Mercury 40 CARB (3 CYL.)(4-STROKE) (0P401000 & Up) Parts & Diagrams

🔎 Mercury 40 CARB (3 CYL.)(4-STROKE) Reference Library — Exploded parts diagrams (35 diagrams), specifications, common issues, and maintenance checklist.

The Mercury 40 CARB (3 CYL.)(4-STROKE) 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 CARB (3 CYL.)(4-STROKE):

Water Pump / Overheating: If the tell-tale stream is weak or absent, the water pump impeller likely needs replacement. Inspect annually or every 100 hours. → Recommended: Water Pump Impeller Kit
Engine Oil / Maintenance Light: 4-stroke engines require regular oil and filter changes. Use marine-grade oil rated for your engine. Change every 100 hours or annually. → Recommended: Oil Filter, Engine Oil
Fuel Injector Issues (EFI models): Rough idle or misfires may indicate clogged fuel injectors. Use fuel stabilizer and clean injectors periodically. → Recommended: Fuel Injector, Fuel Filter
Gear Case Oil Leak: Check lower unit seals if gear oil appears milky (water contamination). Replace seals and gaskets during lower unit service. → Recommended: Lower Unit Seal Kit, Drain Plug Gaskets
Anode Corrosion: Inspect sacrificial anodes regularly, especially in saltwater. Replace when 50% depleted to protect against galvanic corrosion. → Recommended: Zinc/Aluminum Anode Kit

Parts Diagrams & OEM Part Numbers

Expand the sections below to view detailed exploded parts diagrams and find the exact OEM replacement components for your Mercury 40 CARB (3 CYL.)(4-STROKE).

▶Accessories (1 parts)

Ref	OEM Part #	Part Name
-	816667A2	BRACKET ASSEMBLY, Steering Comment: (Without Carrying Handle)

▶Adaptor Plate (24 parts)

Ref	OEM Part #	Part Name
1	8M0162935	DIPSTICK
2	825989003	DIPSTICK TUBE (Included with Adaptor Plate)
3	8560552	SEAL
4	825228A17	ADAPTOR PLATE ASSEMBLY
5	19-822464	PLUG
6	19-48323	PLUG
7	17-23784	PIN, Dowel (Included with Adaptor Plate)
8	22-629101	FITTING, Elbow - 90 Degree (.125-27)
9	54-816311T	TIE STRAP, (8.00 Inches)
10	26-66301	SEAL, Oil Comment: (Long)
11	23-859594	BUSHING Comment: (Long)
12	22-889567	PLUG, (.500-14)
13	25-822408001	GROMMET (Short)
14	27-8M0213113	GASKET
15	25-845746	O-RING
16	10-8M0204741	SCREW, (M6 x 20) Stainless Steel
17	8M0210772	BODY, Oil Pressure Relief
18	893765	PLATE, Top Oil Pickup
19	32-854793	HOSE, Oil Pickup
20	893700	BAFFLE, Oil Pick-up
21	54-855228	CLAMP
22	10-4007455	SCREW, (M6 x 55)
23	8289151	HEAT SHIELD
24	25-8M0179867	GROMMET

▶Bottom Cowl (18 parts)

Ref	OEM Part #	Part Name
1	4020-826277T1	BOTTOM COWL Comment: (Long-Port)
2	4020-826278T7	BOTTOM COWL Comment: (Long-Starboard)
3	10-82684430	SCREW, (M6 x 30)
4	12-8M0204649	WASHER, (.281 x .500 x .060) Stainless Steel
5	825238002	SEAL
6	12-855576	WASHER
7	27-855627	GASKET
8	10-82684460	SCREW, (M6 x 60)
9	22-827948	FITTING
10	826273001	BOOT
11	54-816311T	TIE STRAP, (8.00 Inches)
12	825782F1	LEVER, Cowl Latch
13	23-812707	BUSHING
14	13-12134	WASHER, Wave
15	893766	HOOK, Latch
16	10-1993716	SCREW, (M6 x 16)
17	8M0032848	RETAINER
18	812830T01	PLUG

▶Camshaft/Oil Pump (15 parts)

Ref	OEM Part #	Part Name
-	893504T02	CYLINDER HEAD ASSEMBLY
1	10-82761140	SCREW, (M10 x 40)
2	12-4002320	WASHER
3	8M0151040	BELT
4	833104T6	GEAR, Driven
5	17-878183	PIN, Dowel
6	400-8M0183249	CAMSHAFT
7	17-826149	PIN
8	857087T1	PUMP ASSEMBLY, Oil
9	25-857096	O-RING
10	NSS	NOT SOLD SEPARATE, O Ring
11	25-857094	O-RING
12	25-857093	O-RING
13	10-875206	SCREW, (M6 x 16)
14	10-4000333	SCREW, (M6 x 40)

▶Carburetor (36 parts)

