Mercury 40 (3 CYL.) (0P017000 THRU 0P325499) Parts & Diagrams

🔎 Mercury 40 (3 CYL.) Reference Library — Exploded parts diagrams (51 diagrams), specifications, common issues, and maintenance checklist.

The Mercury 40 (3 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 (3 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 (3 CYL.).

▶Accessories (2 parts)

Ref	OEM Part #	Part Name
-	821455T8	TILLER HANDLE KIT
0	88825A6	REGULATOR KIT, Voltage

▶Attenuator Plate (23 parts)

Ref	OEM Part #	Part Name
-	27-828553A97	GASKET SET
1	828164	ATTENUATOR, Sound
2	10-40019127	SCREW, (M6 x 16)
3	12-35462	WASHER, (.2656 x .625 x .0625) Stainless Steel
4	19-815784	CAP
5	828928	BRACKET
6	26-812889	SEAL
7	828927	BRACKET
8	10-4000363	SCREW, (M8 x 100)
9	11399A1	ARM ASSEMBLY
10	67748	ROLLER
11	10-40056103	SCREW, (M5 x 6)
12	12-8M0204666	WASHER, (.203 x .500 x .032)
13	32-9912878	HOSE, (.187) (26.00 Inches Bulk) (4-1/4 Inch) Comment: (Electric)
14	32-9912878	HOSE, (.187) (26.00 Inches Bulk) (3 Inch) Comment: (Electric)
15	22-830285	FITTING TEE Comment: (Electric)
16	32-9912878	HOSE, (.187) (26.00 Inches Bulk) (1 Inch) Comment: (Electric)
17	54-816311T	TIE STRAP, (8.00 Inches)
18	27-8144461	GASKET, Flange
19	825204T03	LINK, Throttle
20	37-8272822	DECAL, Warning, High Voltage Comment: (Manual)
21	NSS	NOT SOLD SEPARATE Comment: (Decal-Caution)
22	NSS	NOT SOLD SEPARATE Comment: (Decal-Caution in Gear Idle) (Electric)

▶Bottom Cowl (78 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)
7	8M0039049	CLAMP
8	10-40011130	SCREW, (M6 x 30) Stainless Steel
9	87-8M0052927	SWITCH Comment: (Electric Handle)
10	10-88075020	SCREW, (M3 x 20) Comment: (Electric Handle)
11	824923	PLATE Comment: (Electric Handle)
12	84-824934A3	HARNESS ASSEMBLY Comment: (Electric Handle)
13	8M0036802	CAP Comment: (Non-Handle)
14	10-4006731	SCREW, (M6 x 16) Comment: (Non-Handle)
15	8M0041741	LEVER Comment: (Non-Handle)
16	42927	INSERT Comment: (Non-Handle)
17	17-8224561	PIN Comment: (Non-Handle)
18	23-26954	BUSHING Comment: (Non-Handle)
19	23-48475	BUSHING Comment: (Non-Handle)
20	822459	RETAINER Comment: (Non-Handle)
21	11-401386	NUT, (M6) Stainless Steel Comment: (Non-Handle)
22	12-69056	WASHER, (.255 x .620 x .030) Stainless Steel Comment: (Non-Handle)
23	8224701	LINK, Shift Comment: (Non-Handle)
24	23-48475	BUSHING Comment: (Non-Handle)
25	98889	LATCH Comment: (Non-Handle)
26	39519	CUP Comment: (Non-Handle)
27	821483A6	SHIFT SHAFT, Horizontal
28	821487	LEVER, Interlock Actuating Comment: (Manual)
29	10-878607	SCREW, (#10-16 x .375)
30	84-88807A28	CABLE ASSEMBLY (Black-7 1/2 Inch)
31	8M0037997	SHIFT ROD Comment: (Handle)
32	18-210711	COTTER PIN Comment: (Handle)
33	17-8251851	PIN Comment: (Handle)
34	13-827418	LOCKWASHER Comment: (Handle)
35	822011	LEVER, Shift Comment: (Handle)
36	13-825273	WAVE WASHER Comment: (Handle)
37	10-40011107	SCREW, (M5 x 16) Stainless Steel Comment: (Handle)
38	10-42975	DRIVE SCREW
39	25-828462001	GROMMET
40	19-17230	PLUG
41	822424001	SEAL Comment: (Handle)
42	19-823874001	SEAL, Throttle Cable Comment: (Non-Handle)
43	4023-828165A1	BOTTOM COWL Comment: (Black)
44	21-817519A1	CHECK VALVE ASSEMBLY, Drain
45	25-8M0179867	GROMMET Comment: (Non Power Trim)
46	19-824076001	PLUG Comment: (Non-Handle)
47	8214901	HANDLE Comment: (Manual Handle)
48	823572001	SEAL Comment: (Manual Handle)
49	84-8M0210763	ALARM ASSEMBLY, Audio Warning Comment: (Manual Handle)
50	12-8M0214930	WASHER Comment: (Manual Handle)
51	10-82239312	SCREW, (M5 x 12) Comment: (Manual Handle)
52	10-40011107	SCREW, (M5 x 16) Stainless Steel Comment: (Manual Handle)
53	87-8M0042301	SWITCH ASSEMBLY Comment: (Power Trim)
54	812830T01	PLUG, Trim Switch Comment: (Non Power Trim)
55	8M0032848	RETAINER
56	10-1993716	SCREW, (M6 x 16)
57	828464	CAM, Latch
58	13-12134	WASHER, Wave
59	23-812707	BUSHING
60	22-813613	FITTING
61	54-816311T	TIE STRAP, (8.00 Inches)
62	32-7568058	HOSE, (15.00 Inches)
63	23-812707	BUSHING
64	823573F1	LEVER, Cowl Latch
65	10-40011129	SCREW, (M6 x 25) Stainless Steel
66	23-822003	BUSHING
67	25-822002	GROMMET
68	19-824473	PLUG, Warning Alarm Comment: (Electric)
69	10-878608	SCREW, (#10-16 x .500)
70	8M0043169	BUMPER
71	828463	LATCH, Front
72	10-4001987	SCREW, (M4 x 16)
73	25-16226	GROMMET
74	23-812707	BUSHING
75	823573F1	LEVER, Cowl Latch
76	10-40011129	SCREW, (M6 x 25) Stainless Steel
77	23-822003	BUSHING
78	25-822002	GROMMET

▶Carburetor (40 parts)

