 Degree (.125-27 x .250) Nylon (.125 Male)
28	10-878609	SCREW, (#10-16 x .600)
29	787994	SENDER
30	889733	RETAINER
31	12-8M0204666	WASHER, (.203 x .500 x .032)
32	10-878609	SCREW, (#10-16 x .600)
33	10-878609	SCREW, (#10-16 x .600) Comment: (Quantity of 3 on Electric)
34	54-816311T	TIE STRAP, (8.00 Inches) Comment: (Electric)
35	8261151	CLAMP, Connector Comment: (Electric)
36	16-8161949	STUD, (M6 x 44)
37	NSS	NOT SOLD SEPARATE, Decal-Sterialization
38	27-8128672	GASKET, Included With Reference 1
39	8128821	POPPET
40	812887002	DIAPHRAGM
41	12-94182	WASHER
42	10-69570	SCREW, (#10-16 x .750)
43	24-47968	SPRING
44	895338	THERMOSTAT, 62Â°C (143Â°F)
45	190742	COVER Comment: (Greenland)
46	10-40011149	SCREW, (M8 x 25) Stainless Steel, Included With Reference #1
47	27-8M0204714	GASKET, Thermostat (Included With Reference #1)

▶Driveshaft Housing (52 parts)

Ref	OEM Part #	Part Name
-	27-822420A94	GASKET SET
1	10-40011155	SCREW, (M8 x 55) Stainless Steel
2	25-93221002	GROMMET
3	99019	CLAMP
4	42941001	SEAL, Water Tube
5	32-8M0042794	TUBE, Water Comment: (Long)
6	8M0046061	TUBE, Exhaust
7	10-40011153	SCREW, (M8 x 45) Stainless Steel
8	27-8M0000821	GASKET, Driveshaft Housing
9	821439T4	ADAPTOR PLATE
10	17-23784	PIN, Dowel
11	10-4010875	SCREW, (M10 x 75) Hex Flange - Stainless Steel
12	8M0043148	SEAL, Bottom Cowl
13	822419	COUPLER
14	25-822408001	GROMMET, Shift Shaft
15	880042	SHIFT SHAFT, Upper
16	12-89302	WASHER, (.203 x .406 x .040)
17	17-822417	PIN
18	18-210711	COTTER PIN
19	8M0000520	SCREW, (M12 x 162)
20	1400-8M4501487	MOUNT
21	10-40011153	SCREW, (M8 x 45) Stainless Steel
22	12-32834	WASHER, Neoprene
23	12-8M0204648	WASHER, (1.5 x 3.05 x 0.13) Stainless Steel
24	11-896963	NUT, (M12)
25	821512A4	TRIM COVER
26	8M0043155	BUMPER
27	10-826173	SCREW, (M5 x .8 x 60)
28	12-73288	WASHER, (.220 x .500 x .030) Stainless Steel
29	11-401365	NUT, (M5) Stainless Steel
30	8249423	SEAL, Exhaust Bucket
31	8M0036863	BUCKET, Exhaust
32	8M0043170	BUMPER, Trim Cover
33	822395001	SEAL, Exhaust Tube
34	822422001	SEAL, Idle Relief
35	10-817430110	SCREW, (M10 x 110)
36	3531-821447T10	HOUSING, Driveshaft Comment: (Long)
37	16-824083	STUD, (M10 x 114) Comment: (LL)
38	10-824459120	SCREW, (M8 x 120) Stainless Steel
39	821781003	MOUNT
40	821780T5	COVER, Mount
41	12-8M0214963	WASHER, (.406 x .750 x .105) Stainless Steel
42	11-40140	NUT, (M10)
43	10-878607	SCREW, (#10-16 x .375)
44	10-82445965	SCREW, (M8 x 65) Stainless Steel
45	13-72521	LOCKWASHER, Internal Tooth
46	88238A11	CABLE ASSEMBLY
47	821782002	BUMPER, Front
48	821781003	MOUNT
49	821780T5	COVER, Mount
50	12-36001	WASHER
51	11-401378	NUT, (M8)

▶Electrical Components (44 parts)

