Mercury 40 EFI (4 CYL.)(4-STROKE) (1C050252 & Up) Parts & Diagrams

🔎 Mercury 40 EFI (4 CYL.)(4-STROKE) Reference Library — Exploded parts diagrams (51 diagrams), specifications, common issues, and maintenance checklist.

The Mercury 40 EFI (4 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 EFI (4 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 EFI (4 CYL.)(4-STROKE).

▶Accessories (1 parts)

Ref	OEM Part #	Part Name
-	87-897978T02	LED LIGHT AND SWITCH KIT Comment: Used with Big Tiller Handle Assembly

▶Adaptor Plate (28 parts)

Ref	OEM Part #	Part Name
-	27-883599A02	GASKET SET
1	825228T27	ADAPTOR PLATE ASSEMBLY
2	17-23784	PIN, Dowel
3	8M0026249	DIPSTICK TUBE ASSEMBLY, Plastic
4	25-8M0008708	O-RING
5	8M0162935	DIPSTICK
6	10-4006731	SCREW, (M6 x 16)
7	19-822464	PLUG
8	25-19565002	GROMMET
9	22-629101	FITTING, Elbow - 90 Degree (.125-27)
10	54-816311T	TIE STRAP, (8.00 Inches)
11	26-66301	SEAL, Oil
12	23-859594	BUSHING
13	10-4007455	SCREW, (M6 x 55)
14	27-8M0213113	GASKET
15	25-845746	O-RING
16	10-8M0204741	SCREW, (M6 x 20) Stainless Steel
17	893765	PLATE, Top Oil Pickup
18	54-855228	CLAMP
19	32-854793	HOSE, Oil Pickup
20	893700	BAFFLE, Oil Pick-up
21	8M0210772	BODY, Oil Pressure Relief
22	19-8M0021330	PLUG, (M18)
23	54-899145	CLIP, Tie Strap
24	54-816311T	TIE STRAP, (8.00 Inches)
25	32-8M0108355	HOSE, (57.00 Inches Bulk), Cut to 17 Inches
26	22-291112	FITTING
27	19-8M0162962	PLUG Comment: Jet

▶Big Tiller Handle Kit Components, 40-60 EFI 4-Stroke, Manual (28 parts)

Ref	OEM Part #	Part Name
-	879291A04	TILLER HANDLE ASSEMBLY, Big Tiller, 40-60 EFI FourStroke, Manual Mechanical Non Power Steering Comment: 40-50-60 EFI FourStroke
1	879346T20	COVER
2	879347A01	EMERGENCY STOP SWITCH
3	8M0032846	RETAINER, Brass
4	87-8M0044351	LANYARD ASSEMBLY, Stop Switch - 70 inch
5	87-897716K01	SWITCH KIT, Ignition (3 Position) With Keys Comment: See Switch Kit parts breakdown for replacement keys.
6	11-897716001	NUT, Plastic-Key Switch
7	879347A02	TRIM SWITCH ASSEMBLY
8	8M0030401	CAP, Handle Trim Switch
9	10-4005685	SCREW, (M4 x 10)
10	879347A03	HARNESS AND PLATE ASSEMBLY
11	84-8M0210763	ALARM ASSEMBLY, Audio Warning
12	54-816311T	TIE STRAP, (8.00 Inches)
13	10-4005685	SCREW, (M4 x 10)
14	11-8M0204726	NUT, (.375-24) Stainless Steel
15	823792	LEVER
16	12-29330	WASHER
17	821961	ROD
18	8M0006845	PLATE/DISC ASSEMBLY, Brake
19	8165621	DISC
20	8M0007471	PLATE, Swivel Head
21	10-768042	SHOULDER SCREW, Hex
22	37-8237011	DECAL, Co-Pilot
23	22-8M0169589	FITTING, Grease
24	10-4008910	SCREW, (M8 x 10) Stainless Steel
25	87-8M0083437	CONTROL KIT, Trolling
26	8M0082354	THROTTLE AND SHIFT KIT, 40-60 EFI FourStroke (32.5 In. Shift, 36 In. Throttle) Comment: Order Separate-Mechanical Application
27	87-897978T02	LED LIGHT AND SWITCH KIT Comment: Optional - Order Separate

▶Big Tiller Handle Kit(40-60 EFI FourStroke-Manual) (67 parts)

Ref	OEM Part #	Part Name
-	37-8M0032728	DECAL, Lanyard, Black
NS	90-8M0063659	OPERATION MANUAL, Big Tiller -Manual, Mechanical and DTS
1	879346T02	HOUSING, Steering Handle, Upper
2	879346A01	SHIFT HANDLE ASSEMBLY
3	10-83002430	SCREW
4	10-8M0103813	SCREW, (M8 x 30)
5	879346T15	COVER, Shift Handle-Mercury
6	8M0165596	THROTTLE GRIP ASSEMBLY
7	879346T06	GRIP, Rubber
8	11-8M0034107	NUT
9	12-8M0024573	WASHER
10	8M0022037	GROMMET
11	879346T08	CHASSIS, Throttle Grip
12	8M0030401	CAP, Handle Trim Switch
13	10-4005685	SCREW, (M4 x 10)
14	23-8M0021535	BUSHING
15	17-8M0022764	DOWEL PIN
16	879346T16	BEARING CAP
17	10-88552514	SCREW, (M6 x 14 MM) Stainless Steel
18	25-879346T19	GROMMET
19	23-8M0035136	BUSHING
20	8M0045301	GROMMET
21	10-823567105	SCREW, (M10 x 105) Hex Flange - Stainless Steel
22	12-4002319	WASHER
23	12-12024	WASHER, (.402 x .787 x .039 Bellevi)
24	23-8M0031370	BUSHING
25	879346T26	BRACKET
26	11-826292	NUT, (M10) Brass/Nickel Plated
27	10-82484890	SCREW, (M10 x 90)
28	14-8M0044744	TAB WASHER
29	12-4002319	WASHER
30	879346T12	TILT LOCK ASSEMBLY
31	879346T11	HANDLE
32	37-8M0033313	DECAL, On-Off-Start
33	37-8M0029029	DECAL, Throttle
34	37-8M0029030	DECAL, R-N-F
35	879347T07	GEAR PLATE ASSEMBLY
36	879347A04	SHIFT ARM AND GEAR ASSEMBLY
37	23-8M0022826	BUSHING
38	53-29641	E RING
39	879347A05	THROTTLE GEAR ASSEMBLY
40	53-29641	E RING
41	17-8M0028305	PIN
42	15-8M0028543	SHIM, (.040)
43	23-8M0027443	PILLOW BLOCK
44	23-8M0028294	BUSHING
45	10-8M0103808	SCREW, (M6 x 30 MM) Stainless Steel
46	NSS	NOT SOLD SEPARATE, Throttle Shaft
47	8M4501323	BLOCK, Friction
48	10-8M0031550	SCREW, (M4 x 0.7 x 16)
49	879347A08	SPRING AND GUIDE KIT
50	8M0028323	RETAINER
51	84-879347T06	SWITCH, Neutral
52	10-8M0034874	SCREW, (M3 x 0.5)
53	11-8M0034875	NUT, (M3 x 0.5 Hex)
54	10-8M0085515	SCREW, (#8-32 x .375), Not included in Gear Plate Assembly
55	879346T04	COVER, Steering Handle, Lower
56	10-4001991	SCREW, (M4 x 35)
57	879346T10	COVER, Switch/Light
58	25-828249	GROMMET
59	879346A03	THROTTLE FRICTION KNOB ASSEMBLY
60	53-29641	E RING
61	10-4001987	SCREW, (M4 x 16)
62	10-8M0085515	SCREW, (#8-32 x .375)
63	8M0028230	RETAINER
64	10-82130010	SCREW, (M6 x 10)
65	879346T17	BRACKET, Shift Mount