Ref	OEM Part #	Part Name
-	8542561	REPAIR KIT, Carburetor Comment: (1 Per Carburetor)
1	3329-883313T4	CARBURETOR Comment: (Bottom)
2	10-854246	SCREW
3	854245	PLATE
4	27-8542572	GASKET
5	854254T2	ENRICHENER
6	NSS	NOT SOLD SEPARATE, O Ring
7	854255	PLATE
8	19-880814	CAP
9	10-880841	SCREW, Adjusting
10	25-880842	O-RING
11	24-880815	SPRING
12	80391242	JET, Pilot
13	25-880843	O-RING
14	19-880844	PLUG
15	80391595	JET, Main
16	8039143	MAIN NOZZLE
17	854247	VALVE, Float
18	8542531	FLOAT
19	17-8542581	PIN, Float
20	10-880845	SCREW
21	27-8542573	GASKET
22	8039171	FLOAT BOWL Comment: (Center/Bottom)
23	10-8542463	SCREW
24	10-8542464	SCREW, Drain
25	12-8542591	WASHER
26	10-803925	SCREW, Synchronization (Top/Center)
27	24-880846	SPRING (Top/Center)
28	24-803923	SPRING (Top/Center)
29	10-803913	SCREW (Bottom)
30	24-854249	SPRING (Bottom)
31	24-880847	SPRING
32	8542511	PLUNGER
33	10-880848	SCREW
34	NSS	NOT SOLD SEPARATE, Rubber Bellows
35	880849	PLUNGER ROD

▶Crankshaft, Pistons and Connecting Rods (15 parts)

Ref	OEM Part #	Part Name
-	61-803016T06	POWERHEAD ASSEMBLY Comment: (Long)
1	401-858507T04	CRANKSHAFT ASSEMBLY Comment: (Long)
2	28-893761	KEY
3	28-91800	KEY, Woodruff
4	8M0151047	SEAL
5	8M0151048	SEAL
6	600-893530T01	CONNECTING ROD
7	10-8M0049884	BOLT
8	23-893630002	BEARING, Blue Comment: (Blue)
9	700-893524T02	PISTON Comment: (.50MM Oversized)(Bare Piston)
10	39-893525A03	RING, Piston (Top) Comment: (.50MM Oversized)
11	NSS	NOT SOLD SEPARATE, Piston Ring (Second) Comment: (.50 MM Oversized)
12	39-893950	RING, Oil - Piston
13	41-893863	PIN, Piston
14	40-893529	RETAINER, Piston Pin

▶Cylinder Block (26 parts)

Ref	OEM Part #	Part Name
-	61-803016T06	POWERHEAD ASSEMBLY Comment: (Long)
1	800-893500T02	CYLINDER BLOCK Comment: (Long Shaft)
2	17-825010	PIN, Dowel
3	22-479452	PLUG
4	22-384073	PLUG, Pipe (.500-14)
5	22-416223	PLUG, Pipe (.750-14)
6	23-893631002	BEARING, Main - Blue Comment: (Blue)
7	822625	NIPPLE, (M20)
8	10-82506182	SCREW, (M8 x 82)
9	10-8M0205943	SCREW, (M6 x 35)
10	27-8M0163129	GASKET
11	35-8M0162830	FILTER, Oil Comment: (Quicksilver Branded)
12	27-8M4500244	GASKET
13	8M0183025	COVER, Exhaust
14	22-479452	PLUG
15	855676003	THERMOSTAT
16	27-8M0177107	GASKET
17	8M0188835	COVER
18	10-8M0205943	SCREW, (M6 x 35)
19	22-996642	FITTING, Elbow 90 Degree (.125-27 x .250) Nylon
20	54-816311T	TIE STRAP, (8.00 Inches)
21	8M0214984	SENSOR ASSEMBLY
22	25-627021	O-RING, (.301 x .070)
23	893697	LIFTING EYE
24	10-857139	SCREW, (M8 x 35)
25	32-77653101	HOSE, (48.00 Inches Bulk) (Cut to 19 Inches)- To Fitting in Adaptor Plate

▶Cylinder Head (25 parts)

Ref	OEM Part #	Part Name
-	61-803016T06	POWERHEAD ASSEMBLY Comment: (Long)
1	900-8M0224247	CYLINDER HEAD
2	858266	GUIDE
3	10-4000325	SCREW, (M6 x 8)
4	12-859768	WASHER
5	26-893549	SEAL, Oil
6	22-875209	PIPE PLUG
7	25-8M0162934	O-RING
8	8M0174399	COVER
9	22-825054	BREATHER PIPE
10	855236	PLATE, Baffle
11	10-4005685	SCREW, (M4 x 10)
12	NSS	NOT SOLD SEPARATE, Decal- Servicing Referral
13	NSS	NOT SOLD SEPARATE, Decal-Engine Oil/Valve Clearance
14	27-8M0118180	GASKET
15	10-8M0204741	SCREW, (M6 x 20) Stainless Steel
16	10-82503395	SCREW, (M9 x 95)
17	10-893745025	SCREW, (M6 x 25)
18	22-629101	FITTING, Elbow - 90 Degree (.125-27)
19	830294T1	BRACKET (Handle)
20	10-40011126	SCREW, (M6 x 13) Stainless Steel (Handle)
21	859578A1	PLUG ASSEMBLY, Oil
22	25-8M0204673	O-RING, (.921 x .139)
23	NSS	NOT SOLD SEPARATE, Decal- Horse Power Identification
24	17-825010	PIN, Dowel

▶Driveshaft Housing(Long) (25 parts)