Ref	OEM Part #	Part Name
-	27-828553A97	GASKET SET
1	3301-824902T30	CARBURETOR, (WME 93-3), Bottom Comment: (Electric)
2	1395-823632	SHAFT, Throttle, Top/Bottom Comment: (WME-69/91)
3	1395-823633	SHAFT, Throttle, Center Comment: (WME-69/91)
4	1395-823636	SHAFT, Throttle, Bottom Comment: (WME-53/68/92/93)
5	1395-823634	SCREW, Top/Bottom
6	NSS	NOT SOLD SEPARATE Comment: (Spring-Throttle Return)
7	NSS	NOT SOLD SEPARATE Comment: (Idle Needle)
8	NSS	NOT SOLD SEPARATE Comment: (Spring-Idle Needle)
9	NSS	NOT SOLD SEPARATE Comment: (Gasket-Cover Plate)
10	1395-811221	COVER PLATE
11	1395-811220	SCREW, Cover Plate
12	27-8144461	GASKET, Flange
13	1395-8113522	LEVER, Oil Pump, Bottom Comment: (WME-53/68/92/93)
14	1395-8086121	SCREW, Lever Retainer, Bottom Comment: (WME-53/68/92/93)
15	10-F10155	SCREW, Throttle Valve
16	1395-97245	VALVE, Throttle
17	NSS	NOT SOLD SEPARATE Comment: (Retaining Ring)
18	F10064	SHAFT
19	1395-808738	GASKET
20	NSS	NOT SOLD SEPARATE Comment: (Gasket-Fuel Bowl)
21	10-95951	VALVE, Inlet Needle
22	1395-9594	FLOAT
23	1395-808612	SCREW AND WASHER, (#8-32 x .750)
24	1395-811693	BOWL, Fuel, Center/Bottom Comment: (WME-69/91)
25	1395-811694	PLUG KIT Comment: (WME-69/91)
26	1395-802731	SEAL (Consists of 4 Seals)
27	1395-6359	JET, (.052) Comment: (WME-68/93)
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: (.054 - 30 H.P.)
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 (46 parts)

Ref	OEM Part #	Part Name
1	3411-821773T1	CLAMP BRACKET Comment: (Port) (Black)
2	3412-821774T8	CLAMP BRACKET Comment: (Storboard) (Black)
3	10-818883A1	THUMB SCREW ASSEMBLY Comment: (Manual)
4	NSS	NOT SOLD SEPARATE Comment: Handle (Manual)
5	NSS	NOT SOLD SEPARATE Comment: Rivet (Manual)
6	12-818884	WASHER Comment: (Manual)
7	10-768042	SHOULDER SCREW, Hex Comment: (Manual)
8	8224011	CAP Comment: (O.D. Of Ref. # 11 is .75 & Ref. # 10 is not flanged)
9	17-25810	PIN Comment: (O.D. Of Ref. # 11 is .75 & Ref. # 10 is not flanged)
10	23-86637	BEARING Comment: (O.D. Of Ref. # 11 is .75 & Ref. # 10 is not flanged)
11	17-8224002	PIN Comment: (O.D. Of Ref. # 11 is .75 & Ref. # 10 is not flanged)
12	822401	CAP Comment: (O.D. Of Ref. # 15 is .56 & Ref. # 14 is flanged)
13	17-25319	PIN, (.125 x 0.75 Inches) Comment: (O.D. Of Ref. # 15 is .56 & Ref. # 14 is flanged)
14	23-823589	BUSHING Comment: (O.D. Of Ref. # 15 is .56 & Ref. # 14 is flanged)
15	17-8224001	PIN Comment: (O.D. Of Ref. # 15 is .56 & Ref. # 14 is flanged)
16	97-8252711	ANODE
17	12-8M0204649	WASHER, (.281 x .500 x .060) Stainless Steel
18	10-8M0204707	SCREW, (M6 x 25)
19	11-82671117	NUT, (.500-20)
20	12-8M0204648	WASHER, (1.5 x 3.05 x 0.13) Stainless Steel
21	10-814259	SCREW, (.500-20 x 4.00)
22	37-830253	DECAL, Tilt Lock
23	NSS	NOT SOLD SEPARATE Comment: (Decal-Warning)
24	828533T1	TRIM, Hydraulic Assist Comment: (Gas Assist Trim)
25	88238A11	CABLE ASSEMBLY Comment: (Gas Assist Trim)
26	828924	LEVER, Tilt Comment: (Gas Assist Trim)
27	8M0007469	TILT KNOB Comment: (Gas Assist Trim)
28	828930	ARM, Lever Comment: (Gas Assist Trim)
29	13-31030	WAVE WASHER Comment: (Gas Assist Trim)
30	17-25319	PIN, (.125 x 0.75 Inches) Comment: (Gas Assist Trim)
31	8289961	LINK Comment: (Gas Assist Trim)
32	10-32,11-8M0204718	NUT, Comment: (Gas Assist Trim)
33	17-822481001	PIN, Anchor (14 mm) Comment: (Gas Assist/Power Trim)
34	23-822482	BUSHING Comment: (Gas Assist/Power Trim)
35	23-822484	BUSHING Comment: (Gas Assist/Power Trim)
36	12-825190	WASHER Comment: (Gas Assist/Power Trim)
37	11-826712	NUT Comment: (Gas Assist/Power Trim)
38	10-4009040	SCREW, (M10 x 40) Stainless Steel Comment: (Gas Assist/Power Trim)
39	12-4002319	WASHER Comment: (Gas Assist/Power Trim)
40	11-40140	NUT, (M10) Comment: (Gas Assist/Power Trim)
41	17-853923A1	PIN Comment: (Non-Power Trim)
42	24-821461	SPRING Comment: (Non-Power Trim)
43	NSS	NOT SOLD SEPARATE, Warning Decal
44	NSS	NOT SOLD SEPARATE, Shallow Water Drive Decal
45	17-853923A1	PIN Comment: (40 Seapro)
46	24-821461	SPRING Comment: (40 Seapro)

▶Clamp Bracket(Gas Assist Trim) (41 parts)

