🔎 Mercury 40 CARB (3 CYL.)(4-STROKE) Reference Library — Exploded parts diagrams (33 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 (20 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
825228T27 |
ADAPTOR PLATE ASSEMBLY |
| 2 |
17-23784 |
PIN, Dowel |
| 3 |
8M0026249 |
DIPSTICK TUBE ASSEMBLY, Plastic |
| 4 |
8M0162935 |
DIPSTICK |
| 5 |
19-822464 |
PLUG |
| 6 |
19-48323 |
PLUG |
| 7 |
25-8M0179867 |
GROMMET |
| 8 |
22-629101 |
FITTING, Elbow - 90 Degree (.125-27) |
| 9 |
54-816311T |
TIE STRAP, (8.00 Inches) |
| 10 |
26-66301 |
SEAL, Oil |
| 11 |
23-859594 |
BUSHING |
| 12 |
10-4007455 |
SCREW, (M6 x 55) |
| 13 |
27-8M0213113 |
GASKET |
| 14 |
25-845746 |
O-RING |
| 15 |
10-8M0204741 |
SCREW, (M6 x 20) Stainless Steel |
| 16 |
893765 |
PLATE, Top Oil Pickup |
| 17 |
8M0210772 |
BODY, Oil Pressure Relief |
| 18 |
54-855228 |
CLAMP |
| 19 |
32-854793 |
HOSE, Oil Pickup |
| 20 |
893700 |
BAFFLE, Oil Pick-up |
▶Bottom Cowl (28 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
4020-826277T04 |
CHAP, Long - Port |
| 2 |
4020-826278T08 |
CHAP, Long - Starboard |
| 3 |
10-8M0230977 |
SCREW, (M6 x 25 MM) |
| 4 |
10-892073002 |
SHOULDER SCREW, (M6) |
| 5 |
8M0151037 |
BOOT |
| 6 |
8M0188541 |
SEAL |
| 7 |
889246T99 |
PAN |
| 8 |
19-897203 |
PLUG |
| 9 |
10-40011146 |
SCREW, (M8 x 13) Stainless Steel |
| 10 |
8M0151055 |
HOOK |
| 11 |
10-8M0103805 |
SCREW, (M6 x 16 MM) Stainless Steel |
| 12 |
8M4502035 |
GROMMET |
| 13 |
879147T24 |
CAP |
| 14 |
10-8M0103805 |
SCREW, (M6 x 16 MM) Stainless Steel |
| 15 |
10-8M0103807 |
SCREW, (M6 x 25 MM) Stainless Steel |
| 16 |
23-856954 |
BUSHING |
| 17 |
25-8M0025696 |
GROMMET |
| 18 |
888819002 |
DRAIN, Cowl |
| 19 |
822426T03 |
LATCH ASSEMBLY, Rear Comment: SN# 1C084459 & Up |
| 20 |
NSS |
NOT SOLD SEPARATE, Handle-Rear Latch Comment: SN# 1C084459 & Up |
| 21 |
8M0006060 |
SEAL |
| 22 |
8M0006062 |
LINK |
| 23 |
10-88552514 |
SCREW, (M6 x 14 MM) Stainless Steel |
| 24 |
12-897936 |
WASHER |
| 25 |
10-8M0103806 |
SCREW, (M6 x 20 MM) Stainless Steel |
| 26 |
8M0151043 |
GROMMET |
| 27 |
12-855576 |
WASHER Comment: NLA - No Longer Required |
| 28 |
22-827948 |
FITTING |
▶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 |
| - |
893714T05 |
POWERHEAD ASSEMBLY |
| 1 |
401-858507T04 |
CRANKSHAFT ASSEMBLY |
| 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 |
| 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 (28 parts)
| Ref |
OEM Part # |
Part Name |
| - |
893714T05 |
POWERHEAD ASSEMBLY |
| 1 |
800-893500T02 |
CYLINDER BLOCK ASSEMBLY |
| 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 |