Ref	OEM Part #	Part Name
-	61-8M0063311	POWERHEAD ASSEMBLY Comment: 40 HP
1	10-4013930	SCREW, (M5 x 30) Comment: (Manual)
2	398-832074A11	STATOR ASSEMBLY Comment: (Manual)
3	13541	PLUG, Male Comment: (Manual)
4	853960T	TRIGGER Comment: (Manual)
5	56762	TIE STRAP, (4.00 Inches)
6	89-8M0185146	SOLENOID ASSEMBLY Comment: (Electric)
7	23-8M0214955	BUSHING Comment: (Electric)
8	25-818967	GROMMET Comment: (Electric)
9	8-32,11-26419	NUT, Brass Comment: (Electric)
10	10-40011129	SCREW, (M6 x 25) Stainless Steel Comment: (Electric)
11	11-64015	NUT, (.250-20) Comment: (Electric)
12	13-26992	LOCKWASHER, (.250) Stainless Steel Comment: (Electric)
13	85-830233	BOOT, Insulator - Red Comment: (Electric)
14	8275101	RETAINER Comment: (30 Electric Handle)
15	10-878609	SCREW, (#10-16 x .600) Comment: (30 Electric Handle)
16	84-88439A4	CABLE ASSEMBLY, Battery - Negative Comment: (Electric)
17	827509T7	CDM MODULE ASSEMBLY
18	84-857124A1	CABLE ASSEMBLY, Hi-Tension
19	85-857074A1	BOOT/TERMINAL KIT
20	85-815119M	CAP, Spark Plug Comment: (Noise Suppressor) (Use Where Applicable)
21	33-938	SPARK PLUG Comment: (NGK#BPZ-8H-N-10)
22	84-88807A44	CABLE ASSEMBLY Comment: (Manual)
23	10-81893412	SCREW, (M8 x 12) Comment: (Manual)
24	10-82129116	SCREW, (M6 x 16)
25	8302361	PLATE, Electrical
26	10-82239312	SCREW, (M5 x 12)
27	12-89302	WASHER, (.203 x .406 x .040)
28	10-82129114	SCREW, (M6 x 14)
29	12-8M0204649	WASHER, (.281 x .500 x .060) Stainless Steel
30	23-8318701	BUSHING
31	25-822002	GROMMET
32	10-40011130	SCREW, (M6 x 30) Stainless Steel
33	12-8M0214930	WASHER
34	821889A50	REV LIMITER Comment: (Electric)
35	10-82129125	SCREW, (M6 x 25 MM)
36	54-816311T	TIE STRAP, (8.00 Inches)
37	8M0084173	REGULATOR, Voltage Comment: (Electric)
38	10-82129135	SCREW, (M6 x 35) Comment: (Electric)
39	84-854323A2	HARNESS ASSEMBLY, Engine Comment: (Manual)
40	84-854322A2	HARNESS ASSEMBLY, Engine Comment: (Electric)
41	32-828547353	CONDUIT, (.350 Inside Diameter x 3.00 Feet Bulk)
42	88-812619	FUSE, Yellow - 20 Ampere Comment: (Electric)
43	32-828547T	CONDUIT, (1.00 Inside Diameter x 3.00 Feet Bulk)

▶Fuel Pump(Electric) (49 parts)