Ref	OEM Part #	Part Name
1	3411-821773T1	CLAMP BRACKET Comment: (Port)
2	3412-821774T8	CLAMP BRACKET Comment: (Storboard)(Use With .75 O.D. Ref. #11)
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 Comment: (O.D. of Ref. # 11 is .75 & Ref. # 10 Is NOT Flanged)
9	17-25810	PIN Comment: (O.D. of Ref. # 11 is .75 & Ref. # 10 Is NOT Flanged)
10	23-86637	BEARING Comment: (O.D. of Ref. # 11 is .75 & Ref. # 10 Is NOT Flanged)
11	17-8224002	PIN, Tilt Stop Comment: (O.D. of Ref. # 11 is .75 & Ref. # 10 Is NOT Flanged)
12	822401	CAP, Tilt Stop Pin Comment: (O.D. of Ref. # 15 is .56 & Ref. # 14 IS Flanged)
13	17-25319	PIN, (.125 x 0.75 Inches) Comment: (O.D. of Ref. # 15 is .56 & Ref. # 14 IS Flanged)
14	23-823589	BUSHING Comment: (O.D. of Ref. # 15 is .56 & Ref. # 14 IS Flanged)
15	17-8224001	PIN, Tilt Stop Comment: (O.D. of Ref. # 15 is .56 & Ref. # 14 IS Flanged)
16	97-8252711	ANODE
17	12-8M0204649	WASHER, (.281 x .500 x .060) Stainless Steel
18	10-8M0204707	SCREW, (M6 x 25)
19	11-82671117	NUT, (.500-20)
20	12-8M0204648	WASHER, (1.5 x 3.05 x 0.13) Stainless Steel
21	10-814259	SCREW, (.500-20 x 4.00)
22	37-830253	DECAL, Tilt Lock
23	NSS	NOT SOLD SEPARATE, Decal-Warning
24	828533T1	TRIM, Hydraulic Assist Comment: (Gas Assist Trim)
25	88238A11	CABLE ASSEMBLY Comment: (Gas Assist Trim)
26	828924	LEVER, Tilt Comment: (Gas Assist Trim)
27	8M0007469	TILT KNOB Comment: (Gas Assist Trim)
28	828930	ARM, Lever Comment: (Gas Assist Trim)
29	13-31030	WAVE WASHER Comment: (Gas Assist Trim)
30	17-25319	PIN, (.125 x 0.75 Inches) Comment: (Gas Assist Trim)
31	8289961	LINK Comment: (Gas Assist Trim)
32	10-32,11-8M0204718	NUT, Comment: (Gas Assist Trim)
33	17-822481001	PIN, Anchor (14 mm) Comment: (Gas Assist/Power Trim)
34	23-822482	BUSHING Comment: (Gas Assist/Power Trim)
35	23-822484	BUSHING Comment: (Gas Assist/Power Trim)
36	12-825190	WASHER Comment: (Gas Assist/Power Trim)
37	11-826712	NUT Comment: (Gas Assist/Power Trim)
38	10-4009040	SCREW, (M10 x 40) Stainless Steel Comment: (Gas Assist/Power Trim)
39	12-4002319	WASHER Comment: (Gas Assist/Power Trim)
40	11-40140	NUT, (M10) Comment: (Gas Assist/Power Trim)
41	NSS	NOT SOLD SEPARATE, Decal-Shallow Water Drive

▶Crankshaft, Pistons and Connection Rods (20 parts)

Ref	OEM Part #	Part Name
-	852067T98	POWERHEAD ASSEMBLY
1	2411-827954T3	CRANKSHAFT ASSEMBLY
2	43-43019A2	GEAR ASSEMBLY
3	30-63742T	BEARING, Ball
4	53-812877	RING, Retaining
5	28-91800	KEY, Woodruff
6	31-818889A1	BEARING ASSEMBLY, Roller Comment: (Top)
7	26-8173971	SEAL, Oil
8	827955A2	BEARING ASSEMBLY
9	NSS	NOT SOLD SEPARATE Comment: (Roller)
10	NSS	NOT SOLD SEPARATE Comment: (Ring-Seal)
11	705-850026T2	PISTON Comment: (.015 Over Size)
12	53-857196	LOCK RING
13	39-821695A6	RING SET, Piston Comment: (.015 Over Size)
14	NSS	NOT SOLD SEPARATE Comment: Piston Ring (Chrome Face)
15	640-9612A6	CONNECTING ROD ASSEMBLY
16	12-8M0012298	WASHER
17	29-8M0214934	BEARING
18	10-91012	SCREW, (.250-28 Special)
19	8M0234886	BEARING KIT

▶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	812888A1	CARRIER ASSEMBLY
5	21-42657A3	CHECK VALVE
6	21-8282182	CHECK VALVE
7	22-56759	FITTING, 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, (20.00 Feet Bulk) (Cut to 5.50 Inch Length)
27	22-996642	FITTING, Elbow 90 Degree (.125-27 x .250) Nylon (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, 54Â°C (130Â°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)

▶Cylinder Block and Crankcase (41 parts)

Ref	OEM Part #	Part Name
-	27-828553A97	GASKET SET
1	2801-827953T7	CYLINDER BLOCK
2	10-81742780	SCREW, (M8 x 80)
3	10-81742730	SCREW, (M8 x 30)
4	21-426585	CHECK VALVE
5	32-892024122	TUBING, (240.00 Inches Bulk) (Cut to 15.00 Inch Length)
6	21-426232	CHECK VALVE (Press-In)
7	812888A2	CARRIER ASSEMBLY
8	21-42657A4	CHECK VALVE
9	10-814776	SCREW, Adjusting (M6 x 55)
10	11-400212	NUT, (M6) Stainless Steel
11	42942	CAP
12	17-43044	PIN, Dowel - Without Hole (.375 x .625) (Locating)
13	17-8M0084653	PIN (Bearing Race)
14	27-827284	GASKET
15	16-8161949	STUD, (M6 x 44)
16	22-185981	PLUG, Pipe (.375-18)
17	22-328022	PLUG, Pipe (.125-27) Brass
18	22-19725	ELBOW
19	21-426585	CHECK VALVE
20	827251A1	COVER
21	850897	LIFTING EYE Comment: (Manual)
22	10-40011149	SCREW, (M8 x 25) Stainless Steel Comment: (Manual)
23	NSS	NOT SOLD SEPARATE Comment: (Decal-Serialization)
24	10-40011149	SCREW, (M8 x 25) Stainless Steel
25	889735	CARRIER
26	850055001	THERMOSTAT, 43Â°C (110Â°F)
27	26-854639001	SEAL
28	787992	SENDER, Temperature
29	889733	RETAINER
30	10-878609	SCREW, (#10-16 x .600)
31	12-8M0204666	WASHER, (.203 x .500 x .032)
32	22-996642	FITTING, Elbow 90 Degree (.125-27 x .250) Nylon
33	12-8M0204663	WASHER, (.187 x .500 x .062) Neoprene Comment: (Electric)
34	12-69056	WASHER, (.255 x .620 x .030) Stainless Steel Comment: (Electric)
35	11-816872	WING NUT Comment: (Electric)
36	22-56759	FITTING, Barbed Comment: (Electric)
37	8129962	COVER Comment: (Manual)
38	25-48462	O-RING, (.614 x .070) Comment: (Manual)
39	10-40011108	SCREW, (M5 x 20) Stainless Steel Comment: (Manual)
40	32-892024122	TUBING, (20.00 Feet Bulk) (Cut to 5.50 Inch Length)

▶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	11-400263	NUT, (M5)
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)

▶Driveshaft Housing/Exhaust Plate (49 parts)