| 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, Thermostat |
| 18 |
10-8M0205943 |
SCREW, (M6 x 35) |
| 19 |
35-8M0021770 |
STRAINER, Water |
| 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 |
| 26 |
54-8M0009374 |
CLAMP |
| 27 |
10-8248324 |
SCREW, (M6 x 16) |
▶Cylinder Head (26 parts)
| Ref |
OEM Part # |
Part Name |
| - |
893714T05 |
POWERHEAD ASSEMBLY |
| 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 |
SEAL |
| 8 |
8M0174399 |
COVER ASSEMBLY |
| 9 |
893711 |
PLATE, Baffle |
| 10 |
10-8M0001075 |
SCREW, (M4) |
| 11 |
NSS |
NOT SOLD SEPARATE, Decal- Servicing Referral |
| 12 |
NSS |
NOT SOLD SEPARATE, Decal-Engine Oil/Valve Clearance |
| 13 |
17-825010 |
PIN, Dowel |
| 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 Comment: Handle |
| 20 |
10-40011126 |
SCREW, (M6 x 13) Stainless Steel Comment: Handle |
| 21 |
859578A1 |
PLUG ASSEMBLY, Oil |
| 22 |
25-8M0204673 |
O-RING, (.921 x .139) |
| 23 |
NSS |
NOT SOLD SEPARATE, Decal- Horse Power Identification |
| 24 |
8M0026326 |
DEFLECTOR, Cowl |
| 25 |
10-8M0012661 |
SCREW |
▶Driveshaft Housing (22 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
1503-852421T07 |
HOUSING, Driveshaft - Long |
| 2 |
1503-852421T08 |
HOUSING, Driveshaft - Short |
| 3 |
NSS |
NOT SOLD SEPARATE, Exhaust Pipe Comment: Short |
| 4 |
10-88960845 |
SCREW, (M8 x 45) |
| 5 |
10-824459110 |
SCREW, (M8 x 110) Stainless Steel |
| 6 |
8288181 |
PLUG, Drain |
| 7 |
26-8M0007119 |
SEAL |
| 8 |
826276 |
BUMPER |
| 9 |
8M0151042 |
GROMMET Comment: Long |
| 10 |
22-8M0181450 |
FITTING Comment: Long |
| 11 |
54-816311T |
TIE STRAP, (8.00 Inches) Comment: Long |
| 12 |
19-892286 |
CAP Comment: Long |
| 13 |
8M0043364 |
BUMPER |
| 14 |
16-823984 |
STUD, (M10 x 50) |
| 15 |
12-8M0214963 |
WASHER, (.406 x .750 x .105) Stainless Steel |
| 16 |
11-40140 |
NUT, (M10) |
| 17 |
32-897971A01 |
TUBE/SEAL KIT, Water - Long |
| 18 |
32-897970A01 |
TUBE/SEAL KIT, Water - Short |
| 19 |
8M0151041 |
SEAL, Water |
| 20 |
54-828529 |
GUIDE |
| 21 |
893770 |
PLATE, Driveshaft Housing |
| 22 |
10-1993325 |
SCREW, (M10 x 25 MM) |
▶Electrical Components (20 parts)
| Ref |
OEM Part # |
Part Name |
| - |
893714T05 |
POWERHEAD ASSEMBLY |
| 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 |
| - |
893714T05 |
POWERHEAD ASSEMBLY |
| 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 |
32-8M0010663 |
HOSE ASSEMBLY, Carburetor Vent |
| 12 |
32-82381335 |
TUBING, (15.00 Inches Bulk), Cut to 3.15 Inches |
| 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 (11 parts)
| Ref |
OEM Part # |
Part Name |
| - |
25-16524 |
O-RING, Fuel Connector |