▶Bottom Cowl (29 parts)

Ref	OEM Part #	Part Name
-	880093A03	TILLER HANDLE KIT, Remote Control to Tiller Handle
1	4020-852554T03	CHAP, Short - Port Comment: Jet
2	4020-852555T06	CHAP, Short - Starboard Comment: Jet
3	10-8M0230977	SCREW, (M6 x 25 MM) Comment: Quantity of 4 on Jet
4	10-892073002	SHOULDER SCREW, (M6)
5	8M0151037	BOOT
6	8M0188541	SEAL
7	889246T99	PAN
8	22-827948	FITTING
9	87-8M0235191	SWITCH, Trim
10	8M0151055	HOOK
11	10-8M0103806	SCREW, (M6 x 20 MM) Stainless Steel
12	8M4502035	GROMMET
13	879147T25	CAP, Camouflage
14	10-8M0103806	SCREW, (M6 x 20 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# 1C081903 & Up
20	NSS	NOT SOLD SEPARATE, Handle-Rear Latch Comment: SN# 1C081903 & 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	54-850181	TIE STRAP, (11.750 Inches)

▶Camshaft and Oil Pump (11 parts)

Ref	OEM Part #	Part Name
-	893505T05	CYLINDER HEAD ASSEMBLY
1	400-8M0183247	CAMSHAFT
2	17-826149	PIN
3	17-878183	PIN, Dowel
4	857087T1	PUMP ASSEMBLY, Oil
5	25-857096	O-RING
6	NSS	NOT SOLD SEPARATE, O Ring
7	25-857094	O-RING
8	25-857093	O-RING
9	10-875206	SCREW, (M6 x 16)
10	10-4000333	SCREW, (M6 x 40)

▶Crankshaft, Pistons and Connecting Rods (15 parts)

Ref	OEM Part #	Part Name
-	61-893678T03	POWERHEAD ASSEMBLY
1	413-857077T02	CRANKSHAFT ASSEMBLY
2	28-91800	KEY, Woodruff
3	28-893761	KEY
4	8M0151047	SEAL
5	8M0151048	SEAL
6	600-893530T01	CONNECTING ROD
7	10-8M0049884	BOLT
8	23-893630002	BEARING, Blue
9	700-893524T02	PISTON ASSEMBLY Comment: .50MM Oversized/Bare Piston
10	39-893525A03	RING SET, Ring Comment: .50MM Oversized
11	NSS	NOT SOLD SEPARATE, Piston Ring - Second Comment: 50 MM Oversized
12	NSS	NOT SOLD SEPARATE, Ring, Piston Oil
13	41-893863	PIN, Piston
14	40-893529	RETAINER, Piston Pin

▶Cylinder Block and Crankcase (27 parts)

Ref	OEM Part #	Part Name
-	61-893678T03	POWERHEAD ASSEMBLY
1	800-893502T02	CYLINDER BLOCK ASSEMBLY
2	17-825010	PIN, Dowel
3	22-479452	PLUG
4	22-889567	PLUG, (.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	35-8M0162829	FILTER, Oil
12	27-8M0224375	GASKET
13	8M0188836	COVER ASSEMBLY, Exhaust
14	22-479452	PLUG
15	14586	THERMOSTAT
16	27-887978	GASKET
17	27-8M0177107	GASKET
18	8M0188835	COVER
19	10-8M0205943	SCREW, (M6 x 35)
20	35-8M0021770	STRAINER, Water
21	8M0214984	SENSOR ASSEMBLY
22	25-627021	O-RING, (.301 x .070)
23	893697	LIFTING EYE
24	10-857139	SCREW, (M8 x 35)
25	54-816311T	TIE STRAP, (8.00 Inches)
26	32-8M0108349	TUBING, (.312) (70.00 Inches Bulk), Cut to 10 Inches - To VST Cooler

▶Cylinder Head (27 parts)

Ref	OEM Part #	Part Name
-	61-893678T03	POWERHEAD ASSEMBLY Comment: (Does Not Include Cylinder Head)
1	893505T06	CYLINDER HEAD ASSEMBLY
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	25-8M0011870	SEAL
8	8M0174400	COVER ASSEMBLY
9	NSS	NOT SOLD SEPARATE, Breather Pipe
10	NSS	NOT SOLD SEPARATE, Baffle Plate
11	NSS	NOT SOLD SEPARATE, Screw
12	22-629101	FITTING, Elbow - 90 Degree (.125-27)
13	27-8M0118179	GASKET
14	10-8M0204741	SCREW, (M6 x 20) Stainless Steel
15	10-82503395	SCREW, (M9 x 95)
16	17-825010	PIN, Dowel
17	859578A1	PLUG ASSEMBLY, Oil
18	25-8M0204673	O-RING, (.921 x .139)
19	NSS	NOT SOLD SEPARATE, Decal-Servicing Referral
20	NSS	NOT SOLD SEPARATE, Decal-Engine Oil/Valve Clearance
21	32-77653101	HOSE, (48.00 Inches Bulk), Cut to 19 Inches - To Fitting in Adaptor Plate
22	54-816311T	TIE STRAP, (8.00 Inches)
23	10-893745025	SCREW, (M6 x 25)
24	NSS	NOT SOLD SEPARATE, Decal HP ID
25	8M0026326	DEFLECTOR, Cowl
26	10-8M0012661	SCREW

▶Driveshaft Housing (20 parts)