Ref	OEM Part #	Part Name
-	27-828553A97	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	87917217T	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
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	88238A10	CABLE ASSEMBLY, Ground
23	12-32834	WASHER, Neoprene
24	12-8M0204648	WASHER, (1.5 x 3.05 x 0.13) Stainless Steel
25	11-896963	NUT, (M12)
26	828466A1	TRIM COVER Comment: (Black)
27	8M0043155	BUMPER
28	10-826173	SCREW, (M5 x .8 x 60)
29	12-73288	WASHER, (.220 x .500 x .030) Stainless Steel
30	11-401365	NUT, (M5) Stainless Steel
31	8M0043170	BUMPER
32	822395001	SEAL
33	828495001	SEAL, Idle Relief
34	10-817430110	SCREW, (M10 x 110)
35	3525-821841T7	HOUSING, Driveshaft Comment: (Black) (Short) (Jet)
36	16-823984	STUD, (M10 x 50)
37	12-8M0214963	WASHER, (.406 x .750 x .105) Stainless Steel
38	11-40140	NUT, (M10)
39	8284842	MOUNT (Lower)
40	828485F1	COVER, Mount Comment: (Black)
41	10-40011151	SCREW, (M8 x 35) Stainless Steel
42	850030F1	YOKE, Bottom Comment: (Black)
43	10-8M0038368	SCREW, (M8 x 40) Stainless Steel
44	12-36001	WASHER
45	11-401378	NUT, (M8)
46	10-828556	SCREW, (M12 x 125)
47	11-896963	NUT, (M12)
48	88238A11	CABLE ASSEMBLY (A = To Portside of Swivel Bracket)

▶Electrical Components (44 parts)

Ref	OEM Part #	Part Name
-	61-8M0063311	POWERHEAD ASSEMBLY Comment: 40 HP
1	8302351	PLATE, Electrical
2	10-82239312	SCREW, (M5 x 12)
3	12-89302	WASHER, (.203 x .406 x .040)
4	56762	TIE STRAP, (4.00 Inches)
5	821889A50	REV LIMITER Comment: (Electric)
6	8266241	CLAMP Comment: (Electric)
7	10-82239312	SCREW, (M5 x 12) Comment: (Electric)
8	89-8M0185146	SOLENOID ASSEMBLY Comment: (Electric)
9	23-8M0214955	BUSHING Comment: (Electric)
10	25-818967	GROMMET Comment: (Electric)
11	10-82129125	SCREW, (M6 x 25 MM) Comment: (Electric)
12	11-64015	NUT, (.250-20) Comment: (Electric)
13	13-26992	LOCKWASHER, (.250) Stainless Steel Comment: (Electric)
14	84-88807A33	CABLE ASSEMBLY Comment: (Electric)
15	84-88807A16	CABLE ASSEMBLY, (4.00 Inches) Black Comment: (Electric)
16	8-32,11-26419	NUT, Brass Comment: (Electric)
17	8M0084173	REGULATOR, Voltage Comment: (Electric)
18	10-82129140	SCREW, (M6 x 40) Comment: (Electric)
19	54-8M0024808	J CLIP Comment: (Electric)
20	85-830233	BOOT, Insulator - Red Comment: (Electric)
21	84-88439A4	CABLE ASSEMBLY, Battery - Negative Comment: (Electric)
22	12-8M0204649	WASHER, (.281 x .500 x .060) Stainless Steel (Quantity of 3 on Electric)
23	54-816311T	TIE STRAP, (8.00 Inches)
24	10-82129125	SCREW, (M6 x 25 MM)
25	84-88807A31	CABLE ASSEMBLY
26	10-81742720	SCREW, (M8 x 20) Comment: (Manual)
27	10-82129116	SCREW, (M6 x 16) Comment: (Manual)
28	54-54457	J CLIP (Quanity of 3 on Electric)
29	84-850220A2	HARNESS ASSEMBLY, Engine Comment: (Electric)
30	88-812619	FUSE, Yellow - 20 Ampere Comment: (Electric)
31	25-822002	GROMMET
32	23-822003	BUSHING
33	12-8M0214930	WASHER
34	10-40011129	SCREW, (M6 x 25) Stainless Steel
35	84-850221A2	HARNESS ASSEMBLY, Ignition
36	827509A10	CDM MODULE ASSEMBLY Comment: (11 Inch Leads)
37	84-857124A1	CABLE ASSEMBLY, Hi-Tension
38	85-857074A1	BOOT/TERMINAL KIT
39	33-896329885	SPARK PLUG Comment: (NGK#BUZ8H)
40	10-82129116	SCREW, (M6 x 16)
41	84-850052A1	HARNESS ASSEMBLY, Power Comment: (Manual)
42	84-11149T31	HARNESS ASSEMBLY Comment: (Manual)
43	84-852375A4	HARNESS ASSEMBLY Comment: (Electric)

▶Flywheel and Stator(Electric) (11 parts)

Ref	OEM Part #	Part Name
1	812777T1	COVER ASSEMBLY
2	11-42979	NUT, (M16)
3	12-33001	WASHER, (.641 x 1.250 x .190)
4	261-859234T24	FLYWHEEL
5	398-832075A21	IGNITION STATOR KIT
6	10-4013930	SCREW, (M5 x 30)
7	854512T	TRIGGER
8	93421	SWIVEL BALL
9	93254	SWIVEL BASE
10	54-816311T	TIE STRAP, (8.00 Inches)
11	37-804665A04	DECAL, EPA Label Information Comment: (2004)

▶Flywheel and Stator(Manual) (10 parts)

Ref	OEM Part #	Part Name
1	261-859234T25	FLYWHEEL
2	11-42979	NUT, (M16)
3	12-33001	WASHER, (.641 x 1.250 x .190)
4	398-832074A11	STATOR
5	10-4013930	SCREW, (M5 x 30)
6	854512T	TRIGGER
7	93421	SWIVEL BALL
8	93254	SWIVEL BASE
9	54-816311T	TIE STRAP, (8.00 Inches)
10	13541	PLUG, Male

▶Fuel Pump(Electric) (38 parts)

Ref	OEM Part #	Part Name
-	27-828553A97	GASKET SET
1	NSS	NOT SOLD SEPARATE Comment: (Diaphragm Kit)
2	21-857005A1	DIAPHRAGM KIT
3	NSS	NOT SOLD SEPARATE Comment: (Diaphragm)
4	NSS	NOT SOLD SEPARATE Comment: (Retainer)
5	NSS	NOT SOLD SEPARATE Comment: (Spring)
6	NSS	NOT SOLD SEPARATE Comment: (Cap)
7	NSS	NOT SOLD SEPARATE Comment: (Spring)
8	NSS	NOT SOLD SEPARATE Comment: (Cap)
9	NSS	NOT SOLD SEPARATE Comment: (Diaphragm)
10	27-8M0204705	GASKET
11	NSS	NOT SOLD SEPARATE Comment: (Gasket-Boost)
12	NSS	NOT SOLD SEPARATE Comment: (Gasket-Pulse)
13	987752	PLATE
14	22-433351	CONNECTOR, (90 Degree) With Vibraseal
15	10-82130050	SCREW, (M6 x 50)
16	144303	BASE
17	32-831949	HOSE
18	35-816296Q2	FILTER, Fuel
19	32-830761	LINE, Fuel
20	54-816311T	TIE STRAP, (8.00 Inches)
21	32-8M0108349	TUBING, (.312) (70.00 Inches Bulk) (Cut to 1.25 Inch Length) Comment: (50)
22	32-8M0108349	TUBING, (.312) (70.00 Inches Bulk) (Cut to 1.25 Inch Length) Comment: (50)
23	22-818993	CONNECTOR, Tee Comment: (50)
24	32-82381335	TUBING, (15.00 Inches Bulk) (Cut to 1.50 Inch Length) Comment: (50)
25	32-8M0108349	TUBING, (.312) (70.00 Inches Bulk) (Cut to 22.00 Inch Length)
26	22-8189941	CHECK VALVE
27	22-816856T01	CONNECTOR ASSEMBLY, Fuel
28	10-4000332	SCREW, (M6 x 35)
29	32-9912878	HOSE, (.187) (26.00 Inches Bulk) (Cut to 4.25 Inch Length)
30	54-633003	CLAMP
31	89-819503A5	SOLENOID KIT, Enrichner Valve
32	32-9912688	TUBING, (36.00 Inches Bulk) (Cut to 8.00 Inch Length)
33	32-9912688	TUBING, (36.00 Inches Bulk) (Cut to 4.00 Inch Length)
34	32-892024122	TUBING, (240.00 Inches Bulk) (Cut to 14.00 Inch Length)
35	22-59169003	FITTING, Tee
36	32-9912688	TUBING, (36.00 Inches Bulk) (Cut to 2.00 Inch Length)
37	10-4006731	SCREW, (M6 x 16)