| 1 |
8M0141844 |
PUMP, Fuel, Sold Complete Only |
| 2 |
32-8M0108349 |
TUBING, (.312) (70.00 Inches Bulk), Cut to 13 Inches - To Block Exhaust Cover |
| 3 |
32-8M0108349 |
TUBING, (.312) (70.00 Inches Bulk), Cut to 6 Inches - To Telltale |
| 4 |
54-816311T |
TIE STRAP, (8.00 Inches) |
| 5 |
32-856611 |
HOSE and SLEEVE, To Float Bowl |
| 6 |
32-8M0108355 |
HOSE, (57.00 Inches Bulk), Cut to 14 Inches |
| 7 |
35-877565T1 |
FILTER, Fuel |
| 8 |
32-8M0108355 |
HOSE, (57.00 Inches Bulk), Cut to 19 Inches |
| 9 |
22-8M0148585 |
CONNECTOR ASSEMBLY, Fuel |
| 10 |
10-88552535 |
SCREW, (M6 x 35 MM) Stainless Steel |
▶Gear Housing, Driveshaft - 2:1 Gear Ratio (41 parts)
| Ref |
OEM Part # |
Part Name |
| - |
46-812966A12 |
REPAIR KIT, Water Pump |
| 1 |
893680T06 |
GEAR HOUSING ASSEMBLY, Basic |
| 2 |
10-79953Q04 |
SCREW KIT, Drain |
| 3 |
97-826134Q |
ANODE |
| 4 |
17-8M0084244 |
PIN, Dowel - With Hole (.375 x .625) |
| 5 |
17-43044 |
PIN, Dowel - Without Hole (.375 x .625) |
| 6 |
10-897657055 |
SCREW, (M6 x 55) |
| 7 |
11-401386 |
NUT, (M6) Stainless Steel |
| 8 |
818226A1 |
SEAL/PLATE KIT |
| 9 |
NSS |
NOT SOLD SEPARATE, Filler Plate |
| 10 |
43-8M0187297 |
GEAR, Pinion |
| 11 |
8M0012285 |
CAM, Shift |
| 12 |
11-55910 |
NUT, (.437-20) |
| 13 |
26-8M0204693 |
SEAL |
| 14 |
22-878089 |
PLUG, Pipe (.0625-27) |
| 15 |
31-812768 |
BEARING, Roller |
| 16 |
889246A96 |
SHIFT SHAFT ASSEMBLY |
| 17 |
53-29641 |
E RING |
| 18 |
23-813696A2 |
BUSHING ASSEMBLY |
| 19 |
25-45258 |
O-RING, (.987 x .103) |
| 20 |
26-8M0204708 |
SEAL, Oil |
| 21 |
45-859102 |
DRIVESHAFT, Long |
| 22 |
15-812770A1 |
SHIM SET |
| 23 |
31-8M0166756 |
BEARING ASSEMBLY, Roller |
| 24 |
NSS |
NOT SOLD SEPARATE, Cup |
| 25 |
11-8128201 |
NUT |
| 26 |
46-812966A7 |
BASE ASSEMBLY, Water Pump |
| 27 |
25-8M0204651 |
O-RING, (1.859 x .139) |
| 28 |
26-814669 |
SEAL, Oil |
| 29 |
26-814670 |
SEAL, Oil |
| 30 |
47-19453T |
IMPELLER |
| 31 |
28-8M0032831 |
KEY |
| 32 |
12-8M0204720 |
WASHER |
| 33 |
46-812966A12 |
PUMP ASSEMBLY, Water |
| 34 |
27-8M0224241 |
GASKET, Lower |
| 35 |
27-822189 |
GASKET, Upper Water Pump |
| 36 |
19700A2 |
FACE PLATE |
| 37 |
10-8248324 |
SCREW, (M6 x 16) |
| 38 |
8M0151046 |
COUPLING, Short |
| 39 |
8M0151045 |
COUPLER, Long |
| 40 |
23-891637 |
BUSHING |
▶Gear Housing, Propeller Shaft - 2:1 Gear Ratio (39 parts)
| Ref |
OEM Part # |
Part Name |
| - |
26-814669A2 |
SEAL KIT, Gear Housing |
| 1 |
893680T06 |
GEAR HOUSING ASSEMBLY, Basic |
| 2 |
8227731 |
INSERT, Threaded |
| 3 |
43-821315T02 |
GEAR ASSEMBLY, Forward |
| 4 |
31-889246A95 |
BEARING ASSEMBLY, Roller |