Ref	OEM Part #	Part Name
1	1503-852421T09	HOUSING, Driveshaft Comment: Jet
2	NSS	NOT SOLD SEPARATE, Retainer Assembly Comment: Jet
3	10-1993325	SCREW, (M10 x 25) Comment: Jet
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: Non-Jet
10	22-8M0181450	FITTING Comment: Non-Jet
11	54-816311T	TIE STRAP, (8.00 Inches) Comment: Non-Jet
12	19-892286	CAP Comment: Non-Jet
13	8M0043364	BUMPER Comment: Non-Jet
14	16-903501	STUD, (M10 x 100) Comment: Bigfoot/Non-Jet
15	12-8M0214963	WASHER, (.406 x .750 x .105) Stainless Steel
16	11-40140	NUT, (M10) Comment: Non-Jet
17	32-897970A01	TUBE/SEAL KIT, Water - Short Comment: Jet
18	8M0151041	SEAL, Water
19	54-828529	GUIDE
20	893770	PLATE, Driveshaft Housing

▶Electrical Components, 1C104423/0P560349 and Below (43 parts)

Ref	OEM Part #	Part Name
-	61-893678T03	POWERHEAD ASSEMBLY
1	10-82129125	SCREW, (M6 x 25 MM)
2	893774002	BRACKET
3	12-8M0214930	WASHER
4	25-8M0190980	GROMMET
5	898369T09	ECM, Engine Control Module Comment: 60 Horsepower EU
6	23-856954	BUSHING
7	33-883323001	SPARK PLUG
8	84-897940T01	HARNESS ASSEMBLY, Fuse
9	54-858954	CLIP, (.625)
10	54-879962	CLIP, Part of Electrical Harness
11	8M0022449	PLATE
12	10-8248324	SCREW, (M6 x 16)
13	54-24836	CLIP
14	8M0007734	BRACE
15	10-82129114	SCREW, (M6 x 14)
16	893768	PLATE, Solenoid
17	10-82129114	SCREW, (M6 x 14)
18	8M0010250	BRACKET
19	825096T01	RELAY
20	84-93388A16	CABLE ASSEMBLY, (8.50 Inches)
21	11-401386	NUT, (M6) Stainless Steel
22	84-88439A9	CABLE ASSEMBLY, Battery - Positive
23	85-880786	BOOT, Insulator - Red
24	84-893666T04	HARNESS ASSEMBLY
25	88-8M0207797	FUSE, Mini - Gray - 2 Ampere
26	NSS	NOT SOLD SEPARATE, Cover
27	84-883834T01	CABLE ASSEMBLY, Diode
28	13541	PLUG, Male
29	8M0082988	SENSOR, Crank Position
30	10-40011107	SCREW, (M5 x 16) Stainless Steel
31	893640T01	REGULATOR, Voltage
32	893771	BRACKET, Connector
33	8308971	FOAM PAD
34	10-8248329	SCREW, (M6 x 40)
35	87-8M0098207	PRESSURE SWITCH
36	50-893888T	STARTER MOTOR ASSEMBLY, Complete
37	11-94330	NUT, (.250-20) Brass
38	84-88439A4	CABLE ASSEMBLY, Battery - Negative
39	54-8M0024808	J CLIP
40	10-40011153	SCREW, (M8 x 45) Stainless Steel
41	10-82239312	SCREW, (M5 x 12)
42	54-816311T	TIE STRAP, (8.00 Inches)

▶Electrical Components, 1C104424/0P560350 and Up (43 parts)

Ref	OEM Part #	Part Name
-	61-893678T03	POWERHEAD ASSEMBLY
1	10-82129125	SCREW, (M6 x 25 MM)
2	893774002	BRACKET
3	12-8M0214930	WASHER
4	25-8M0190980	GROMMET
5	8M0059790	ECM, Engine Control Module - 60 EU
6	23-856954	BUSHING
7	33-883323001	SPARK PLUG
8	84-897940T01	HARNESS ASSEMBLY, Fuse
9	54-858954	CLIP, (.625)
10	54-879962	CLIP, Part of Electrical Harness
11	8M0022449	PLATE
12	10-8248324	SCREW, (M6 x 16)
13	54-24836	CLIP
14	8M0007734	BRACE
15	10-82129114	SCREW, (M6 x 14)
16	893768	PLATE, Solenoid
17	10-82129114	SCREW, (M6 x 14)
18	8M0010250	BRACKET
19	825096T01	RELAY
20	84-93388A16	CABLE ASSEMBLY, (8.50 Inches)
21	11-401386	NUT, (M6) Stainless Steel
22	84-88439A9	CABLE ASSEMBLY, Battery - Positive
23	85-880786	BOOT, Insulator - Red
24	84-8M0044999	HARNESS ASSEMBLY
25	88-8M0207797	FUSE, Mini - Gray - 2 Ampere
26	8M0045270	COVER
27	84-883834T01	CABLE ASSEMBLY, Diode
28	13541	PLUG, Male
29	8M0082988	SENSOR, Crank Position
30	10-40011107	SCREW, (M5 x 16) Stainless Steel
31	893640T01	REGULATOR, Voltage
32	893771	BRACKET, Connector
33	8308971	FOAM PAD
34	10-8248329	SCREW, (M6 x 40)
35	87-8M0098207	PRESSURE SWITCH
36	50-893888T	STARTER MOTOR ASSEMBLY, Complete
37	11-94330	NUT, (.250-20) Brass
38	84-88439A4	CABLE ASSEMBLY, Battery - Negative
39	54-8M0024808	J CLIP
40	10-40011153	SCREW, (M8 x 45) Stainless Steel
41	10-82239312	SCREW, (M5 x 12)
42	54-816311T	TIE STRAP, (8.00 Inches)

▶Extension Kit - 2.5 Inch, Driveshaft Housing (879150A88) (26 parts)

Ref	OEM Part #	Part Name
-	90-879345036	INSTRUCTION SHEET, Extension Kit
1	816696T5	SPACER
2	17-43044	PIN, Dowel - Without Hole (.375 x .625)
3	17-8M0084244	PIN, Dowel - With Hole (.375 x .625)
4	16-8M0034425	STUD, (M10 x 120)
5	12-8M0214963	WASHER, (.406 x .750 x .105) Stainless Steel
6	11-40140	NUT, (M10)
7	23-813745	SPACER
8	25-45258	O-RING, (.987 x .103)
9	879172A39	SHIFT SHAFT ASSEMBLY
10	53-29641	E RING
11	8M0151045	COUPLER
12	32-8289372	TUBE, Water
13	430232	SEAL
14	45-880184	DRIVESHAFT
15	15-812770A1	SHIM SET
16	26-8M0204708	SEAL, Oil
17	46-812966A7	BASE ASSEMBLY, Water Pump
18	25-8M0204651	O-RING, (1.859 x .139)
19	26-814669	SEAL, Oil
20	26-814670	SEAL, Oil
21	27-822189	GASKET, Upper Water Pump
22	27-8M0224241	GASKET
23	25-815460	O-RING
24	26-8M0204693	SEAL
25	11-559101	NUT, Pinion Gear