▶Fuel Pump(Electric)(Design I) (43 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)
16	10-82130050	SCREW, (M6 x 50)
17	22-433351	CONNECTOR, 90 Degree (.125-27) Nylon
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) (.50 X 5 Inch)
24	54-816311T	TIE STRAP, (8.00 Inches)
25	22-59169003	FITTING, Tee
26	32-892024122	TUBING, (20.00 Feet Bulk) (Cut to 4 Inch Length)
27	32-9912688	TUBING, (36.00 Inches Bulk) (Cut to 3.25 Inch Length)
28	32-830764	HOSE
29	32-9912878	HOSE, (.187) (26.00 Inches Bulk) (Cut to 3.25 Inch Length)
30	8507051	INSULATOR
31	32-8M0108349	TUBING, (.312) (70.00 Inches Bulk) (Cut to 9.00 Inch Length)
32	22-818992	CONNECTOR
33	32-8M0108349	TUBING, (.312) (70.00 Inches Bulk) (Cut to 4.00 Inch Length)
34	22-8189941	CHECK VALVE
35	32-82381335	TUBING, (15.00 Inches Bulk) (Cut to 1.50 Inch Length)
36	32-8M0108349	TUBING, (.312) (70.00 Inches Bulk) (Cut to 1.50 Inch Length)
37	35-891642T03	FILTER, Fuel
38	822387	BRACKET
39	11-401366	NUT, (M6) Stainless Steel
40	32-8M0108349	TUBING, (.312) (70.00 Inches Bulk) (Cut to 14.25 Inch Length)
41	22-816856T01	CONNECTOR ASSEMBLY, Fuel
42	10-4000332	SCREW, (M6 x 35)

▶Fuel Pump(Electric)(Design II) (43 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 (.125-27) Nylon
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) (.50 x 5.00 Inch)
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	32-892037	HOSE, Molded
34	22-8189941	CHECK VALVE
35	32-82381335	TUBING, (15.00 Inches Bulk) (Cut to 1.50 Inch Length)
36	32-8M0108349	TUBING, (.312) (70.00 Inches Bulk) (Cut to 1.50 Inch Length)
37	35-891642T03	FILTER ASSEMBLY, Fuel
38	822387	BRACKET
39	11-401366	NUT, (M6) Stainless Steel
40	32-892040	HOSE, Molded
41	22-816856T01	CONNECTOR ASSEMBLY, Fuel
42	10-4000332	SCREW, (M6 x 35)

▶Fuel Pump(Manual) (30 parts)

Ref	OEM Part #	Part Name
-	27-828553A97	GASKET SET
1	NSS	NOT SOLD SEPARATE Comment: (Fuel Pump)
2	21-857005A1	DIAPHRAGM KIT
3	NSS	NOT SOLD SEPARATE Comment: (Diaphragm Kit)
4	NSS	NOT SOLD SEPARATE Comment: (Retainer)
5	NSS	NOT SOLD SEPARATE Comment: (Spring)
6	NSS	NOT SOLD SEPARATE Comment: (Cap)
7	NSS	NOT SOLD SEPARATE Comment: (Diaphragm)
8	NSS	NOT SOLD SEPARATE Comment: (Cap)
9	NSS	NOT SOLD SEPARATE Comment: (Diaphragm)
10	27-8M0204705	GASKET
11	NSS	NOT SOLD SEPARATE Comment: (Gasket-Boost)
12	NSS	NOT SOLD SEPARATE Comment: (Gasket-Pulse)
13	987752	PLATE
14	22-433351	CONNECTOR, (90 Degree) With Vibraseal
15	10-82130050	SCREW, (M6 x 50)
16	144303	BASE
17	32-8M0108349	TUBING, (.312) (70.00 Inches Bulk) (22 Inch)
18	54-816311T	TIE STRAP, (8.00 Inches)
19	32-830761	LINE, Fuel
20	32-9912878	HOSE, (.187) (26.00 Inches Bulk) (Cut to 4.25 Inch Length)
21	35-816296Q2	FILTER, Fuel
22	32-831949	HOSE
23	22-59169003	FITTING, Tee
24	32-892024122	TUBING, (20.00 Feet Bulk) (Cut to 9.50 Inch Length)
25	858763	PRIMER BULB
26	22-816856T01	CONNECTOR ASSEMBLY, Fuel
27	10-4000332	SCREW, (M6 x 35)
28	32-892024122	TUBING, (20.00 Feet Bulk) (Cut to 5.50 Inch Length)5-1/2 Inch)
29	32-892024122	TUBING, (20.00 Feet Bulk) (Cut to 1.50 Inch Length)1-1/2 Inch)

▶Fuel Pump(Manual)(Design I) (32 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)
16	10-82130050	SCREW, (M6 x 50)
17	22-433351	CONNECTOR, 90 Degree (.125-27) Nylon
18	858763	PRIMER BULB
19	32-892024122	TUBING, (20.00 Feet Bulk)
20	23-82538115	SLEEVE, (.500 x 5.00)
21	32-830764	HOSE
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	32-830765	HOSE, Molded
26	35-891642T03	FILTER, Fuel
27	822387	BRACKET
28	11-401366	NUT, (M6) Stainless Steel
29	32-8M0108349	TUBING, (.312) (70.00 Inches Bulk) (Cut to 14.25 Inch Length)
30	22-816856T01	CONNECTOR ASSEMBLY, Fuel
31	10-4000332	SCREW, (M6 x 35)

▶Fuel Pump(Manual)(Design II) (32 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 (.125-27) Nylon
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	35-891642T03	FILTER ASSEMBLY, Fuel
27	822387	BRACKET
28	11-401366	NUT, (M6) Stainless Steel
29	32-892037	HOSE, Molded
30	22-816856T01	CONNECTOR ASSEMBLY, Fuel
31	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)

▶Gasket Set Components-Engine Overhaul (2 parts)