| 5 |
NSS |
NOT SOLD SEPARATE, Cup |
| 6 |
31-21700 |
BEARING, Needle |
| 7 |
8M0005743 |
ROD ACTUATOR |
| 8 |
17-8M0084682 |
PIN, Spring |
| 9 |
24-79910 |
SPRING Comment: Design I SN# 1C267558 & Below |
| 10 |
12-78910 |
WASHER |
| 11 |
52-821314T01 |
CLUTCH |
| 12 |
17-8M0009287 |
PIN, Cross Comment: Design I SN# 1C267558 & Below |
| 13 |
24-38114 |
SPRING |
| 14 |
44-826193T03 |
PROPELLER SHAFT |
| 15 |
43-821312T02 |
GEAR, Reverse |
| 16 |
30-20839T |
BEARING, Ball |
| 17 |
8M0168900 |
CARRIER ASSEMBLY, Bearing |
| 18 |
25-815460 |
O-RING |
| 19 |
31-21700 |
BEARING, Needle |
| 20 |
26-8M0205511 |
SEAL, Oil |
| 21 |
26-8M0203757 |
SEAL, Oil |
| 22 |
10-85594030 |
SCREW, (M8 x 30) |
| 23 |
12-855941 |
WASHER, (.323 x .590 x .112) Stainless Steel |
| 24 |
15-889246A98 |
SHIM SET |
| 25 |
NSS |
NOT SOLD SEPARATE, Decal-Gear Ratio |
| 26 |
17264T2 |
TRIM TAB, Zinc |
| 27 |
10-858771 |
SCREW, (M10 x 30) |
| 28 |
8M0008716 |
CAM, Follower |
| 29 |
17-8M0091340 |
SPRING / PIN KIT Comment: Design II SN# 1C267559 & Up |
| 30 |
NSS |
NOT SOLD SEPARATE, PIN Comment: Design II SN# 1C267559 & Up |
| 31 |
NSS |
NOT SOLD SEPARATE, SPRING Comment: Design II SN# 1C267559 & Up |
| 32 |
NSS |
NOT SOLD SEPARATE, GUIDE, Spring Comment: Design II SN# 1C267559 & Up |
| 33 |
73345A1 |
THRUST HUB |
| 34 |
11-69578Q1 |
PROP NUT KIT |
| 35 |
14-8M0214942 |
TAB WASHER |
| 36 |
12-8M0214963 |
WASHER, (.406 x .750 x .105) Stainless Steel |
| 37 |
10-4000380 |
SCREW, (M10 x 45) |
| 38 |
12-8M0214963 |
WASHER, (.406 x .750 x .105) Stainless Steel |
▶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 |
| - |
893714T05 |
POWERHEAD 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 |
▶Manual Starter (33 parts)
| Ref |
OEM Part # |
Part Name |
| - |
835253T14 |
HOUSING ASSEMBLY |
| 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 |
NSS |
NOT SOLD SEPARATE, DECAL, EPA (2009 & Up) Comment: (Contact Mercury Marine Warranty Administration for Replacement-Service Bulletin 2009-18) |
▶Manual Tilt (15 parts)
| Ref |
OEM Part # |
Part Name |
| - |
25-893922A01 |
O-RING KIT |
| 1 |
8M0118572 |
SHOCK ROD KIT |
| 2 |
893903A01 |
PISTON KIT |
| 3 |
25-893917A01 |
REBUILD KIT, O-Ring |
| 4 |
NSS |
NOT SOLD SEPARATE, O Ring |
| 5 |
893918A01 |
CYLINDER KIT |
| 6 |
893919A01 |
SCREW/SEAL KIT |
| 7 |
893920A01 |
ACCUMULATOR KIT |
| 8 |
893921A01 |
VALVE BODY KIT |
| 9 |
893923A01 |
CAM KIT |
| 10 |
893924A01 |
VALVE KIT |
| 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 |
| - |
NSS |
NOT SOLD SEPARATE, DECAL, EPA (2009 & Up) Comment: (Contact Mercury Marine Warranty Administration for Replacement-Service Bulletin 2009-18) |