Ref	OEM Part #	Part Name
1	1503-852421T07	HOUSING, Driveshaft - Long Comment: SN# 0P502070 & Up
2	825220T06	PIPE, Exhaust
3	10-824459110	SCREW, (M8 x 110) Stainless Steel
4	10-88960845	SCREW, (M8 x 45)
5	8288181	PLUG, Drain
6	27-8M0204692	GASKET
7	826276	BUMPER
8	8M0151042	GROMMET
9	16-823984	STUD, (M10 x 50)
10	12-8M0214963	WASHER, (.406 x .750 x .105) Stainless Steel
11	11-40140	NUT, (M10)
12	32-897971A01	TUBE, Water
13	54-828529	GUIDE
14	8M0043364	BUMPER
15	42941001	SEAL, Water Tube
16	893770	PLATE, Driveshaft Housing
17	10-1993325	SCREW, (M10 x 25 MM)
18	19-892286	CAP
19	54-816311T	TIE STRAP, (8.00 Inches)
20	22-8M0181450	FITTING
21	23-813745	SPACER
22	43585	COUPLING
23	23-855623	BUSHING
24	12-45176	WASHER, (.453 x .812 x .105) Stainless Steel
25	11-40140	NUT, (M10)

▶Driveshaft Housing(Short) (13 parts)

Ref	OEM Part #	Part Name
1	42941001	SEAL, Water Tube
2	1501-850168T5	HOUSING, Driveshaft
3	NSS	NOT SOLD SEPARATE, Exhaust Pipe
4	10-824459110	SCREW, (M8 x 110) Stainless Steel
5	10-88960845	SCREW, (M8 x 45)
6	8288181	PLUG, Drain
7	27-8M0204692	GASKET
8	826276	BUMPER
9	54-828529	GUIDE
10	16-823984	STUD, (M10 x 50)
11	12-8M0214963	WASHER, (.406 x .750 x .105) Stainless Steel
12	11-40140	NUT, (M10)
13	32-897970A01	TUBE, Water

▶Electrical Components (20 parts)

Ref	OEM Part #	Part Name
-	61-803016T06	POWERHEAD ASSEMBLY Comment: (Long)
1	8M0082988	SENSOR
2	10-40011107	SCREW, (M5 x 16) Stainless Steel
3	10-82130025	SCREW, (M6 x 25)
4	12-8M0214930	WASHER
5	859224	PLATE
6	23-856954	BUSHING
7	25-8M0190980	GROMMET
8	87843302S	ECM, Engine Control Module
9	23-8539201	BUSHING
10	10-82129140	SCREW, (M6 x 40)
11	84-859196T1	HARNESS ASSEMBLY, Engine Wiring
12	54-816311T	TIE STRAP, (8.00 Inches)
13	87-8M0098207	PRESSURE SWITCH
14	33-827858Q	SPARK PLUG, NGK-DPR6EA-9
15	339-858942T1	COIL ASSEMBLY, Ignition
16	10-8M0204741	SCREW, (M6 x 20) Stainless Steel
17	10-8248324	SCREW, (M6 x 16)
18	54-8M0024808	J CLIP
19	10-40011149	SCREW, (M8 x 25) Stainless Steel

▶Flywheel (11 parts)

Ref	OEM Part #	Part Name
-	61-803016T06	POWERHEAD ASSEMBLY Comment: (Long)
1	284-832010T27	FLYWHEEL
2	NSS	NOT SOLD SEPARATE, Decal-Warning Spinning Flywheel
3	NSS	NOT SOLD SEPARATE, Decal-Timing Marks
4	NSS	NOT SOLD SEPARATE, Decal-Warning-Neutral
5	11-893789	NUT
6	12-893762	WASHER
7	10-4013930	SCREW, (M5 x 30)
8	398-852386T6	STATOR
9	834838	LOAD RING
10	833102T	GEAR, Drive

▶Fuel Lines (17 parts)

Ref	OEM Part #	Part Name
1	32-856607	HOSE
2	32-856609	HOSE
3	856610	LINKAGE
4	23-803896	BUSHING
5	823548T	TIE STRAP
6	32-856613	HOSE
7	32-856611	HOSE and SLEEVE
8	22-822771	CONNECTOR
9	22-878404	FITTING, 45 Degree
10	32-878423	HOSE
11	32-85682239	TUBING, (17.00 Inches Bulk) (Cut to 3.5 Inches)
12	32-82381310	HOSE, (80 mm)
13	54-878425	CLIP
14	56762	TIE STRAP, (4.00 Inches)
15	12-8542592	WASHER
16	18-880850	COTTER PIN
17	22-878593	Y-CONNECTOR

▶Fuel Pump (13 parts)

Ref	OEM Part #	Part Name
-	25-16524	O-RING, Fuel Connector
1	8M0141844	PUMP, Fuel (Sold Complete Only)
2	8M0007776	DEFLECTOR, Cowl
3	10-82684430	SCREW, (M6 x 30)
4	32-8M0108349	TUBING, (.312) (70.00 Inches Bulk) (Cut to 13 Inches) To Block Exhaust Cover
5	32-8M0108349	TUBING, (.312) (70.00 Inches Bulk) (Cut to 6 Inches) To Telltale
6	32-856611	HOSE and SLEEVE, To Float Bowl
7	54-8M0024808	J CLIP
8	32-8M0108355	HOSE, (57.00 Inches Bulk) (Cut to 14 Inches)
9	35-877565T1	FILTER, Fuel
10	32-8M0108355	HOSE, (57.00 Inches Bulk) (Cut to 19 Inches)
11	54-816311T	TIE STRAP, (8.00 Inches)
12	22-8M0148585	CONNECTOR ASSEMBLY, Fuel