Ref	OEM Part #	Part Name
-	27-828553A97	GASKET SET
0	27-8144461	GASKET, Flange, Carburetor

▶Gear Housing(Driveshaft)(1.83:1 Gear Ratio) (40 parts)

Ref	OEM Part #	Part Name
-	821354A2	REPAIR KIT, Water Pump
1	1682-821306T12	GEAR HOUSING ASSEMBLY, Basic Comment: (Basic-Black)
2	818226A1	SEAL/PLATE KIT
3	NSS	NOT SOLD SEPARATE Comment: (Plate)
4	10-79953Q04	SCREW KIT, (.375-16 x .250) Drain (.375-16 X .25)
5	12-191833	WASHER
6	22-8M0058389	FITTING KIT, Magnetic, Plug Fill/Drain
7	12-191833	WASHER
8	11-55910	NUT, (.437-20)
9	43-822161T2	GEAR, Pinion (12 Teeth)
10	31-821321A2	BEARING ASSEMBLY
11	NSS	NOT SOLD SEPARATE Comment: (Cup)
12	10-8248324	SCREW, (M6 x 16)
13	46-821351A3	HOUSING ASSEMBLY, Water Pump Upper
14	8235471	SEAL
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
24	26-821310	SEAL
25	25-821308	O-RING, (1.421 x .139)
26	45-822159T1	DRIVESHAFT Comment: (Long)
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	821319A1	SHIFT SHAFT Comment: (Long)
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(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	FITTING KIT, Magnetic, Plug Fill/Drain
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 - 1.83:1 Gear Ratio (36 parts)

Ref	OEM Part #	Part Name
-	823547A2	SEAL KIT
1	1682-821306T12	GEAR HOUSING ASSEMBLY, Basic Comment: (Basic-Black)
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	43-822162T2	GEAR, Forward (22 Teeth)
49	31-8M0103470	BEARING ASSEMBLY, Roller
50	NSS	NOT SOLD SEPARATE Comment: (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	43-822163T1	GEAR, Reverse (22 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 Comment: (Use with Threaded Insert)
66	10-85594030	SCREW, (M8 x 30) Comment: (Use with Threaded Insert)
67	8227731	INSERT, Threaded
68	NSS	NOT SOLD SEPARATE (Decal 1.83:1) (12 X 22)
69	73345A1	THRUST HUB
70	11-69578Q1	PROP NUT KIT
71	14-8M0214942	TAB WASHER
72	10-4000380	SCREW, (M10 x 45)
73	12-8M0214963	WASHER, (.406 x .750 x .105) Stainless Steel

▶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)
7	10-81742730	SCREW, (M8 x 30)
8	830246T3	REED VALVE Comment: (40 H.P.)

▶Induction Manifold and Reed Block (28 parts)

Ref	OEM Part #	Part Name
-	27-828553A97	GASKET SET
1	27-8M0000822	GASKET
2	1171-9812A8	END CAP ASSEMBLY
3	26-828932	SEAL, Oil
4	26-41953	SEAL
5	25-8M0142854	O-RING, (2.175 x .175)
6	10-81742720	SCREW, (M8 x 20)
7	19077A07	BRACKET ASSEMBLY
8	16-8161949	STUD, (M6 x 44)
9	12-8M0204663	WASHER, (.187 x .500 x .062) Neoprene Comment: (Electric)
10	12-69056	WASHER, (.255 x .620 x .030) Stainless Steel Comment: (Electric)
11	11-816872	WING NUT Comment: (Electric)
12	10-82127335	SCREW, (M8 x 35 MM)
13	827998A1	MANIFOLD ASSEMBLY, Induction
14	22-19725	ELBOW Comment: (Electric)
15	22-19725	ELBOW Comment: (Manual)
16	22-15026	CAP Comment: (Manual)
17	54-816311T	TIE STRAP, (8.00 Inches)
18	27-812869	GASKET
19	10-81742730	SCREW, (M8 x 30)
20	8M0219197	REED BLOCK ASSEMBLY
21	27-812868	GASKET
22	NSS	NOT SOLD SEPARATE Comment: (Dowel Pin)
23	34-812880A03	REED ASSEMBLY
24	14-429821	TAB WASHER
25	812879002	RETAINER, Reed Comment: (50)
26	825267	RETAINER, Reed Comment: (40)
27	10-88421471	SCREW, (M6 x 16)

▶Jet Components (12 parts)

Ref	OEM Part #	Part Name
-	27-828553A97	GASKET SET
1	10-8248324	SCREW, (M6 x 16)
2	46-821351A3	HOUSING ASSEMBLY, Water Pump Upper
3	8235471	SEAL
4	12-866451	WASHER
5	28-8M0214993	KEY
6	12-866451	WASHER
7	27-822189	GASKET, Upper Water Pump
8	27-8M0214956	GASKET, Lower Water Pump
9	8213542	FACE PLATE
10	47-8M0204712	IMPELLER
11	854491	EXTENSION, Water Tube

▶Jet Pump Assembly (33 parts)

Ref	OEM Part #	Part Name
-	856143A5	JET PUMP ASSEMBLY Comment: (With Stainless Steel Impeller)
1	801411401	HOUSING, Pump
2	32-827490	HOSE, Lube
3	878376	SHIFT LINKAGE KIT
4	878381	CAM
5	878379	GATE, Reverse - With Bumper
6	47-855708T40	IMPELLER Comment: (Stainless Steel)
7	80141240	HOUSING, Intake
8	827188T1	LINER
9	45-801413401	DRIVESHAFT
10	12-879652	THRUST WASHER
11	30-879653	BEARING, Ball
12	23-827189	SLEEVE
13	11-827190	NUT
14	28-801405625	KEY, Impeller
15	15-801404625	SHIM, Impeller
16	14-801403625	TAB WASHER
17	10-90192	SCREW, (.250-20 x .750) Stainless Steel
18	10-19923088	SCREW, (.250-20 x .875)
19	12-35044	WASHER, (.281 x .625 x .065) Stainless Steel
20	10-19923062	SCREW, (.250-20 x .625)
21	10-60411	SCREW, (.312-18 x 1.250)
22	801410	BRACKET, Cable Support
23	11-82670910	NUT, (.312-18)
24	17-801406	PIN, Dowel
25	10-19924275	SCREW, (.312-18 x 2.75)
26	12-8M0207778	WASHER
27	10-19925125	SCREW, (.375-16 x 1.25)
28	853881	ADAPTOR
29	10-1993330	SCREW, (M10 x 1.5 x 30)
30	12-34931	WASHER, (.406 x .734 x .063) Stainless Steel
31	10-87810178	SCREW, (M10 x 35)
32	17-821327	PIN, Dowel