▶Extension Kit - 5 Inch, Driveshaft Housing (12092A20) (24 parts)

Ref	OEM Part #	Part Name
-	26-816575A2	SEAL KIT
NS	NSS	NOT SOLD SEPARATE, TOOL, Seal Kit Setting
1	12092A3	SPACER KIT
2	17-8M0084244	PIN, Dowel - With Hole (.375 x .625)
3	17-43044	PIN, Dowel - Without Hole (.375 x .625)
4	16-8M0034462	STUD, (M10 x 190)
5	16-9035015	STUD, (M10 x 227)
6	12-8M0214963	WASHER, (.406 x .750 x .105) Stainless Steel
7	11-40140	NUT, (M10)
8	25-8M0214974	O-RING
9	26-8M0204693	SEAL
10	11-35921	NUT, (.625-18)
11	27-8M0214931	GASKET
12	866233001	FACEPLATE
13	26-8M0142851	SEAL, Face
14	430232	SEAL
15	32-8M4501430	TUBE, Water
16	8M0151044	COUPLER
17	45-875222A1	DRIVESHAFT ASSEMBLY
18	25-8M0204681	O-RING, (1.424 x .103)
19	884565A00	SHIFT SHAFT ASSEMBLY
20	53-29641	E RING
21	23-813745	SPACER
22	92-8M0215008	LOCTITE 271 THREADLOCKER, .5 ml

▶Extension Kit, Driveshaft Housing 12092A20 - Bigfoot (19 parts)

Ref	OEM Part #	Part Name
-	12092A20	CONVERSION KIT, X-Long-Bigfoot
1	12092A3	SPACER KIT
2	17-8M0084244	PIN, Dowel - With Hole (.375 x .625)
3	17-43044	PIN, Dowel - Without Hole (.375 x .625)
4	16-903503	STUD, (M10 x 190)
5	16-903502	STUD, (M10 x 227)
6	23-813745	SPACER
7	12-8M0214963	WASHER, (.406 x .750 x .105) Stainless Steel
8	11-40140	NUT, (M10)
9	25-8M0214974	O-RING
10	26-8M0204693	SEAL
11	8M0151044	COUPLER
12	32-8M4501430	TUBE, Water
13	430232	SEAL
14	27-8M0214931	GASKET
15	45-875222A1	DRIVESHAFT ASSEMBLY
16	884565A00	SHIFT SHAFT ASSEMBLY
17	53-29641	E RING
18	25-8M0204681	O-RING, (1.424 x .103)

▶Flywheel (18 parts)

Ref	OEM Part #	Part Name
1	859284T2	FLYWHEEL COVER
2	10-8248326	SCREW, (M6 x 25 MM)
3	NSS	NOT SOLD SEPARATE, DECAL, EPA (2009 & Up) Comment: (Contact Mercury Marine Warranty Administration for Replacement-Service Bulletin 2009-18)
4	200-8M0118173	FLYWHEEL Comment: Serial No. 1C104424 and Up
5	54-816311T	TIE STRAP, (8.00 Inches)
6	NSS	NOT SOLD SEPARATE, Decal-Warning Spinning Flywheel
7	NSS	NOT SOLD SEPARATE, Decal-Timing Marks
8	NSS	NOT SOLD SEPARATE, Decal-Warning-Neutral
9	11-893789	NUT
10	12-893762	WASHER
11	10-4013930	SCREW, (M5 x 30)
12	398-878143T05	STATOR
13	834838	LOAD RING
14	833102T	GEAR, Drive
15	8M0151040	BELT
16	833104T6	GEAR, Driven
17	10-82761140	SCREW, (M10 x 40)
18	12-4002320	WASHER

▶Fuel Lines (5 parts)

Ref	OEM Part #	Part Name
1	32-828547353	CONDUIT, (.350 Inside Diameter x 3.00 Feet Bulk), Cut to 24 Inches
2	32-8M0222164	LINE, Fuel Comment: SN# 1C109093 & Up
3	35-879885Q	FILTER, Fuel
4	8775381	PROTECTIVE SLEEVE
5	32-8M0111510	LINE, Fuel Comment: SN# 1C109093 & Up

▶Fuel Pump (22 parts)

Ref	OEM Part #	Part Name
1	8M0141827	PUMP ASSEMBLY, Fuel
2	32-828547T1	CONDUIT, (.500 Inside Diameter x 3.00 Feet Bulk), Cut to 26 Inches
3	10-82684430	SCREW, (M6 x 30)
4	32-8M0108349	TUBING, (.312) (70.00 Inches Bulk), To VST Cooler - Cut to 37 Inches
5	32-8M0108355	HOSE, (57.00 Inches Bulk), To Vapor Separator Cover - Cut to 16.5 Inches
6	32-8M0108349	TUBING, (.312) (70.00 Inches Bulk), To Telltale - Cut to 6 Inches
7	54-888988023	CLAMP
8	32-8M0108355	HOSE, (57.00 Inches Bulk), Cut to 8 Inches
9	35-879884T	FILTER, Fuel
10	32-8M0108355	HOSE, (57.00 Inches Bulk), Cut to 31.50 Inches Comment: Handle
11	22-8M0148584	FITTING ASSEMBLY, Fuel Comment: Handle
12	23-856954	BUSHING
13	25-8M0190980	GROMMET
14	12-8M0214930	WASHER
15	11-401196	NUT, (M6)
16	22-8M0022500	FITTING, Reducer Comment: Remote
17	54-8M0022218	CLAMP
18	10-8M0022331	SCREW, Ratchet
19	893772	BRACKET
20	10-8M0082833	SCREW, M6 x 13 stainless steel, Pack of 2 Comment: Big Tiller Gas Assist
21	32-828547633	CONDUIT, (.620 Inside Diameter x 3.00 Feet Bulk)
22	10-88552535	SCREW, (M6 x 35 MM) Stainless Steel

▶Gear Housing, Driveshaft - 1.83:1 Gear Ratio (40 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	43-859103T	GEAR, Pinion - 12 Teeth
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	8M0151045	COUPLER
39	23-891637	BUSHING

▶Gear Housing, Driveshaft - 2.33:1 Gear Ratio (44 parts)