▶Gear Housing(Driveshaft-Long-2:1 Gear Ratio) (37 parts)

Ref	OEM Part #	Part Name
-	46-812966A12	REPAIR KIT, Water Pump
1	1671-9760T42	GEAR HOUSING ASSEMBLY, Basic
2	10-79953Q04	SCREW KIT, (.375-16 x .250) Drain
3	10-79953Q04	SCREW KIT, (.375-16 x .250) Drain
4	12-191833	SEAL
5	17-8M0084244	PIN, Dowel - With Hole (.375 x .625)
6	17-43044	PIN, Dowel - Without Hole (.375 x .625)
7	22-878089	PLUG, Pipe (.0625-27)
8	31-812768	BEARING, Roller
9	818226A1	SEAL/PLATE KIT
10	NSS	NOT SOLD SEPARATE, Filler Plate
11	43-8M0187297	GEAR, Pinion
12	11-55910	NUT, (.437-20)
13	859607A1	SHIFT SHAFT ASSEMBLY
14	53-29641	E RING
15	23-813696A2	BUSHING ASSEMBLY
16	25-45258	O-RING, (.987 x .103)
17	26-8M0204708	SEAL, Oil
18	45-859102	DRIVESHAFT, Long
19	15-812770A1	SHIM SET
20	31-8M0166756	BEARING ASSEMBLY, Roller
21	NSS	NOT SOLD SEPARATE, Cup
22	11-8128201	NUT
23	46-812966A7	BASE ASSEMBLY, Water Pump
24	25-8M0204651	O-RING, (1.859 x .139)
25	26-814669	SEAL, Oil
26	26-814670	SEAL, Oil
27	47-19453T	IMPELLER
28	28-8M0032831	KEY
29	12-8M0204720	WASHER
30	46-812966A12	PUMP ASSEMBLY, Water
31	27-8M0224241	GASKET (Lower)
32	27-822189	GASKET, Upper Water Pump (Upper)
33	19700A2	FACE PLATE
34	10-8248324	SCREW, (M6 x 16)
35	760394	CAM, Shift Control
36	8M0151045	COUPLER

▶Gear Housing(Driveshaft-Short-2:1 Gear Ratio) (39 parts)

Ref	OEM Part #	Part Name
-	821354A04	REPAIR KIT, Water Pump
1	1682-821306T12	GEAR HOUSING ASSEMBLY, Basic
2	818226A1	SEAL/PLATE KIT
3	NSS	NOT SOLD SEPARATE, Plate
4	10-79953Q04	SCREW KIT, (.375-16 x .250) Drain
5	26-8M0204693	SEAL
6	10-79953Q04	SCREW KIT, (.375-16 x .250) Drain
7	26-8M0204693	SEAL
8	11-55910	NUT, (.437-20)
9	43-821326T1	GEAR, Pinion - 13 Teeth
10	31-821321A2	BEARING ASSEMBLY
11	NSS	NOT SOLD SEPARATE, Cup
12	10-8248324	SCREW, (M6 x 16)
13	46-821351A3	HOUSING ASSEMBLY, Water Pump Upper
14	8M0151044	SEAL, Water Tube
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	45-826193T2	DRIVESHAFT
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	827865A2	SHIFT SHAFT
35	12-8M0204649	WASHER, (.281 x .500 x .060) Stainless Steel
36	17-85593	PIN, (.078 x .437)
37	8213161	CAM, Shift
38	17-822369	PIN, (.125 x .625)

▶Gear Housing, Propeller Shaft - Long-2:1 Gear Ratio (33 parts)

Ref	OEM Part #	Part Name
-	26-814669A2	SEAL KIT, Gear Housing
1	1671-9760T42	GEAR HOUSING ASSEMBLY, Basic
37	15-812769A1	SHIM SET
38	31-8M0103476	BEARING ASSEMBLY, Tapered Roller
39	NSS	NOT SOLD SEPARATE, Cup
40	43-893603T01	GEAR, Forward
41	31-21739	BEARING, Roller
42	8129291	FOLLOWER, Cam
43	20843	SLIDE
44	24-38114	SPRING
45	52-813697T	CLUTCH
46	17-8M0020942	PIN, Cross
47	24-815418	SPRING
48	44-14493	PROPELLER SHAFT
49	43-893605T	GEAR, Reverse
50	30-20839T	BEARING, Ball
51	8M0168900	CARRIER ASSEMBLY, Bearing
52	25-815460	O-RING
53	31-21700	BEARING, Needle
54	26-8M0205511	SEAL, Oil
55	26-8M0203757	SEAL, Oil
56	10-85594030	SCREW, (M8 x 30)
57	12-855941	WASHER, (.323 x .590 x .112) Stainless Steel
58	8227731	INSERT, Threaded
59	NSS	NOT SOLD SEPARATE, Decal-Gear Ratio
60	17264T2	TRIM TAB, Zinc
61	10-4000377	SCREW, (M10 x 30)
62	12-8M0214963	WASHER, (.406 x .750 x .105) Stainless Steel
63	73345A1	THRUST HUB
64	11-69578Q1	PROP NUT KIT
65	14-8M0214942	TAB WASHER
66	12-8M0214963	WASHER, (.406 x .750 x .105) Stainless Steel
67	10-4000380	SCREW, (M10 x 45)

▶Gear Housing, Propeller Shaft - Short-2:1 Gear Ratio (37 parts)