Ref	OEM Part #	Part Name
-	61-8M0063311	POWERHEAD ASSEMBLY Comment: 40 HP
1	NSS	NOT SOLD SEPARATE, Fuel Pump
2	21-857005A1	DIAPHRAGM KIT
3	NSS	NOT SOLD SEPARATE, Diaphragm
4	NSS	NOT SOLD SEPARATE, Retainer
5	NSS	NOT SOLD SEPARATE, Spring
6	NSS	NOT SOLD SEPARATE, Cap
7	NSS	NOT SOLD SEPARATE, Spring
8	NSS	NOT SOLD SEPARATE, Cap
9	NSS	NOT SOLD SEPARATE, Diaphragm
10	27-8M0204705	GASKET
11	NSS	NOT SOLD SEPARATE, Gasket-Boost
12	NSS	NOT SOLD SEPARATE, Gasket-Pulse
13	144303	BASE
14	987752	PLATE
15	10-82104540	SCREW, (M5 x 40), Pump
16	10-82130050	SCREW, (M6 x 50), Pump to Crankcase
17	22-433351	CONNECTOR, 90 Degree - With Vibraseal
18	10-4006731	SCREW, (M6 x 16)
19	54-633003	CLAMP
20	89-819503A5	SOLENOID KIT, Enrichner Valve
21	25-F694504	GROMMET
22	32-9912688	TUBING, (36.00 Inches Bulk) (Cut to 11.50 Inch Length)
23	23-82538115	SLEEVE, (.500 x 5.00)
24	8M0214940	TIE STRAP, (5.50 Inches)
25	22-59169003	FITTING, Tee
26	32-892024122	TUBING, (240.00 Inches Bulk) (Cut to 4.00 Inch Length)
27	32-9912688	TUBING, (36.00 Inches Bulk) (Cut to 3.25 Inch Length)
28	32-9912878	HOSE, (.187) (26.00 Inches Bulk) (Cut to 3.25 Inch Length)
29	32-892040	HOSE, Molded
30	8507051	INSULATOR
31	32-892039	HOSE, Molded
32	22-818992	CONNECTOR
33	32-8M0108349	TUBING, (.312) (70.00 Inches Bulk) (Cut to 1.50 Inch Length)
34	22-8189941	CHECK VALVE
35	32-82381335	TUBING, (15.00 Inches Bulk) (Cut to 1.50 Inch Length)
36	32-892040	HOSE, Molded
37	22-816856T01	CONNECTOR ASSEMBLY, Fuel
38	10-4000332	SCREW, (M6 x 35)
39	32-892037	HOSE, Molded Comment: (Use with 35-891642T03 Fuel Filter)
40	35-889527T02	FILTER ASSEMBLY, Fuel Comment: SN# 0P366572 & Up
41	35-896375K01	FILTER KIT Comment: (Mercury Brand)
42	25-98277001	SEAL
43	35-891642T03	FILTER ASSEMBLY, Fuel Comment: SN# 0P366571 & Below
44	35-87946K04	FILTER KIT, Fuel Comment: (Mercury Brand)
45	25-897536	SEAL
46	889625002	BRACKET Comment: (Use with 35-889527T02 Fuel Filter)
47	822387	BRACKET Comment: (Use with 35-891642T03 Fuel Filter)
48	11-401366	NUT, (M6) Stainless Steel

▶Fuel Pump(Manual) (38 parts)

Ref	OEM Part #	Part Name
-	61-8M0063311	POWERHEAD ASSEMBLY Comment: 40 HP
1	NSS	NOT SOLD SEPARATE, Fuel Pump
2	21-857005A1	DIAPHRAGM KIT
3	NSS	NOT SOLD SEPARATE, Diaphragm
4	NSS	NOT SOLD SEPARATE, Retainer
5	NSS	NOT SOLD SEPARATE, Spring
6	NSS	NOT SOLD SEPARATE, Cap
7	NSS	NOT SOLD SEPARATE, Spring
8	NSS	NOT SOLD SEPARATE, Cap
9	NSS	NOT SOLD SEPARATE, Diaphragm
10	27-8M0204705	GASKET
11	NSS	NOT SOLD SEPARATE, Gasket-Boost
12	NSS	NOT SOLD SEPARATE, Gasket-Pulse
13	144303	BASE
14	987752	PLATE
15	10-82104540	SCREW, (M5 x 40), Pump
16	10-82130050	SCREW, (M6 x 50), Pump to Crankcase
17	22-433351	CONNECTOR, 90 Degree - With Vibraseal
18	858763	PRIMER BULB
19	32-892024122	TUBING, (240.00 Inches Bulk) (Cut to 9.50 Inch Length)
20	23-82538115	SLEEVE, (.500 x 5.00)
21	32-892038	HOSE, Molded
22	54-816311T	TIE STRAP, (8.00 Inches)
23	32-9912878	HOSE, (.187) (26.00 Inches Bulk) (Cut to 3.25 Inch Length)
24	8507051	INSULATOR
25	32-892040	HOSE, Molded
26	35-889527T02	FILTER ASSEMBLY, Fuel Comment: SN# 0P366572 & Up
27	35-896375K01	FILTER KIT Comment: (Mercury Brand)
28	25-98277001	SEAL
29	35-891642T03	FILTER ASSEMBLY, Fuel
30	35-87946K04	FILTER KIT, Fuel Comment: (Mercury Brand)
31	25-897536	SEAL
32	889625002	BRACKET Comment: (Use with 35-889527T02 Fuel Filter)
33	822387	BRACKET Comment: (Use with 35-891642T03 Fuel Filter)
34	11-401366	NUT, (M6) Stainless Steel
35	32-892037	HOSE, Molded Comment: (Use with 35-891642T03 Fuel Filter)
36	22-816856T01	CONNECTOR ASSEMBLY, Fuel
37	10-4000332	SCREW, (M6 x 35)

▶Gasket Set Components, Engine Overhaul (1 parts)