▶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)
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	37-804664A04	DECAL, EPA Label Information Comment: (2004)
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
-	27-828553A97	GASKET SET
1	23-822003	BUSHING
2	25-822002	GROMMET
3	10-40011129	SCREW, (M6 x 25) Stainless Steel
4	1276-828163A2	TANK ASSEMBLY, Oil
5	36-828765A2	CAP ASSEMBLY
6	NSS	NOT SOLD SEPARATE, Tether
7	11-821285	PUSH NUT
8	19299A1	VENT ASSEMBLY
9	21-64871	VALVE
10	8M0039080	SEAL
11	54-816311T	TIE STRAP, (8.00 Inches)
12	25-813644002	GROMMET
13	87-12886A6	SWITCH ASSEMBLY
14	10-58376	SCREW, (.164-18 x .375)
15	12-72761	WASHER, (.203 x .562 x .060) Stainless Steel
16	23-826084	SPACER
17	32-82381335	TUBING, (15.00 Inches Bulk) (12 Inch)
18	818902A2	PUMP ASSEMBLY, Oil Injection Comment: (40)
19	818902A1	PUMP ASSEMBLY, Oil Injection Comment: (50)
20	25-36390	O-RING
21	25-8M0204667	O-RING
22	10-40011108	SCREW, (M5 x 20) Stainless Steel
23	43-19277	GEAR, Driven
24	23-19278A2	BEARING ASSEMBLY
25	23-17597	BUSHING (Flanged)
26	23-17596	BUSHING
27	8M0084729	LINK
28	25-8M0204667	O-RING
29	10-40011108	SCREW, (M5 x 20) Stainless Steel
30	826581T01	LINK

▶Power Trim (31 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 Comment: (Ball/Spring)
8	NSS	NOT SOLD SEPARATE Comment: (Screw)
9	NSS	NOT SOLD SEPARATE Comment: (Filter)
10	NSS	NOT SOLD SEPARATE Comment: (O Ring)
11	827675A1	MOTOR ASSEMBLY
12	NSS	NOT SOLD SEPARATE Comment: (Screw)
13	NSS	NOT SOLD SEPARATE Comment: (Washer)
14	88238A15	CABLE ASSEMBLY
15	NSS	NOT SOLD SEPARATE Comment: (O Ring)
16	NSS	NOT SOLD SEPARATE Comment: (Coupler)
17	827676	PISTON, Memory
18	893929A01	MANUAL RELEASE ASSEMBLY
19	19-811613	PLUG ASSEMBLY
20	831276T	BRACKET
21	84-826802A9	HARNESS ASSEMBLY, 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 Comment: (Decal)
28	10-878609	SCREW, (#10-16 x .600)
29	8M0084613	C WASHER
30	54-22740	CLIP

▶Power Trim Mounting (11 parts)

Ref	OEM Part #	Part Name
1	17-822481001	PIN, Anchor (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
0	37-804665A04	DECAL, EPA Label Information Comment: (2004)

▶Starter Assembly(Manual) (38 parts)

Ref	OEM Part #	Part Name
-	816728T14	STARTER ASSEMBLY, Recoil
1	85174A1	HANDLE ASSEMBLY
2	NSS	NOT SOLD SEPARATE Comment: (Retainer)
3	NSS	NOT SOLD SEPARATE Comment: (Rest)
4	8M0043416	SEAL
5	10-4010630	SCREW, (M6 x 30) Stainless Steel
6	23-830190	SPACER
7	23-816086	BUSHING
8	25-8157951	GROMMET
9	12-858779	WASHER, (.265 x .750 x .048)
10	11-401196	NUT, (M6)
11	8567541	CABLE, Interlock
12	10-8214281	SCREW, (#10-16 x .625)
13	12-73288	WASHER, (.220 x .500 x .030) Stainless Steel
14	18-26811	COTTER PIN
15	10-878608	SCREW, (#10-16 x .500)
16	18-26811	COTTER PIN
17	816728T05	HOUSING
18	24-826791	SPRING
19	8166903	LEVER
20	816712T01	CAM
21	816711	RETAINER
22	10-8182491	SCREW, (#10-16 x 1.00)
23	13-826229	LOCKWASHER, SPRING
24	24-86857T01	SPRING
25	50-825269T01	SHEAVE, Starter
26	24-86851T02	SPRING
27	868501	CAM
28	53-86849T01	RING, Retaining
29	50-12066Q10	ROPE
30	24-868523	SPRING
31	86853T01	CAM
32	10-826253	SCREW, (.250-20 x .625)
33	8M0183792	BUSHING
34	53-818853	RING, Retaining
35	NSS	NOT SOLD SEPARATE Comment: (Timing Decal)
36	NSS	NOT SOLD SEPARATE Comment: (Decal-Caution in Gear Idle)
37	37-804665A04	DECAL, EPA Label Information Comment: (2004)

▶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
14	10-40011153	SCREW, (M8 x 45) Stainless Steel
15	NSS	NOT SOLD SEPARATE, Decal-Warning
16	823989	BRACKET, Oil Tank

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

Ref	OEM Part #	Part Name
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	23-822392	SPACER, Handle Rest
7	11-816872	WING NUT
8	12-69056	WASHER, (.255 x .620 x .030) Stainless Steel
9	12-8M0204663	WASHER, (.187 x .500 x .062) Neoprene, Neoprene
10	812777T1	COVER ASSEMBLY
11	10-4013930	SCREW, (M5 x 30)
12	398-832075A21	IGNITION STATOR KIT
13	853960T	TRIGGER
14	37-804664A04	DECAL, EPA Label Information Comment: (2004)
15	NSS	NOT SOLD SEPARATE, Decal-Caution in Gear Idle
16	NSS	NOT SOLD SEPARATE, Decal-Timing

▶Swivel Bracket (41 parts)

Ref	OEM Part #	Part Name
1	19608A14	ATTACHING KIT, Engine Steering Comment: (Non-Handle)
2	10-823919	SCREW, (.375-24 x 1.500) Comment: (Non-Handle)
3	12-8M0109680	WASHER, (.390 x .546 x .12) Comment: (Non-Handle)
4	12-37828	WASHER, (.390 x .625 x .062) Stainless Steel Comment: (Non-Handle)
5	11-8M0204726	NUT, (.375-24) Stainless Steel Comment: (Non-Handle)
6	822397	PUCK Comment: (Non-Handle)
7	3410-827402T5	SWIVEL BRACKET ASSEMBLY
8	23-8217711	BUSHING (Upper)
9	22-8M0169589	FITTING, Grease Comment: (Quanty of 4 on Handle Version)
10	23-821777	BUSHING (Lower)
11	26-8M0205512	SEAL
12	NSS	NOT SOLD SEPARATE Comment: (Decal-Serial Overlaminate)
13	88238A11	CABLE ASSEMBLY
14	12-19619	WASHER
15	10-40011149	SCREW, (M8 x 25) Stainless Steel Comment: (Non-Handle)
16	8282451	SEAL Comment: (Non-Handle)
17	19624A1	SEAL KIT Comment: (Non-Handle)
18	25-29619	O-RING, (.583 x .103) Comment: (NonHandle)
19	23-78861	SPACER Comment: (Non-Handle)
20	12-19619	WASHER
21	8M0041938	TILT TUBE
22	11-858869	NUT, (.875-14)
23	37-8237011	DECAL, Co-Pilot
24	17-821539	PIN, Trilobe
25	23-823507	BUSHING
26	17-822480	PIN, Pivot (Upper)
27	10-878607	SCREW, (#10-16 x .375)
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,
39	NSS	NOT SOLD SEPARATE, Decal-Serial Overlaminate
40	822005	BOOT, Rubber Comment: (Non-Handle)(Use Where Applicable)
41	24-821784	SPRING Comment: (Non-Handle)(Use Where Applicable)