Ref	OEM Part #	Part Name
-	823547A03	SEAL KIT, Gear Housing
1	1682-821306T12	GEAR HOUSING ASSEMBLY, Basic
39	17-821327	PIN, Dowel
40	27-823942	GASKET
41	32-8M0026108	TUBE
42	19-824928001	PLUG, Rubber
43	821829	SCREEN
44	822157T2	TRIM TAB
45	10-82497020	SCREW, (M8 x 20)
46	12-72397	WASHER
47	43-821315T1	GEAR ASSEMBLY, Forward - 26 Teeth
48	31-8M0103470	BEARING ASSEMBLY, Roller
49	NSS	NOT SOLD SEPARATE, Cup
50	31-41326	BEARING, Roller
51	821578	FOLLOWER, Cam
52	24-8261991	SPRING
53	17-8M0020999	PIN
54	52-821314T	CLUTCH
55	24-38114	SPRING
56	44-8M0140441	PROPELLER SHAFT
57	43-821312T1	GEAR, Reverse - 26 Teeth
58	30-20839T	BEARING, Ball
59	8M0168900	CARRIER ASSEMBLY, Bearing
60	25-815460	O-RING
61	31-21700	BEARING, Needle
62	26-8M0205511	SEAL, Oil
63	26-8M0203757	SEAL, Oil
64	12-855941	WASHER, (.323 x .590 x .112) Stainless Steel
65	10-85594030	SCREW, (M8 x 30)
66	8227731	INSERT, Threaded
67	NSS	NOT SOLD SEPARATE, Decal 2:1
68	73345A1	THRUST HUB
69	11-69578Q1	PROP NUT KIT
70	14-8M0214942	TAB WASHER
71	10-4000380	SCREW, (M10 x 45)
72	12-8M0214963	WASHER, (.406 x .750 x .105) Stainless Steel
73	19-95925	PLUG

▶Intake (18 parts)

Ref	OEM Part #	Part Name
-	27-825231A02	GASKET SET, Engine
1	10-82615890	SCREW, (M6 x 90)
2	856126T	INTAKE, Air
3	25-856525	O-RING
4	834783T	PLATE
5	834784T	ISOLATOR
6	19-827633	PLUG
7	856127A2	ATTENUATOR ASSEMBLY, Sound
8	23-856954	BUSHING
9	10-8M0204741	SCREW, (M6 x 20) Stainless Steel
10	54-850181	TIE STRAP, (11.750 Inches)
11	26-856128001	SEAL
12	25-8250572	O-RING
13	25-8250572	O-RING
14	17-23784	PIN, Dowel
15	10-8248326	SCREW, (M6 x 25 MM)
16	32-8M0182223	BREATHER HOSE
17	54-816311T	TIE STRAP, (8.00 Inches)

▶Intake/Exhaust Valves (20 parts)

Ref	OEM Part #	Part Name
-	893504T02	CYLINDER HEAD ASSEMBLY
1	8M0065029	VALVE, Exhaust
2	832990T3	VALVE, Intake
3	26-858271	SEAL
4	24-893552	SPRING, Valve - Outer
5	822650	RETAINER
6	28-893554	KEY
7	898821A01	ROCKER ARM
8	10-825046	SCREW
9	11-826150	NUT
10	834780T1	SHAFT, Rocker
11	NSS	NOT SOLD SEPARATE, Plug
12	893560	BRACKET
13	24-893562	SPRING
14	893561	BRACKET
15	24-854713	SPRING
16	27-893645	GASKET
17	17-859575	PIN
18	10-875218	SCREW, (M8 x 23)
19	24-893563	SPRING, Overload

▶Key, Choke and Horn Kit, 15000A14 (12 parts)

Ref	OEM Part #	Part Name
-	15000A14	KEY SWITCH KIT, Remote Ignition
NS	86-8M0204694	CONNECTOR
1	NSS	NOT SOLD SEPARATE, Housing
2	NSS	NOT SOLD SEPARATE, Key Switch Kit Comment: Uses 89491 Series Keys
4	11-879755	NUT, Special - Black Nylon
5	16564A1	HORN ASSEMBLY, Warning
6	10-47994	SCREW, (#10 x 1.50), Top
7	10-62568	SCREW, (#10-16 x .375), Housing
8	54-816311T	TIE STRAP, (8.00 Inches)
9	13541	PLUG, Male
10	15097	SHEET, Neoprene
11	90468A1	COVER ASSEMBLY, Key

▶Linkage (32 parts)