Ref	OEM Part #	Part Name
-	31-803496T2	BEARING/SEAL KIT
NS	NSS	NOT SOLD SEPARATE, TOOL, Face Seal Setting
1	1600-8M0118594	GEAR HOUSING ASSEMBLY, Basic
2	17-8M0084244	PIN, Dowel - With Hole (.375 x .625) , Front
3	43046	TUBE, Oiler
4	10-79953Q04	SCREW KIT, Drain
5	26-8M0204693	SEAL
6	17-43044	PIN, Dowel - Without Hole (.375 x .625), Rear
7	31640T07	TRIM TAB
8	10-825427	SCREW, (.437-14 x 1.250) Stainless Steel
9	12-451761	WASHER, (.453 x .812 x .105) Black Oxide
10	43040T1	CARRIER ASSEMBLY
11	NSS	NOT SOLD SEPARATE, Needle Bearing
12	97-826134Q	ANODE
13	11-401386	NUT, (M6) Stainless Steel
14	10-4000333	SCREW, (M6 x 40)
15	NSS	NOT SOLD SEPARATE, Pinion Gear - Part of Forward Gear Kit
16	11-35921	NUT, (.625-18)
17	31-883047A1	BEARING ASSEMBLY, Tapered Roller
18	15-44492A1	SHIM SET
19	45-875222A1	DRIVESHAFT ASSEMBLY Comment: (X-Long)
20	42461A1	SLEEVE/RING KIT
21	NSS	NOT SOLD SEPARATE, Ring-Seal
22	43055A4	COVER ASSEMBLY, Water Pump
23	27-430331	GASKET
24	27-8M0214931	GASKET
25	26-43036	SEAL, Oil, Lower
26	26-43035	SEAL, Oil, Upper
27	27-8172771	GASKET
28	817275A2	HOUSING KIT, Upper Water Pump
29	8M0204709	FACEPLATE
30	10-82684430	SCREW, (M6 x 30)
31	8M0151044	COUPLER
32	28-8M0204723	KEY
33	47-43026T2	IMPELLER
34	10-82684425	SCREW, (M6 x 25)
35	26-8M0142851	SEAL, Face
36	884565A00	SHIFT SHAFT ASSEMBLY Comment: (X-Long)
37	53-29641	E RING
38	23-43052A4	BUSHING ASSEMBLY
39	25-8M0204681	O-RING, (1.424 x .103)
40	26-8M0204708	SEAL, Oil
41	10-82684425	SCREW, (M6 x 25)
42	23-891637	BUSHING

▶Gear Housing, Propeller Shaft - 1.83:1 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	43-859101T03	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	43-859104T01	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

▶Gear Housing, Propeller Shaft - 2.33:1 Gear Ratio (32 parts)

Ref	OEM Part #	Part Name
-	52-888805A00	REPAIR KIT, Clutch And Cam Follower
1	1600-8M0118594	GEAR HOUSING ASSEMBLY, Basic
2	8227731	INSERT, Threaded
3	899070	FOLLOWER, Cam
4	8M4504018	CAM, Shift
5	888806	ROD, Clutch Actuator
6	17-8M0084243	PIN, Cross
7	17-8M0084245	PIN, Spring Locator
8	24-79910	SPRING
9	12-78910	WASHER
10	15-44491A1	SHIM SET
11	31-30894A1	BEARING SET, Cup And Cone
12	NSS	NOT SOLD SEPARATE, Cup
13	43-882813A3	GEAR KIT, Forward And Pinion 28 Teeth
14	31-30895T	BEARING, Needle
15	53-856823	RING, Retaining
16	52-888805T	CLUTCH
17	44-8M0140444	PROPELLER SHAFT
18	24-30893	SPRING
19	43-889990T	GEAR, Reverse
20	8M0168901	CARRIER ASSEMBLY, Bearing
21	25-8M0214974	O-RING
22	31-30956T	BEARING, Needle
23	26-8M0205728	SEAL, Oil, Inner
24	26-8M0205729	SEAL, Oil, Outer
25	31-12578T	BEARING, Roller
26	12-12577	THRUST WASHER
27	31-12576	BEARING, Thrust
28	16-8M0034456	STUD, (M8 x 48)
29	12-855941	WASHER, (.323 x .590 x .112) Stainless Steel
30	11-401378	NUT, (M8)
31	NSS	NOT SOLD SEPARATE, Decal-Gearcase Pinion Identification

▶Ignition Coil Mounting, 1C104423/0P560349 and Below (20 parts)

Ref	OEM Part #	Part Name
1	892869T	PLATE, Coil
2	300-8M0077471	COIL, Ignition
3	84-881908T	CABLE SET
4	23-8M0206979	SPACER
5	10-82129145	SCREW, (M6 x 45)
6	8M0207773	RELAY ASSEMBLY
7	828102	BRACKET
8	25-818967	GROMMET
9	23-8M0214955	BUSHING
10	10-82129125	SCREW, (M6 x 25 MM)
11	54-8M0024807	CLIP
12	84-826802T36	HARNESS ASSEMBLY, Trim
13	23-856954	BUSHING
14	25-8M0190980	GROMMET
15	84-858414A3	CABLE ASSEMBLY
16	12-8M0204649	WASHER, (.281 x .500 x .060) Stainless Steel
17	10-82129114	SCREW, (M6 x 14)
18	10-8M0103807	SCREW, (M6 x 25 MM) Stainless Steel
19	12-8M0214930	WASHER
20	54-8M0024808	J-CLIP

▶Ignition Coil Mounting, 1C104424/0P560350 and Up (17 parts)

Ref	OEM Part #	Part Name
1	8M0044994	COIL PLATE
2	300-8M0044991	COIL, Ignition Dual Output
3	84-881908T	CABLE SET
4	10-82129130	SCREW, (M6 x 30)
5	8M0207773	RELAY ASSEMBLY
6	828102	BRACKET
7	25-818967	GROMMET
8	23-8M0214955	BUSHING
9	10-82129125	SCREW, (M6 x 25 MM)
10	54-8M0024808	J-CLIP
11	10-82129110	SCREW, (M6 x 10)
12	23-856954	BUSHING
13	25-8M0190980	GROMMET
14	10-8M0103807	SCREW, (M6 x 25 MM) Stainless Steel
15	12-8M0214930	WASHER
16	54-898454	CLIP, (19 mm)
17	84-826802T36	HARNESS ASSEMBLY, Trim

▶Intake Manifold (31 parts)