Ref	OEM Part #	Part Name
-	27-821370	GASKET, Induction Manifold Comment: (Not Used In This Application)

▶Gear Housing(Driveshaft)(2.00:1 Gear Ratio) (40 parts)

Ref	OEM Part #	Part Name
-	821354A2	REPAIR KIT, Water Pump
1	1682-821306T12	GEAR HOUSING ASSEMBLY, Basic Comment: (Basic)
2	818226A1	SEAL/PLATE KIT
3	NSS	NOT SOLD SEPARATE, Plate
4	10-79953Q04	SCREW KIT, (.375-16 x .250) Drain (.375-16 X .25)
5	12-191833	SEAL
6	22-8M0058389	PLUG KIT, Drain (Magnetic), Magnetic
7	12-191833	SEAL
8	11-55910	NUT, (.437-20)
9	43-821326T1	GEAR, Pinion - 13 Teeth
10	31-821321A2	BEARING ASSEMBLY, Roller
11	NSS	NOT SOLD SEPARATE, Cup (Part of Reference #10)
12	10-8248324	SCREW, (M6 x 16)
13	46-821351A3	HOUSING ASSEMBLY, Water Pump Upper
14	8235471	SEAL, Water Tube Comment: (Short/Long)
15	12-866451	WASHER
16	28-8M0214993	KEY
17	12-866451	WASHER
18	27-822189	GASKET, Upper Water Pump
19	27-8M0214956	GASKET, Lower Water Pump, Lower
20	8213542	FACE PLATE
21	47-8M0204712	IMPELLER
22	46-821307A2	BASE ASSEMBLY, Water Pump
23	26-821309	SEAL, Oil
24	26-821310	SEAL, Oil
25	25-821308	O-RING, (1.421 x .139)
26	45-822552A1	DRIVESHAFT Comment: (LL)(Refer to Model Length)
27	30-821311	BEARING, Ball
28	823548T	TIE STRAP
29	822158	BOOT
30	821827	RETAINER
31	25-26855	O-RING, (1.609 x .139)
32	25-85594	O-RING, (.239 x .174)
33	12-814803	WASHER
34	822543A1	SHIFT SHAFT Comment: (LL)(Refer to Model Length)
35	11-400212	NUT, (M6) Stainless Steel
36	12-8M0204649	WASHER, (.281 x .500 x .060) Stainless Steel
37	17-85593	PIN, (.078 x .437)
38	8213161	CAM, Shift
39	17-822369	PIN, (.125 x .625)

▶Gear Housing, Propeller Shaft - 2.00:1 Gear Ratio (36 parts)

Ref	OEM Part #	Part Name
-	823547A2	SEAL KIT
1	1682-821306T12	GEAR HOUSING ASSEMBLY, Basic Comment: (Basic)
40	17-821327	PIN, Dowel
41	27-823942	GASKET
42	32-8M0026108	TUBE
43	19-824928001	PLUG, Rubber
44	821829	SCREEN
45	822157T2	TRIM TAB
46	10-82497020	SCREW, (M8 x 20)
47	12-72397	WASHER
48	43-821315T1	GEAR ASSEMBLY, Forward - 26 Teeth
49	31-8M0103470	BEARING ASSEMBLY, Roller
50	NSS	NOT SOLD SEPARATE, Cup
51	31-41326	BEARING, Roller
52	821578	FOLLOWER, Cam
53	24-8261991	SPRING
54	17-8M0020999	PIN
55	52-821314T	CLUTCH
56	24-38114	SPRING
57	44-8M0140441	PROPELLER SHAFT
58	43-821312T1	GEAR, Reverse - 26 Teeth
59	30-20839T	BEARING, Ball
60	8M0168900	CARRIER ASSEMBLY, Bearing
61	25-815460	O-RING
62	31-21700	BEARING, Needle
63	26-8M0205511	SEAL, Oil
64	26-8M0203757	SEAL, Oil
65	12-855941	WASHER, (.323 x .590 x .112) Stainless Steel
66	10-85594030	SCREW, (M8 x 30)
67	8227731	INSERT, Threaded
68	73345A1	THRUST HUB
69	11-69578Q1	PROP NUT KIT
70	14-8M0214942	TAB WASHER
71	10-4000380	SCREW, (M10 x 45), Short/Long
72	12-8M0214963	WASHER, (.406 x .750 x .105) Stainless Steel
73	NSS	NOT SOLD SEPARATE, Decal-Gear Ratio

▶Heater Manifold (9 parts)