Ref	OEM Part #	Part Name
1	10-40011158	SCREW, (M8 x 70) Stainless Steel
2	10-8147763	SCREW, (M6 x 60)
3	11-401196	NUT, (M6)
4	42942	CAP
5	822682A4	LEVER ASSEMBLY, Throttle
6	23-825078	BUSHING
7	8535853	CAM, Throttle
8	23-309772	SPACER
9	12-4002314	WASHER
10	10-40056107	SCREW, (M5 x 16)
11	826588A4	SHIFT SHAFT ASSEMBLY, Horizontal (Short)
12	8277071	RETAINER (Short)
13	12-8M0204649	WASHER, (.281 x .500 x .060) Stainless Steel (Short)
14	18-210711	COTTER PIN (Short)
15	24-826077	SPRING, Detent (Short)
16	24-824993	SPRING, Backing (Short)
17	824994	SPRING, Plate (Short)
18	10-40011107	SCREW, (M5 x 16) Stainless Steel (Short)
19	10-8248326	SCREW, (M6 x 25 MM) (Long)
20	858245	SHIFT GUIDE (Long)
21	10-82239312	SCREW, (M5 x 12) (Long)
22	858246	SHIFT SLIDE (Long)
23	12016A2	DETENT/SPRING KIT (Long)
24	NSS	NOT SOLD SEPARATE, Spring (Long)
25	858247	SHIFT ROD (Long)
26	18-210711	COTTER PIN (Long)
27	11-401386	NUT, (M6) Stainless Steel (Long)
28	12-8M0204649	WASHER, (.281 x .500 x .060) Stainless Steel (Long)
29	858248	SHIFT LINK (Long)
30	23-48475	BUSHING (Long)
31	23-850165	BUSHING (Long)
32	850166T2	LEVER ASSEMBLY, Shift Shaft

▶Manual Starter (33 parts)

Ref	OEM Part #	Part Name
-	835253A13	STARTER ASSEMBLY, Recoil
1	835253A12	HOUSING ASSEMBLY, Recoil
2	8167122	CAM
3	24-8267911	SPRING
4	8M0026455	SEAL
5	835256T	ROLLER
6	23-852987T	BUSHING
7	826414T	WASHER
8	10-82684430	SCREW, (M6 x 30)
9	13-826229	LOCKWASHER
10	24-86857T01	SPRING
11	50-854317T5	SHEAVE ASSEMBLY, Starter
12	868501	CAM
13	24-86851T02	SPRING
14	53-86849T01	RING, Retaining
15	24-868523	SPRING
16	86853T01	CAM
17	10-826253	SCREW, (.250-20 x .625)
18	50-12066Q10	ROPE
19	856073	LEVER, Interlock
20	856072T	RETAINER
21	24-856138T03	SPRING
22	854779T	BUSHING
23	10-8182491	SCREW, (#10-16 x 1.00)
24	85174A1	HANDLE ASSEMBLY
25	NSS	NOT SOLD SEPARATE, Retainer
26	10-8248326	SCREW, (M6 x 25 MM)
27	856754003	CABLE, Interlock (Included with complete Recoil Starter Assembly)
28	10-40011107	SCREW, (M5 x 16) Stainless Steel (Included with complete Recoil Starter Assembly)
29	12-73288	WASHER, (.220 x .500 x .030) Stainless Steel
30	18-26811	COTTER PIN
31	10-40011107	SCREW, (M5 x 16) Stainless Steel
32	37-804654A06	DECAL, EPA Label Information

▶Manual Tilt (15 parts)

Ref	OEM Part #	Part Name
-	25-893922A01	O-RING KIT
1	8M0118572	SHOCK ROD ASSEMBLY
2	893903A01	PISTON ASSEMBLY, Trim Memory
3	25-893917A01	O-RING KIT, Cylinder
4	NSS	NOT SOLD SEPARATE, O Ring
5	893918A01	CYLINDER ASSEMBLY
6	893919A01	SCREW AND SEAL KIT
7	893920A01	ACCUMULATOR ASSEMBLY
8	893921A01	VALVE BODY ASSEMBLY
9	893923A01	CAM KIT
10	893924A01	VALVE KIT, Velocity
11	893925A01	REPAIR KIT
12	8M0207768	CABLE ASSEMBLY, Ground
13	17-19607	PIN
14	17-821539	PIN, Trilobe

▶Powerhead Gasket Set Components (2 parts)

Ref	OEM Part #	Part Name
-	27-825231A02	GASKET SET, Engine
0	8M0151048	SEAL, Crankshaft-Bottom

▶Service/Support Material (1 parts)

Ref	OEM Part #	Part Name
-	37-804654A06	DECAL, EPA Label Information

▶Steering Arm (18 parts)

Ref	OEM Part #	Part Name
1	11-896963	NUT, (M12)
2	893773002	STRAP, Upper Mount
3	8M0224385	MOUNT, Upper
4	10-8M0204741	SCREW, (M6 x 20) Stainless Steel
5	8M0156878	BUMPER
6	53-89531	RING, Retaining
7	8M0118183	ARM, Steering
8	10-898835001	BOLT, (M12 x 154)
9	23-8279971	SPACER Comment: (Long)
10	893590T01	SWIVEL TUBE Comment: (Long)
11	84-88238T01	CABLE ASSEMBLY, Steering Arm to Driveshaft Housing
12	8M0207768	CABLE ASSEMBLY, Ground, Steering Arm to Swivel Bracket
13	10-8M0103829	SCREW, (M10 x 120) Comment: SN# 0P502070 & Up
14	893703	STRAP, Lower Mount
15	10-878607	SCREW, (#10-16 x .375)
16	11-40140	NUT, (M10)
17	12-45176	WASHER, (.453 x .812 x .105) Stainless Steel Comment: SN# 0P502069 & Below
18	12-4002319	WASHER Comment: SN# 0P502070 & Up

▶Swivel Bracket (17 parts)