Ref	OEM Part #	Part Name
-	27-883599A02	GASKET SET
1	877829T01	MANIFOLD, Intake
2	27-879866	GASKET SET Comment: (Contains 4 Gaskets)
3	10-881059	SCREW
4	877834	BRACKET
5	11-401366	NUT, (M6) Stainless Steel
6	877805T	SOLENOID VALVE
7	879887T	TFI SYSTEM
8	892123002	INJECTOR
9	10-881059	SCREW
10	10-881059	SCREW
11	54-883460	CLIP
12	32-877831A1	HOSE
13	877831A02	THROTTLE BODY ASSEMBLY
14	10-8M0000578	SCREW, Adjustment
15	10-881059	SCREW
16	8M0125617	SENSOR, Position
17	10-881060	SCREW
18	854445	SENSOR, MAP
19	8M0148668	SENSOR ASSEMBLY
20	25-896699	O-RING, (1.78 mm x .08 mm)
21	27-879867	GASKET
22	893521	ATTENUATOR
23	10-8248326	SCREW, (M6 x 25 MM)
24	8831482	RESTRICTOR Comment: 40 Horsepower/Non Jet
25	32-8M0113740	HOSE, Breather
26	10-82684430	SCREW, (M6 x 30)
27	54-850181	TIE STRAP, (11.750 Inches)
28	10-8214281	SCREW, (#10-16 x .625)
29	8M0007495	RETAINER
30	10-8248326	SCREW, (M6 x 25 MM) Comment: Big Tiller Gas Assist

▶Intake/Exhaust Valves (19 parts)

Ref	OEM Part #	Part Name
-	893505T05	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	8570851	SHAFT, Rocker
11	NSS	NOT SOLD SEPARATE, Plug
12	893560	BRACKET
13	893561	BRACKET
14	24-893562	SPRING
15	10-875218	SCREW, (M8 x 23)
16	27-893645	GASKET
17	17-859575	PIN
18	24-893563	SPRING, Overload

▶Jet Unit (31 parts)

Ref	OEM Part #	Part Name
-	NSS	NOT SOLD SEPARATE, Jet Unit-Complete
1	855767T01	HOUSING, Pump
2	878377T01	LINKAGE KIT, Shift
3	878382	CAM
4	878380T01	REVERSE GATE, With Bumper
5	32-827490	HOSE, Lube
6	16-8M0034456	STUD, (M8 x 48)
7	11-401388	NUT, (M8) Stainless Steel
8	10-4007153	SCREW, (M8 x 25)
9	47-8M0230713	IMPELLER
10	801412T02	HOUSING, Intake
11	827188T02	LINER
12	45-855769T01	DRIVESHAFT
13	12-8796522	THRUST WASHER
14	30-8796531	BEARING, Ball
15	23-8271891	SLEEVE
16	11-8271901	NUT
17	12-36001	WASHER
18	28-801405875	KEY
19	15-801404875	SHIM, Impeller
20	14-801403875	TAB WASHER
21	10-8M0214928	SCREW, (M6 x 16)
22	10-8M0009111	SCREW, (M8 x 30)
23	898101382	BRACKET, Cable Support
24	11-401388	NUT, (M8) Stainless Steel
25	17-43044	PIN, Dowel - Without Hole (.375 x .625)
26	10-1995660	SCREW, (M10 x 60)
27	10-4010890	SCREW, (M10 x 90)
28	10-1995670	SCREW, (M10 x 70)
29	12-8M0214930	WASHER
30	12-4002317	WASHER

▶Jet Water Pump Components (9 parts)

Ref	OEM Part #	Part Name
1	8M0151046	COUPLING, Short
2	46-812966A12	PUMP ASSEMBLY, Water
3	27-822189	GASKET, Upper Water Pump
4	8M0001338	FACE PLATE
5	12-8M0204720	WASHER
6	27-8M0224241	GASKET
7	10-8248324	SCREW, (M6 x 16)
8	28-8M0032831	KEY
9	47-19453T	IMPELLER

▶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 Tilt Components (15 parts)

Ref	OEM Part #	Part Name
-	25-893922A01	O-RING KIT, Tilt Overhaul
1	8M0118573	SHOCK ROD KIT
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	893933A01	ACCUMULATOR ASSEMBLY
8	893921A01	VALVE BODY ASSEMBLY
9	893923A01	CAM KIT
10	893924A01	VALVE KIT, Velocity
11	893925A01	REPAIR KIT, Velocity Valve
12	8M0207768	CABLE ASSEMBLY, Ground
13	17-19607	PIN
14	17-821539	PIN, Trilobe

▶Power Trim (20 parts)

Ref	OEM Part #	Part Name
-	25-893914A02	O-RING KIT
1	8M0118573	SHOCK ROD KIT
2	8M0171822	PISTON ASSEMBLY, Memory
3	25-8M0171819	O-RING KIT
4	NSS	NOT SOLD SEPARATE, O Ring
5	893904T01	CYLINDER ASSEMBLY
6	893944A01	VAVLE KIT, Trim Limit
7	893906A02	PUMP ASSEMBLY
8	893907A02	MOTOR KIT
9	22-8134351	PLUG
10	893929A01	VALVE KIT, Relief
11	893909A02	MANIFOLD KIT
12	10-809876A1	SCREW KIT, Motor
13	809877A1	DRIVESHAFT/SEAL KIT
14	35-893912A02	FILTER KIT
15	893913A02	POPPET KIT
16	88238A18	CABLE ASSEMBLY
17	17-821539	PIN, Trilobe
18	17-19607	PIN
19	17-822869001	PIN

▶Powerhead Gasket Set Components (2 parts)

Ref	OEM Part #	Part Name
-	27-883599A02	GASKET SET
0	25-845746	O-RING, Oil Pick-UP Plate

▶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, Big Tiller Gas Assist (14 parts)

Ref	OEM Part #	Part Name
1	899044	LATCH
2	824015	CUP, Barrel Retainer
3	8M0192158	BRACKET
4	10-8M0204706	SCREW, (M6 x 20)
5	8M0001157	PIN, Bow Tie Clip
6	899042	ROLLER
7	12-888832	WASHER
8	899041	LINK, Shift
9	11-401386	NUT, (M6) Stainless Steel
10	12-35462	WASHER, (.2656 x .625 x .0625) Stainless Steel
11	23-892263	BUSHING
12	8M0091612	SHIFT SHAFT, Upper - Long
13	23-74647	NYLINER
14	888823001	SHIFT DETENT ASSEMBLY

▶Shift Linkage, Remote (14 parts)

Ref	OEM Part #	Part Name
1	899044	LATCH
2	824015	CUP, Barrel Retainer
3	8M0192158	BRACKET
4	10-8M0204706	SCREW, (M6 x 20)
5	8M0001157	PIN, Bow Tie Clip
6	899042	ROLLER
7	12-888832	WASHER
8	899041	LINK, Shift
9	11-401386	NUT, (M6) Stainless Steel
10	12-35462	WASHER, (.2656 x .625 x .0625) Stainless Steel
11	23-892263	BUSHING
12	8M0091612	SHIFT SHAFT, Upper - Long
13	23-74647	NYLINER
14	888823001	SHIFT DETENT ASSEMBLY