Ref	OEM Part #	Part Name
1	828155A1	MANIFOLD ASSEMBLY, Heater
2	27-826138	GASKET
3	10-20597	SCREW, (#8-32 x .380)
4	32-9912878	HOSE, (.187) (26.00 Inches Bulk) (Cut to 17 Inch Length)
5	22-33373001	ELBOW, 90 Degree
6	32-9912878	HOSE, (.187) (26.00 Inches Bulk)
7	19-828167	FITTING
8	54-816311T	TIE STRAP, (8.00 Inches)
9	22-15026	CAP

▶Induction Manifold (9 parts)

Ref	OEM Part #	Part Name
-	61-8M0063311	POWERHEAD ASSEMBLY Comment: 40 HP
1	821371A2	MANIFOLD ASSEMBLY, Induction
2	21-426233	CHECK VALVE
3	22-823563	FITTING, Barbed
4	16-8161949	STUD, (M6 x 44)
5	10-82130040	SCREW, (M6 x 40)
6	32-892024122	TUBING, (240.00 Inches Bulk) (Cut to 12.50 Inch Length) Comment: (A = To Base of Oil Pump)
7	10-81742730	SCREW, (M8 x 30)
8	830246T3	REED VALVE Comment: (40 H.P.)

▶Lube Chart (0 parts)

▶Manual Start Components (39 parts)

Ref	OEM Part #	Part Name
-	816728T14	STARTER ASSEMBLY, Recoil
1	8M0043416	SEAL, Handle Rest
2	23-822392	SPACER, Handle Rest
3	821788T02	REST, Starter Handle
4	85174A1	HANDLE ASSEMBLY
5	NSS	NOT SOLD SEPARATE, Retainer
6	11-401366	NUT, (M6) Stainless Steel
7	12-858779	WASHER, (.265 x .750 x .048)
8	25-8157951	GROMMET
9	23-816086	BUSHING
10	25-8157951	GROMMET
11	12-858779	WASHER, (.265 x .750 x .048)
12	816728T05	HOUSING
13	53-818853	RING, Retaining
14	8M0183792	BUSHING
15	13-826229	LOCKWASHER
16	24-86857T01	SPRING
17	50-825269T01	SHEAVE, Starter
18	50-12066Q10	ROPE
19	24-868523	SPRING
20	86853T01	CAM
21	10-826253	SCREW, (.250-20 x .625)
22	53-86849T01	RING, Retaining
23	868501	CAM
24	24-86851T02	SPRING
25	10-8182491	SCREW, (#10-16 x 1.00)
26	816711	RETAINER
27	816712T01	CAM
28	8166903	LEVER
29	24-826791	SPRING
30	8567542	CABLE, Interlock, Interlock
31	10-878608	SCREW, (#10-16 x .500)
32	12-73288	WASHER, (.220 x .500 x .030) Stainless Steel
33	10-8214281	SCREW, (#10-16 x .625)
34	18-26811	COTTER PIN
35	37-804664A06	DECAL, EPA Label Information (2006)
36	37-8272822	DECAL, Warning, High Voltage
37	NSS	NOT SOLD SEPARATE, Decal-Caution in Gear Idle
38	NSS	NOT SOLD SEPARATE, Decal-Timing

▶Oil Injection Components (31 parts)

Ref	OEM Part #	Part Name
-	27-822420A94	GASKET SET
1	23-822003	BUSHING
2	25-822002	GROMMET
3	1271-8M0219215	TANK ASSEMBLY, Oil
4	36-828765A1	CAP ASSEMBLY
5	27-828766	GASKET
6	NSS	NOT SOLD SEPARATE, Retainer
7	11-821285	PUSH NUT
8	19299A1	VENT ASSEMBLY
9	21-64871	VALVE
10	54-816311T	TIE STRAP, (8.00 Inches)
11	54-814200	CLAMP
12	32-9004934	TUBING, (14.50 Inches Bulk) (Cut to 4.75 Inch Length)
13	22-826083	ELBOW
14	32-82381455	TUBING, (25.00 Inches Bulk) (Cut to 1.25 Inch Length)
15	25-823770001	GROMMET
16	23-826084	SPACER
17	87-12886A6	SWITCH ASSEMBLY
18	10-58376	SCREW, (.164-18 x .375)
19	12-72761	WASHER, (.203 x .562 x .060) Stainless Steel
20	32-82381335	TUBING, (15.00 Inches Bulk) (Cut to 10.00 Inch Length)
21	54-816311T	TIE STRAP, (8.00 Inches)
22	43-826143	GEAR, Driven
23	23-19278A2	BEARING ASSEMBLY
24	23-17597	BUSHING, Flanged
25	23-17596	BUSHING
26	818902A2	PUMP ASSEMBLY, Oil Injection
27	25-36390	O-RING
28	25-8M0204667	O-RING
29	10-40011108	SCREW, (M5 x 20) Stainless Steel
30	826581T01	LINK