Ref	OEM Part #	Part Name
1	1401-850066T01	SWIVEL BRACKET
2	23-19606	BEARING, Trim Pin
3	22-8M0169589	FITTING, Grease
4	37-8237011	DECAL, Co-Pilot
5	NSS	NOT SOLD SEPARATE, Decal-Serial Overlaminate
6	23-821777	BUSHING (Lower)
7	26-8M0205512	SEAL, Lower
8	10-4008910	SCREW, (M8 x 10) Stainless Steel
9	23-8217711	BUSHING, Upper
10	11-8M0204726	NUT, (.375-24) Stainless Steel
11	823792	LEVER, Co-Pilot
12	12-29330	WASHER
13	821961	ROD, Co-Pilot (Threaded)
14	8M0006845	PLATE/DISC ASSEMBLY
15	8M0007471	PLATE
16	8165621	DISC, Friction
17	10-768042	SHOULDER SCREW, Hex

▶Tiller Handle (43 parts)

Ref	OEM Part #	Part Name
-	37-8M0032728	DECAL, Lanyard, Black
1	822148T06	COVER KIT
2	822150	PULLEY
3	NSS	NOT SOLD SEPARATE, Case
4	10-878608	SCREW, (#10-16 x .500)
5	4324210	CABLE ASSEMBLY, Throttle (30.50 Inches)
6	4324211	CABLE ASSEMBLY, Throttle (41.50 Inches)
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
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
20	821465	HANDLE, Throttle
21	8M0221732	GRIP
22	87-8M0104614	SWITCH, Stop
23	10-82239312	SCREW, (M5 x 12)
24	12-8M0214930	WASHER
25	84-8M0088388	ALARM
26	823687	CLIP
27	87-11083A31	SWITCH, Stop
28	8M0032846	RETAINER, Brass
29	821455A4	BRACKET, Tiller
30	13-826792	WAVE WASHER
31	23-821477	BUSHING
32	12-827314	WASHER
33	32-828547633	CONDUIT, (.620 Inside Diameter x 3.00 Feet Bulk)
34	54-816311T	TIE STRAP, (8.00 Inches)
35	37-82409316	DECAL, F-N-R Shift
36	15920Q54	LANYARD ASSEMBLY
37	10-40011151	SCREW, (M8 x 35) Stainless Steel
38	830180A01	HANDLE
39	23-830181	BUSHING
40	8301821	SHIFT ROD (Short)
41	14-8M0009820	TAB WASHER
42	10-82484890	SCREW, (M10 x 90)

▶Tools 1 (23 parts)

Ref	OEM Part #	Part Name
1	44357Q2	FLUSHING ATTACHMENT
2	802889Q1	PUMP, Crankcase Oil
3	91-802653Q02	WRENCH, Oil Filter
4	91-8M0161873	HOLDER TOOL, Flywheel
5	91-83164M	FLYWHEEL PULLER
6	91-99379	TIMING LIGHT
7	91-890451	ADAPTOR TOOL, Direct Voltage
8	91-892647A01	MULTI-METER KIT, DMT 2004
9	91-823686A2	DIGITAL DIAGNOSTIC TESTER
10	91-8226086	CARTRIDGE
11	84-822560A7	HARNESS ASSEMBLY, Adaptor
12	84-822560A10	HARNESS ASSEMBLY, Adaptor
13	91-36392	GAUGE TOOL, Carburetor
14	91-809495001	REMOVER TOOL, Valve Guide
15	91-809496A1	INSTALLER TOOL, Valve Guide Bushing
16	91-809497A1	REAMER TOOL, Valve Guide
17	91-809494A1	COMPRESSOR TOOL, Valve Spring
18	NSS	NOT SOLD SEPARATE, Valve Seat cutter Kit Comment: OBTAIN LOCALLY
19	FT2997	COMPRESSOR TOOL, Piston Ring
20	91-827001A1	STAND TOOL, Powerhead
21	91-24697	EXPANDER TOOL, Piston Ring
22	91-74951	SPANNER WRENCH
23	91-822778A3	DOWN PRESSURE KIT

▶Tools 2 (29 parts)

Ref	OEM Part #	Part Name
-	91-31229A7	PULLER KIT, Bearing
24	91-63209	HEAT LAMP
25	31-85560	BEARING, Thrust
26	91-13779	REMOVER TOOL, Bearing
27	NSS	NOT SOLD SEPARATE, Expanding rod (P/N-CG-41-11)
28	NSS	NOT SOLD SEPARATE, Collet (P/N-CG-41-14)
29	11-24156	NUT, (.625-18)
30	12-34961	WASHER
31	91-29310	PLATE
32	91-31229	SHAFT
33	91-36571T	WRENCH TOOL, Driveshaft Bearing
34	91-37323	DRIVER ROD TOOL, Needle Bearings
35	91-15755T	MANDREL
36	91-36569T	DRIVE HEAD TOOL
37	91-27780	PULLER
38	91-37241	PULLER PLATE
39	91-37312T	DRIVER HEAD TOOL
40	91-817011T	INSTALLER TOOL, Needle Bearing
41	91-83180M	HOLDING TOOL, Driveshaft
42	91-825197T	INSTALLER TOOL, Oil Seal
43	91-817007T	INSTALLER TOOL, Seal
44	91-825198	MANDREL
45	91-825199	PILOT
46	91-825200A1	HOOK TOOL, Spring
47	91-826872	INSTALLER TOOL, Bearing
48	FT8950	TESTER KIT
49	91-12349A05	TOOL, Pinion Locating
50	91-13945	INSTALLATION TOOL, Bearing
51	91-13949	DRIVER TOOL, Oil Seal

▶Tools 3 (17 parts)