▶Swivel Tube (16 parts)

Ref	OEM Part #	Part Name
1	821769T2	SWIVEL TUBE HEAD, Gray
2	8M0184092	BRACKET Comment: (Non-Handle)
3	14-8M0009820	TAB WASHER Comment: (Non-Handle)
4	10-4000377	SCREW, (M10 x 30) Comment: (Non-Handle)
5	11-8M0204726	NUT, (.375-24) Stainless Steel
6	823792	LEVER
7	12-29330	WASHER
8	821961	ROD (Threaded)
9	821957	BRAKE PLATE
10	8165621	DISC
11	8M0007471	PLATE
12	8165621	DISC
13	10-768042	SHOULDER SCREW, Hex
14	8M0156878	BUMPER
15	8165621	DISC
16	10-768042	SHOULDER SCREW, Hex

▶Throttle Lever and Linkage (32 parts)

Ref	OEM Part #	Part Name
1	42946T1	LEVER, Throttle
2	10-817582	SCREW, Adjusting (M5 x 35)
3	11-400211	NUT, (M5) Stainless Steel
4	42927	INSERT
5	12-35459	WASHER
6	11-401386	NUT, (M6) Stainless Steel
7	10-814776	SCREW, Adjusting (M6 x 55)
8	11-400212	NUT, (M6) Stainless Steel
9	42942	CAP
10	23-812930A1	BUSHING
11	NSS	NOT SOLD SEPARATE Comment: (Insert)
12	10-4007180	SCREW, (M10 x 45)
13	23-8M0215006	BUSHING
14	24-55162	SPRING
15	12-42980	WASHER
16	19663T02	LEVER, Spark Advance
17	878172	ROD
18	93254	SWIVEL BASE
19	10-814776	SCREW, Adjusting (M6 x 55)
20	11-400212	NUT, (M6) Stainless Steel
21	42942	CAP
22	93421	SWIVEL BALL
23	16-8161949	STUD
24	24-817702	SPRING Comment: (Electric)
25	828160A2	CAM ASSEMBLY, Throttle
26	23-8M0215006	BUSHING
27	878174	ROD, Throttle
28	12-65567	WASHER, (.265 x .750 x .048) Stainless Steel
29	11-401386	NUT, (M6) Stainless Steel
30	12-828494	WASHER Comment: (Electric)
31	8214943	BRACKET Comment: (Handle Versions)
32	10-4006731	SCREW, (M6 x 16) Comment: (Handle Versions)

▶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 (34 parts)

Ref	OEM Part #	Part Name
-	37-8M0032728	DECAL, Lanyard, Black
1	822148A7	COVER KIT
2	822150	PULLEY
3	NSS	NOT SOLD SEPARATE Comment: (Case)
4	10-878608	SCREW, (#10-16 x .500)
5	4324212	CABLE ASSEMBLY, Throttle (28.50 Inches)
6	4324213	CABLE ASSEMBLY, Throttle (30.00 Inches)
7	85-960099	SLEEVE, (12.00 Inches)
8	10-82526225	SCREW, (M8 x 25 MM)
9	8M0072298	COVER Comment: (Black)
10	23-821477	BUSHING
11	828813T1	ARM, Steering Handle Comment: (Black)
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
19	37-8242004	DECAL Comment: (Turtle/Rabbit)
20	821465	HANDLE, Throttle
21	8M0221732	GRIP
22	87-8M0104614	SWITCH ASSEMBLY
23	10-824848110	SCREW, (M10 x 110)
24	14-8M0009820	TAB WASHER
25	823687	CLIP
26	23-828569	SPACER
27	821455A4	BRACKET, Tiller Comment: (Black)
28	13-826792	WAVE WASHER
29	23-821477	BUSHING
30	12-827314	WASHER
31	87-11083A31	SWITCH
32	8M0032846	RETAINER, Brass
33	15920Q54	LANYARD ASSEMBLY

▶Tools, Special (2 parts)

Ref	OEM Part #	Part Name
-	56-817383A1	TOOL BAG Comment: (Seapro/Marathon)
0	91-37241	PULLER PLATE, Universal Comment: (Gear Housing)

▶Top Cowl (27 parts)

Ref	OEM Part #	Part Name
1	4019-825239T14	TOP COWL ASSEMBLY Comment: (Silver)(Electric)
2	4019-825239T12	TOP COWL ASSEMBLY Comment: (Silver)(Manual)
3	8M0041044	BRACKET, Cowl Support Comment: (Rear)
4	828433T	SPACER, Bracket
5	10-83208630	SCREW
6	11-400632	NUT
7	893763	BRACKET ASSEMBLY, Latch Roller
8	10-4006731	SCREW, (M6 x 16)
9	813546003	MOUNT
10	47341A11	ROPE AND HANDLE KIT, Manual Starting
11	8M0041646	BRACKET, Cowl Support - Front Comment: (Front)
12	828503	LATCH KEEPER
13	10-83208616	SCREW
14	11-400632	NUT
15	8M0038217	DUCT, Air Inlet
16	NSS	NOT SOLD SEPARATE Comment: (Induction Insert)
17	10-F2317	SCREW, (.250-20 x .875)
18	8M0043404	SEAL
19	813504A1	GAUGE KIT, Oil Level Comment: (Electric)
20	813505	GROMMET Comment: (Electric)
21	113171	RETAINER Comment: (Electric)
22	11-65110	NUT Comment: (Electric)
23	828180A02	SOUND BLANKET KIT (All)
24	NSS	NOT SOLD SEPARATE Comment: (Storboard and Rear)
25	NSS	NOT SOLD SEPARATE Comment: (Port and Rear)
26	NSS	NOT SOLD SEPARATE Comment: (Tape)
27	37-82409316	DECAL, F-N-R Shift

▶Trim Switch Kit (8 parts)

Ref	OEM Part #	Part Name
-	87-18286A18	SWITCH KIT, Trim (10.00 Feet)
1	18861	RETAINER
2	814820	ADAPTOR
3	NSS	NOT SOLD SEPARATE Comment: (Switch)
4	88-8M0207796	FUSE, 20 Ampere
5	84-95084A2	CABLE ASSEMBLY
6	84-11149A2	CABLE ASSEMBLY, (6.00 Inches)
7	10-813523	SCREW, (#10-16 x 2.25)

▶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 (3 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 (3 CYL.) (0P017000 THRU 0P325499) Parts & Diagrams

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