▶Power Trim (28 parts)

Ref	OEM Part #	Part Name
-	25-827668A1	O-RING KIT
1	822344T14	POWER TRIM ASSEMBLY
2	893931A01	SHOCK ROD ASSEMBLY
3	827671A1	PILOT CHECK ASSEMBLY
4	827672A1	TILT RELIEF VALVE ASSEMBLY
5	827673A1	SEAT ASSEMBLY, Suction
6	827674A1	PUMP ASSEMBLY
7	NSS	NOT SOLD SEPARATE, Ball and Spring
8	NSS	NOT SOLD SEPARATE, Screw
9	NSS	NOT SOLD SEPARATE, Filter
10	NSS	NOT SOLD SEPARATE, O Ring
11	827675A1	MOTOR ASSEMBLY
12	NSS	NOT SOLD SEPARATE, Screw
13	NSS	NOT SOLD SEPARATE, Washer
14	88238A15	CABLE ASSEMBLY
15	NSS	NOT SOLD SEPARATE, O Ring
16	NSS	NOT SOLD SEPARATE, Coupler
17	827676	PISTON, Memory
18	893929A01	MANUAL RELEASE ASSEMBLY
19	19-811613	PLUG ASSEMBLY
20	830238T	BRACKET
21	84-826802A9	HARNESS ASSEMBLY, Trim, Trim
22	10-82129125	SCREW, (M6 x 25 MM)
23	8M0207773	RELAY ASSEMBLY
24	828102	BRACKET
25	25-818967	GROMMET
26	23-8M0214955	BUSHING
27	NSS	NOT SOLD SEPARATE, Decal-Trim Relay

▶Power Trim Mounting (11 parts)

Ref	OEM Part #	Part Name
1	17-822481001	PIN, (14 mm)
2	23-822482	BUSHING
3	23-822484	BUSHING
4	12-825190	WASHER
5	11-826712	NUT
6	10-4009040	SCREW, (M10 x 40) Stainless Steel
7	12-4002319	WASHER
8	11-40140	NUT, (M10)
9	10-878609	SCREW, (#10-16 x .600)
10	8M0084613	C WASHER
11	54-22740	CLIP

▶Service/Support Material (1 parts)

Ref	OEM Part #	Part Name
-	37-804664A06	DECAL, EPA Label Information (2006)

▶Starter Motor (16 parts)

Ref	OEM Part #	Part Name
1	50-893890T	STARTER MOTOR ASSEMBLY
2	10-965661	THRU BOLT
3	90643	DRIVE KIT
4	685753	DRIVE ASSEMBLY
5	8236392	DRIVE CAP
6	965651	ARMATURE
7	8119011	CAP, Commutator
8	898265016	BRUSH/SPRING KIT
9	898265014	HOLDER
10	F15158	SCREW
11	13-26992	LOCKWASHER, (.250) Stainless Steel
12	11-64015	NUT, (.250-20)
13	84-88439A9	CABLE ASSEMBLY, Battery - Positive (.3125)
14	10-40011153	SCREW, (M8 x 45) Stainless Steel
15	84-88807A33	CABLE ASSEMBLY, Black (6.25 Inch Terminals)
16	37-8272822	DECAL, Warning, High Voltage

▶Stator/Trigger(Electric Models) (16 parts)

Ref	OEM Part #	Part Name
-	84-11149A27	CABLE ASSEMBLY
1	8M0043416	SEAL
2	821788A1	REST KIT, Oil Injection
3	19-822513002	PLUG, Starter Handle
4	823771001	GROMMET, Oil Tank
5	19-822464	PLUG
6	11-816872	WING NUT
7	12-69056	WASHER, (.255 x .620 x .030) Stainless Steel
8	12-8M0204663	WASHER, (.187 x .500 x .062) Neoprene, Neoprene
9	812777T1	COVER ASSEMBLY
10	10-4013930	SCREW, (M5 x 30)
11	398-832075A21	STATOR ASSEMBLY
12	853960T	TRIGGER
13	37-804664A06	DECAL, EPA Label Information (2006)
14	NSS	NOT SOLD SEPARATE, Decal-Caution in Gear Idle
15	NSS	NOT SOLD SEPARATE, Decal-Timing