▶Shift Linkage, Tiller, Design I-Shift Detent (20 parts)

Ref	OEM Part #	Part Name
-	880093A03	TILLER HANDLE KIT, Remote Control to Tiller Handle
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	87-8M0052940	SWITCH ASSEMBLY
15	10-69570	SCREW, (#10-16 x .750)
16	56762	TIE STRAP, (4.00 Inches)
17	8M0091612	SHIFT SHAFT, Upper - Long
18	23-74647	NYLINER
19	888823001	SHIFT DETENT ASSEMBLY

▶Shift Linkage, Tiller, Design II-No Shift Detent (19 parts)

Ref	OEM Part #	Part Name
-	880093A03	TILLER HANDLE KIT, Remote Control to Tiller Handle
1	8M0162940	SLIDE, Shift
2	8M0075211	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	898289T33	BRACKET
13	10-8M0204706	SCREW, (M6 x 20)
14	87-8M0052940	SWITCH ASSEMBLY
15	10-69570	SCREW, (#10-16 x .750)
16	56762	TIE STRAP, (4.00 Inches)
17	8M0091612	SHIFT SHAFT, Upper - Long
18	23-74647	NYLINER

▶Steering Arm (26 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	SCREW, (M12 x 154)
9	23-8279973	SPACER Comment: Jet
10	8M0219910	SWIVEL TUBE ASSEMBLY, Short Comment: Jet
11	84-88238T01	CABLE ASSEMBLY
12	8M0207768	CABLE ASSEMBLY, Ground Comment: Jet
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	8M0026161	LINK ROD Comment: Non Handle
18	10-823919	SCREW, (.375-24 x 1.500) Comment: Non Handle
19	12-8M0109680	WASHER, (.390 x .546 x .12) Comment: Non Handle
20	12-37828	WASHER, (.390 x .625 x .062) Stainless Steel Comment: Non Handle
21	11-8M0204726	NUT, (.375-24) Brass Comment: Non Handle
22	11-8M0204726	NUT, (.375-24) Stainless Steel Comment: Non Handle
23	8M0184092	BRACKET, Ride-Guide Comment: Non Handle
24	14-8M0009820	TAB WASHER Comment: Jet
25	10-4000377	SCREW, (M10 x 30) Comment: Non Handle
26	12-4002319	WASHER

▶Swivel Bracket (25 parts)

Ref	OEM Part #	Part Name
-	880093A03	TILLER HANDLE KIT, Remote Control to Tiller Handle
1	1401-850066T01	SWIVEL BRACKET
2	23-19606	BEARING, Trim Pin
3	22-8M0169589	FITTING, Grease
4	22-8M0169589	FITTING, Grease Comment: Handle
5	37-8237011	DECAL, Co-Pilot Comment: Handle
6	NSS	NOT SOLD SEPARATE, Decal-Serial Overlaminate
7	23-821777	BUSHING, Lower
8	26-8M0205512	SEAL
9	10-40011149	SCREW, (M8 x 25) Stainless Steel
10	8282451	SEAL, Co-Pilot
11	822397	PUCK Comment: Non Handle
12	23-8217711	BUSHING
13	11-8M0204726	NUT, (.375-24) Stainless Steel Comment: Handle
14	823792	LEVER, Co-Pilot Comment: Handle
15	12-29330	WASHER Comment: Handle
16	821961	ROD, Threaded Comment: Handle
17	8M0006845	PLATE/DISC ASSEMBLY, Brake Comment: Handle
18	8M0007471	PLATE, Swivel Head Comment: Handle
19	8165621	DISC, Friction Comment: Handle
20	10-768042	SHOULDER SCREW, Hex Comment: Handle
21	821400A2	SENDER KIT, Power Trim
22	10-41069	SCREW, (#10-24 x .750)
23	10,13-26996	LOCKWASHER, Stainless Steel
24	12-89302	WASHER, (.203 x .406 x .040)

▶Throttle Linkage, Big Tiller Gas Assist (12 parts)

Ref	OEM Part #	Part Name
1	8M0006021	LINK ASSEMBLY, Throttle
2	8M0084742	SOCKET
3	24-897535005	SPRING, Throttle Cam Return
4	12-897937	WASHER
5	13-898093	WASHER, Wave
6	10-8M0071815	BOLT
7	8M0021603	CAM, Throttle
8	8M0001157	PIN, Bow Tie Clip
9	23-8M0215006	BUSHING
10	8M0008317	FOLLOWER, Cam
11	8M0037159	ROLLER
12	12-897936	WASHER

▶Throttle Linkage, Jet (20 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	8226824	LEVER, Throttle
6	883160	RETAINER
7	10-8248329	SCREW, (M6 x 40)
8	879865	CAM, Throttle
9	23-8M0215006	BUSHING
10	10-8214281	SCREW, (#10-16 x .625)
11	23-883005	BUSHING
12	883006A1	ARM ASSEMBLY, Throttle
13	893780A01	LINK ASSEMBLY, Throttle
14	8M0084742	SOCKET
15	23-825078	BUSHING
16	8M0007035	SPACER, (1.49 x 22 x 24)
17	827706A4	BRACKET
18	98889	LATCH
19	10-8248324	SCREW, (M6 x 16)
20	23-15885	SLEEVE

▶Throttle Linkage, Remote (12 parts)

Ref	OEM Part #	Part Name
1	8M0006021	LINK ASSEMBLY, Throttle
2	8M0084742	SOCKET
3	24-897535005	SPRING, Throttle Cam Return
4	12-897937	WASHER
5	13-898093	WASHER, Wave
6	10-8M0071815	BOLT
7	8M0021603	CAM, Throttle
8	8M0001157	PIN, Bow Tie Clip
9	23-8M0215006	BUSHING
10	8M0008317	FOLLOWER, Cam
11	8M0037159	ROLLER
12	12-897936	WASHER

▶Throttle Linkage, Tiller (17 parts)

Ref	OEM Part #	Part Name
-	880093A03	TILLER HANDLE KIT, Remote Control to Tiller Handle
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	830294T3	BRACKET
7	10-8M0204741	SCREW, (M6 x 20) Stainless Steel
8	23-825078	BUSHING
9	879865	CAM, Throttle
10	10-8248329	SCREW, (M6 x 40)
11	883006A1	ARM ASSEMBLY, Throttle
12	23-883005	BUSHING
13	10-8214281	SCREW, (#10-16 x .625)
14	23-8M0215006	BUSHING
15	893775A01	LINK ASSEMBLY, Throttle
16	8M0084742	SOCKET