▶Shift Linkage (16 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
8M0001557 |
SLIDE, Shift |
| 2 |
12016A2 |
DETENT/SPRING KIT |
| 3 |
NSS |
NOT SOLD SEPARATE, Spring-Compression, Detent |
| 4 |
8M0001157 |
PIN, Bow Tie Clip |
| 5 |
12-35462 |
WASHER, (.2656 x .625 x .0625) Stainless Steel |
| 6 |
12-8M0204649 |
WASHER, (.281 x .500 x .060) Stainless Steel |
| 7 |
18-210711 |
COTTER PIN |
| 8 |
8M0005914 |
ROD, Shift |
| 9 |
11-401386 |
NUT, (M6) Stainless Steel |
| 10 |
8M0007151 |
LINK, Shift |
| 11 |
23-892263 |
BUSHING |
| 12 |
8M0192159 |
BRACKET, Shift Link |
| 13 |
10-8M0204706 |
SCREW, (M6 x 20) |
| 14 |
8M0091611 |
SHIFT SHAFT, Upper - Short |
| 15 |
23-74647 |
NYLINER |
| 16 |
888823001 |
SHIFT DETENT ASSEMBLY |
▶Steering Arm (17 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 |
8M0219911 |
SWIVEL TUBE ASSEMBLY, 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) |
| 14 |
893703 |
STRAP, Lower Mount |
| 15 |
10-878607 |
SCREW, (#10-16 x .375) |
| 16 |
11-40140 |
NUT, (M10) |
| 17 |
12-4002319 |
WASHER |
▶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) Brass |
| 11 |
823792 |
LEVER, Co-Pilot |
| 12 |
12-29330 |
WASHER |
| 13 |
821961 |
ROD, Co-Pilot - Threaded |
| 14 |
8M0006845 |
PLATE/DISC ASSEMBLY, Brake |
| 15 |
8M0007471 |
PLATE, Swivel Head |
| 16 |
8165621 |
DISC, Friction |
| 17 |
10-768042 |
SHOULDER SCREW, Hex |
▶Throttle Linkage (10 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
10-4010770 |
SCREW, (M8 x 70) |
| 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) |
▶Tiller Handle (41 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 |
10-8M0021519 |
SHOULDER SCREW, (10 x 20) |
| 38 |
830180A01 |
HANDLE KIT, Shift |
| 39 |
14-8M0009820 |
TAB WASHER |
| 40 |
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 (11 parts)
| Ref |
OEM Part # |
Part Name |
| - |
37-8M0012388 |
DECAL, 40 |
| 1 |
100-8M0118169 |
TOP COWL ASSEMBLY, Mariner |
| 2 |
8M0118172 |
CAP, Air Dam - Mariner |
| 3 |
10-8M0103805 |
SCREW, (M6 x 16 MM) Stainless Steel |
| 4 |
8M0006055 |
BRACKET |
| 5 |
826291T02 |
BRACKET, Front Latch |
| 6 |
10-8231871 |
SCREW, (M4 x 14.5) |
| 7 |
12-89302 |
WASHER, (.203 x .406 x .040) |
| 8 |
11-400632 |
NUT |
| 9 |
834786A05 |
SOUND BLANKET KIT |
| 10 |
8M0109278 |
SEAL |
▶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, Tilt Lock |
| 6 |
24-99622 |
SPRING |
| 7 |
23-65830 |
NYLINER |
| 8 |
24-812708 |
SPRING |
| 9 |
8M0007470 |
KNOB |
| 10 |
17-8M0021914 |
PIN , (.125 x 30 mm) |
| 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.