▶Swivel Bracket (39 parts)

Ref	OEM Part #	Part Name
1	19608A14	ATTACHING KIT, Engine Steering
2	10-823919	SCREW, (.375-24 x 1.500)
3	12-8M0109680	WASHER, (.390 x .546 x .12)
4	12-37828	WASHER, (.390 x .625 x .062) Stainless Steel
5	11-8M0204726	NUT, (.375-24) Brass
6	822397	PUCK, Co-Pilot Comment: (Non Handle)
7	3410-827402T5	SWIVEL BRACKET Comment: (Power Trim/Manual Trim)
8	23-8217711	BUSHING, Upper
9	22-8M0169589	FITTING, Grease
10	23-821777	BUSHING, Lower
11	26-8M0205512	SEAL
12	22-8M0169589	FITTING, Grease
13	88238A11	CABLE ASSEMBLY
14	12-19619	WASHER
15	11-858869	NUT, (.875-14)
16	18-26811	COTTER PIN
17	821799002	PIN, Pivot, Reverse Lock
18	10-40011149	SCREW, (M8 x 25) Stainless Steel Comment: (Non Handle)
19	8282451	SEAL Comment: (Non Handle)
20	NSS	NOT SOLD SEPARATE, Decal-Shallow Water Drive
21	12-19619	WASHER
22	8M0041938	TILT TUBE
23	11-858869	NUT, (.875-14)
24	37-8237011	DECAL, Co-Pilot
25	17-821539	PIN, Trilobe
26	23-823507	BUSHING
27	17-822480	PIN, Pivot, Upper
28	8217751	STRAP, Tilt Stop Comment: (Non Power Trim)
29	821800	LINK, Upper-Reverse Lock
30	8217981	LEVER, Reverse Lock
31	6-32,11-8M0207777	NUT,
32	826578	PIN, Reverse Lock
33	24-F366300	SPRING, Reverse Lock
34	8M0026107	LINK, Reverse Lock
35	12-71055	WASHER
36	825181003	ARM, Reverse Lock
37	8289861	LOCK, Reverse
38	10-32,11-8M0204718	NUT, Stainless Steel
39	NSS	NOT SOLD SEPARATE, Decal-Serial Overlaminate

▶Swivel Tube (13 parts)

Ref	OEM Part #	Part Name
1	821769T2	SWIVEL TUBE HEAD, Gray
2	816667A2	BRACKET ASSEMBLY, Steering
3	14-8M0009820	TAB WASHER
4	10-4000377	SCREW, (M10 x 30)
5	11-8M0204726	NUT, (.375-24) Stainless Steel
6	823792	LEVER, Co-Pilot
7	12-29330	WASHER
8	821961	ROD, Threaded
9	821957	BRAKE PLATE
10	8165621	DISC
11	8M0007471	PLATE, Swivel Head
12	8165621	DISC
13	10-768042	SHOULDER SCREW, Hex

▶Throttle Linkage (30 parts)

Ref	OEM Part #	Part Name
1	822458	BUMPER, Throttle Stop
2	12-42980	WASHER
3	822458	BUMPER, Throttle Stop
4	8M0041742	LEVER, Throttle Control
5	8235695	BALL, Threaded
6	23-812930A1	BUSHING
7	NSS	NOT SOLD SEPARATE, Insert
8	10-4007180	SCREW, (M10 x 45)
9	11-401386	NUT, (M6) Stainless Steel
10	12-69056	WASHER, (.255 x .620 x .030) Stainless Steel
11	822459	RETAINER, Cable
12	42927	INSERT
13	17-8224561	PIN
14	881227A4	LINK, Throttle Control
15	817428	SOCKET
16	10-32,11-45076	NUT, Brass
17	12-65567	WASHER, (.265 x .750 x .048) Stainless Steel
18	10-4006731	SCREW, (M6 x 16)
19	8214943	BRACKET, Throttle Cable
20	853926	SPARK ARM
21	853925	CAM, Throttle
22	24-42164	SPRING
23	23-823807	BUSHING
24	13-99611	WAVE WASHER
25	10-4000332	SCREW, (M6 x 35)
26	10-40019111	SCREW, (M5 x 35)
27	11-400211	NUT, (M5) Stainless Steel
28	881227A05	SPARK CONTROL LINK Comment: (Use with Carburetors WME-97/98/99)
29	817428	SOCKET
30	10-32,11-45076	NUT, Brass