▶Tiller Handle (40 parts)

Ref	OEM Part #	Part Name
-	880093A03	TILLER HANDLE KIT, Remote Control to Tiller Handle
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	823687	CLIP
24	87-11083A31	SWITCH, Stop
25	8M0032846	RETAINER, Brass
26	821455A4	BRACKET, Tiller
27	13-826792	WAVE WASHER
28	23-821477	BUSHING
29	12-827314	WASHER
30	32-828547633	CONDUIT, (.620 Inside Diameter x 3.00 Feet Bulk)
31	54-816311T	TIE STRAP, (8.00 Inches)
32	37-82409316	DECAL, F-N-R Shift
33	15920Q54	LANYARD ASSEMBLY
34	830180A01	HANDLE KIT, Shift
35	10-8M0021519	SHOULDER SCREW, (10 x 20)
36	14-8M0009820	TAB WASHER
37	10-82484890	SCREW, (M10 x 90)
38	54-8M0009374	CLAMP
39	10-8248324	SCREW, (M6 x 16)

▶Tools 1 (20 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	91-24697	EXPANDER TOOL, Piston Ring
10	91-880118A04	DDT CARTRIDGE
11	84-822560A5	HARNESS ASSEMBLY, DDT Adaptor
12	91-883877A1	REMOVAL TOOL, Fuel Injector
13	NSS	NOT SOLD SEPARATE, Lock ring Pliers (P/N-SRP2)
14	91-809495001	TOOL, Valve Guide
15	91-809496A1	INSTALLER TOOL, Valve Guide Bushing
16	91-74951	SPANNER WRENCH
17	91-809494A1	COMPRESSOR TOOL, Valve Spring
18	NSS	NOT SOLD SEPARATE, Valve Seat Cutter Kit
19	FT2997	COMPRESSOR TOOL, Piston Ring
20	92-8M0071838	ANTI-CORROSION GREASE, 8 oz

▶Tools 2 (27 parts)

Ref	OEM Part #	Part Name
-	91-31229A7	PULLER KIT, Bearing
24	91-63209	HEAT LAMP
25	91-877321A1	INSTALLATION TOOL, Bearing
26	91-13945	INSTALLATION 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, Universal
39	91-37312T	DRIVER HEAD TOOL
40	91-817011T	INSTALLER TOOL, Needle Bearing
41	84-825003A1	CABLE ASSEMBLY, DDT, 10 Feet
42	91-13949	DRIVER TOOL, Oil Seal
43	91-817007T	INSTALLER TOOL, Seal
44	91-43506T	RETAINING TOOL, Bearing
45	91-817005	INSTALLER TOOL, Bearing
46	91-817006	INSTALLER TOOL, Water Pump Base Seal
47	91-817008A2	LOCATION TOOL, Pinion Gear
48	91-817009T	DRIVER TOOL, Bearing Cup
49	91-12349A05	TOOL, Pinion Locating

▶Tools 3 (21 parts)

Ref	OEM Part #	Part Name
-	91-883420	TOOL, Sleeve (.625)
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	91-196601	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	91-817070	HOLDING TOOL, Driveshaft
63	91-58222A1	DIAL INDICATOR TOOL
64	91-85716	PULLER BOLT TOOL, Bearing Carrier
65	91-83155	ADAPTER KIT, Dial Indicator
66	91-83165T	PULLER ASSEMBLY
67	91-856875A1	INSTALLATION TOOL, Bearing
68	91-817057A02	TOOL, Backlash Indicator
69	91-817058A1	DRIVER TOOL, Bearing
70	91-877840A1	HOLDING TOOL, Driveshaft
71	91-8M0162977	TOOL KIT

▶Top Cowl (11 parts)

Ref	OEM Part #	Part Name
-	37-8M0063354	DECAL, Jet Drive Comment: SN# 1C194950 & Up
1	100-899208T03	TOP COWL ASSEMBLY, Camouflage
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 (33 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	8M0041938	TILT TUBE
21	11-858869	NUT, (.875-14)
22	19624A1	SEAL KIT Comment: Non-Handle
23	25-29619	O-RING, (.583 x .103) Comment: Non-Handle
24	23-78861	SPACER Comment: Non-Handle
25	54-22740	CLIP
26	8M0084613	C WASHER
27	10-878609	SCREW, (#10-16 x .600)
28	10-814259	SCREW, (.500-20 x 4.00)
29	12-8M0204648	WASHER, (1.5 x 3.05 x 0.13) Stainless Steel
30	11-82671117	NUT, (.500-20)
31	10-4009040	SCREW, (M10 x 40) Stainless Steel
32	12-4002319	WASHER
33	11-40140	NUT, (M10)

▶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)

▶Vapor Separator (41 parts)

Ref	OEM Part #	Part Name
-	892267T03	VAPOR SEPARATOR ASSEMBLY
1	892267A54	BODY ASSEMBLY
2	10-892267506	SCREW, Drain
3	25-892267530	O-RING
4	32-8M0054213	HOSE, (40.00 Inches Bulk), Cut to 9 Inches
5	892267A55	COOLER ASSEMBLY, Fuel
6	54-888988023	CLAMP
7	10-82130025	SCREW, (M6 x 25)
8	12-892267511	WASHER
9	32-892267504	HOSE
10	32-892267503	HOSE
11	25-8M0190980	GROMMET
12	23-856954	BUSHING
13	892267A51	PUMP KIT, Fuel, Also includes cover to body o ring 25-892267530
14	892267521	INSULATOR
15	892267510	ISOLATOR
16	892267523	INSULTOR
17	892267534	STRAINER, Fuel
18	892267519	COVER
19	892267T57	COVER ASSEMBLY
20	892267537	VALVE, Schrader
21	892267535	CONNECTOR, Electrical
22	10-892267531	SCREW, (M4 x 16)
23	883220	CAP
24	892267A52	FLOAT VALVE KIT
25	892267A50	REGULATOR KIT, Pressure
26	25-892267513	O-RING
27	892267512	SCREEN
28	10-892267515	SCREW, (M5 x 18)
29	54-888988023	CLAMP
30	892267520	PLTE
31	10-892267529	SCREW, (M4 x 8)
32	892267527	FLOAT
33	17-892267528	PIN, Float
34	54-892267517	CLIP
35	32-892267516	HOSE
36	56762	TIE STRAP, (4.00 Inches)
37	10-82130025	SCREW, (M6 x 25)
38	12-8M0214930	WASHER
39	54-888988023	CLAMP
40	22-8M0022107	FITTING

100-Hour / Annual Service Checklist

Regular maintenance keeps your Mercury 40 EFI (4 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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