Ref	OEM Part #	Part Name
-	91-8M0162977	TOOL KIT (Included with Engine)(Includes Spark Plug Wrench)
52	91-14308T02	TOOL KIT, Bearing Race
53	91-14309T02	INSTALLATION TOOL, Bearing
54	91-14310T1	WEAR SLEEVE INSTALLATION TOOL
55	91-14311A04	TOOL, Preload
56	91-8M0053505	INDICATOR TOOL, Backlash
57	91-31106T	MANDREL, Bearing Driver Cup
58	91-31108T	DRIVER, Oil Seal
59	91-34569A1	PULLER ASSEMBLY, Slide Hammer
60	91-46086A1	PULLER JAW ASSEMBLY
61	91-37350T	MANDREL
62	91-56775T	HOLDING TOOL, Driveshaft
63	91-58222A1	DIAL INDICATOR TOOL
64	91-85716	PULLER TOOL
65	91-83155	ADAPTER KIT, Dial Indicator
66	91-83165T	PULLER ASSEMBLY
67	91-856875A1	INSTALLATION TOOL, Bearing

▶Top Cowl (18 parts)

Ref	OEM Part #	Part Name
-	37-803643A03	DECAL SET Comment: (Mariner)
1	102-834785T6	TOP COWL ASSEMBLY Comment: (Silver)
2	NSS	NOT SOLD SEPARATE, Induction Insert
3	826291F1	LATCH Comment: (Silver)
4	10-8231871	SCREW, (M4 x 14.5)
5	8,13-26995	LOCKWASHER, Stainless Steel
6	11-8237515	NUT, (M4)
7	8M0153618	SEAL
8	834786A04	SOUND BLANKET KIT
9	NSS	NOT SOLD SEPARATE, Sound Blanket-Top
10	893763	BRACKET, Roller Latch
11	10-4006731	SCREW, (M6 x 16)
12	8M0038412	BRACKET
13	10-8231871	SCREW, (M4 x 14.5)
14	8,13-26995	LOCKWASHER, Stainless Steel
15	11-8237515	NUT, (M4)
16	47341A11	ROPE AND HANDLE KIT, Manual Starting
17	854318	INSERT, Cowl

▶Transom Bracket (37 parts)

Ref	OEM Part #	Part Name
1	3418-822866T04	BRACKET, Transom - Port
2	22-8M0169588	FITTING, Grease
3	17-99604	PIN, Groove
4	3418-822865T05	BRACKET, Transom - Starboard
5	893704T01	LEVER ASSEMBLY, Tilt Lock
6	24-99622	SPRING
7	23-65830	NYLINER
8	24-812708	SPRING
9	812709	KNOB
10	17-99615	PIN, Groove
11	12-19619	WASHER
12	18486A08	BRACKET KIT, Anchor
13	97-818298Q1	ANODE KIT
14	10-8M0204707	SCREW, (M6 x 25)
15	12-8M0204649	WASHER, (.281 x .500 x .060) Stainless Steel
16	10-85594030	SCREW, (M8 x 30) Comment: (Included with Anchor Bracket Kit)
17	10-8M0000586	SCREW, (M8 x 35) Comment: (Included with Anchor Bracket Kit)
18	12-843108	WASHER, (.330 x .560 x .060) Stainless Steel Comment: (Included with Anchor Bracket Kit)
19	11-401388	NUT, (M8) Stainless Steel
20	17-8M0026068	PIN ASSEMBLY, Tilt Lock
21	24-821461	SPRING
22	8M0041938	TILT TUBE
23	11-858869	NUT, (.875-14)
24	10-814259	SCREW, (.500-20 x 4.00)
25	12-8M0204648	WASHER, (1.5 x 3.05 x 0.13) Stainless Steel
26	11-82671117	NUT, (.500-20)
27	8M0084737	LINK
28	19615A05	LEVER ASSEMBLY, Tilt
29	23-812707	BUSHING
30	12-8M0042643	WASHER, (.520 x .850 x .060) Nylon - Black
31	13-99611	WAVE WASHER
32	8M0007469	TILT KNOB
33	10-19611	SCREW, (.375-16 x .62)
34	10-4009040	SCREW, (M10 x 40) Stainless Steel
35	12-4002319	WASHER
36	11-40140	NUT, (M10)
37	37-830253	DECAL, Tilt Lock

▶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, 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)

100-Hour / Annual Service Checklist

Regular maintenance keeps your Mercury 40 CARB (3 CYL.)(4-STROKE) running reliably season after season. Most of these tasks can be performed with basic tools and the factory service manual.

Replace water pump impeller and inspect wear plate
Change engine oil and oil filter (check drain plug washer)
Replace spark plugs and check ignition timing
Drain and refill lower unit gear oil; inspect for water contamination
Inspect fuel lines, primer bulb, and fuel filter for deterioration
Check and replace sacrificial anodes (zinc or aluminum)
Inspect propeller for damage; check shaft seal and cotter pin
Check valve clearance (refer to service manual for specifications)
Lubricate all grease points (steering, tilt tube, shift linkage)
Inspect control cables and throttle/shift linkage for smooth operation

Pro Tip: Always flush the engine with fresh water after saltwater use — even a quick 10-minute flush significantly extends component life.
Pro Tip: Use fuel stabilizer in the tank before winter storage, and fog the cylinders to prevent internal corrosion during extended periods of non-use.

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