▶Tiller Handle (32 parts)

Ref	OEM Part #	Part Name
-	37-8M0032728	DECAL, Lanyard, Black
1	822148A1	COVER KIT
2	822150	PULLEY
3	NSS	NOT SOLD SEPARATE, Case
4	10-878608	SCREW, (#10-16 x .500)
5	432425	CABLE, Throttle
6	432427	CABLE, Throttle
7	85-960099	SLEEVE, (12.00 Inches)
8	10-82526225	SCREW, (M8 x 25 MM)
9	8M0072298	COVER
10	23-821477	BUSHING
11	828813T1	ARM, Steering Handle Comment: (Greenland)
12	822441	RETAINER
13	10-40011107	SCREW, (M5 x 16) Stainless Steel
14	10-8M0204707	SCREW, (M6 x 25)
15	892995	LOCK, Throttle
16	24-96203	SPRING
17	821972T	KNOB, Throttle
18	8M0138696	TILLER TUBE Comment: (Greenland)
19	37-8242004	DECAL Comment: (Turtle/Rabbit)
20	821465	HANDLE, Throttle
21	8M0221732	GRIP
22	87-8M0104614	SWITCH ASSEMBLY Comment: (Greenland)
23	10-82484890	SCREW, (M10 x 90)
24	14-8M0009820	TAB WASHER
25	823687	CLIP
26	8M0156878	BUMPER
27	821455A4	BRACKET, Tiller
28	19-17230	PLUG, Stop Switch
29	13-826792	WAVE WASHER
30	23-821477	BUSHING
31	12-827314	WASHER

▶Tools, Special (1 parts)

Ref	OEM Part #	Part Name
-	56-817383A1	TOOL BAG Comment: (Seapro/Marathon)

▶Top Cowl (27 parts)

Ref	OEM Part #	Part Name
1	4011-821528T11	TOP COWL ASSEMBLY Comment: (Silver-Manual)
2	4011-821528T8	TOP COWL ASSEMBLY Comment: (Silver-Electric)
3	825742F3	LATCH Comment: (Silver)
4	10-8231871	SCREW, (M4 x 14.5)
5	8,13-26995	LOCKWASHER, Stainless Steel
6	11-8237515	NUT, (M4)
7	8M0043406	SEAL, Cowl
8	821530A02	SOUND BLANKET KIT, (Top/Side)(Pre-Applied Pressure Sensitive Adhesive)
9	NSS	NOT SOLD SEPARATE, Front Sound Blanket
10	NSS	NOT SOLD SEPARATE, Side/Rear Sound Blanket
11	47341A11	ROPE AND HANDLE KIT, Manual Starting
12	NSS	NOT SOLD SEPARATE, Rope
13	NSS	NOT SOLD SEPARATE, Envelope
14	893763	BRACKET ASSEMBLY, Latch Roller, Roller Latch
15	10-4006731	SCREW, (M6 x 16)
16	10-4006731	SCREW, (M6 x 16)
17	8M0038412	BRACKET
18	10-8231871	SCREW, (M4 x 14.5)
19	8,13-26995	LOCKWASHER, Stainless Steel
20	11-8237515	NUT, (M4)
21	NSS	NOT SOLD SEPARATE, Duct-Air Inlet
22	19-815784	CAP, Plug
23	10-4006731	SCREW, (M6 x 16)
24	NSS	NOT SOLD SEPARATE, Double Sided
25	821529T3	SHIELD, Air Inlet Comment: (Silver)
26	NSS	NOT SOLD SEPARATE, Window-Oil Sight Gauge
27	37-82409316	DECAL, F-N-R Shift

▶X-Long Components (8 parts)

Ref	OEM Part #	Part Name
-	823547A2	SEAL KIT
1	11-40140	NUT, (M10)
2	16-8M0034425	STUD, (M10 x 120)
3	824072A1	SPACER, Driveshaft Housing Extension
4	17-821327	PIN, Dowel
5	824082A1	TUBE ASSEMBLY, Water - Extension
6	25-8M0204645	O-RING, (.796 x .139)
7	26-824084	SEAL

100-Hour / Annual Service Checklist

Regular maintenance keeps your Mercury 40 (2 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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Mercury 40 (2 CYL.) (0T980000 THRU 0T999999) Parts & Diagrams

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