Mercury 402, 40 (2 CYL.) (5556230 & Up) Parts & Diagrams

🔎 Mercury 402, 40 (2 CYL.) Reference Library — Exploded parts diagrams (20 diagrams), specifications, common issues, and maintenance checklist.

The Mercury 402, 40 (2 CYL.) is a 4-Stroke, Inline 4-Cylinder, EFI, SOHC outboard motor. Commonly used on jon boats, pontoons, and mid-size utility craft.

Quick Reference Specifications

Specification	Value
Engine Type	4-Stroke, Inline 4-Cylinder, EFI, SOHC
Horsepower	40 HP
Displacement	995 cc
Bore x Stroke	65 mm x 75 mm
Spark Plug (Type & Gap)	NGK IZFR6F-11
Engine Oil Capacity	3.0 L (3.17 quart)
Recommended Engine Oil	SAE 25W-40 Mercury FourStroke Oil
Gear Case Oil Capacity	440 mL (14.9 fl oz)
Idle Speed (in gear)	700 ± 50 RPM (in gear)
Full Throttle RPM Range	5500-6000
Fuel	Unleaded Gasoline, 87 Octane min.

Always verify specifications against your owner's manual for your specific serial number range.

Common Issues & Recommended Parts

Below are common maintenance scenarios for the Mercury 402, 40 (2 CYL.):

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

Parts Diagrams & OEM Part Numbers

Expand the sections below to view detailed exploded parts diagrams and find the exact OEM replacement components for your Mercury 402, 40 (2 CYL.).

▶BOTTOM COWL AND EXHAUST PLATE (51 parts)

Ref	OEM Part #	Part Name
-	27-78028A78	GASKET SET
1	2139-7642A2	BOTTOM COWL ASSEMBLY
2	48472	COVER, PLUG - BOTTOM COWL HARNESS HOLE Comment: MANUAL
3	10-61802	SCREW, PLUG COVER TO BOTTOM COWL (7/8") Comment: MANUAL
4	88618	PLUG, BOTTOM COWL Comment: MANUAL
5	10-48409	SCREW, (#10-16 x .625) Stainless Steel, PLUG TO BOTTOM COWL Comment: MANUAL
6	12-8M0204666	WASHER, (.203 x .500 x .032), PLUG SCREW Comment: MANUAL
7	27-628601	GASKET
8	39622	SEAL, RUBBER
9	42818A1	PLATE ASSEMBLY, EXHAUST EXTENSION
10	23-71980	BUSHING, FLANGE EXHAUST PLATE
11	12-38453	WASHER, NYLON - WATER OUTLET TUBE
12	26-38452	SEAL, RUBBER
13	79799	HOUSING, WATER INLET TUBE SEAL
14	27-797971	GASKET, HOUSING
15	10-79798	SCREW, (#10-32 x 1.380)
16	27-385011	GASKET
17	37637	BOOT, FUEL CONNECTOR - BOTTOM COWL
18	39616	BOOT, CONTROL CABLE - BOTTOM COWL
19	39555	COVER PLATE
20	10-8M0113176	SCREW, (#10-24 x .375), COVER PLATE TO BOTTOM COWL
21	76176	LEVER, FRONT COVER
22	24-76177	SPRING, FRONT COVER LEVER
23	17-26541	PIN, Roll, LEVER TO BOTTOM COWL
24	47969	KNOB AND SHAFT, CHOKE
25	12-30314	WASHER, CHOKE SHAFT
26	24-47968	SPRING, COMPRESSION - CHOKE SHAFT
27	55180	LEVER, CHOKE
28	87-69508A9	SWITCH ASSEMBLY, Stop Comment: MANUAL SN# USA-5823918/Australia-8070640/Belgium-9298956/Canada-7169338 & Up
29	87-99525A1	COVER ASSEMBLY, STOP SWITCH Comment: MANUAL
30	11-69844	NUT, STOP SWITCH Comment: MANUAL
31	84-88238T01	CABLE ASSEMBLY, BOTTOM COWL
32	10-8M0113176	SCREW, (#10-24 x .375), GROUND STRAP
33	76132	BRACKET, SUPPORT - TOP COWL (REAR)
34	60577	MOUNT, RUBBER - REAR SUPPORT BRACKET
35	12-69056	WASHER, (.255 x .625 x .0312), RUBBER MOUNT
36	13-26992	LOCKWASHER, (.250) Stainless Steel, RUBBER MOUNT
37	11-36069	NUT, RUBBER MOUNT
38	90435	MOUNT, RUBBER - REAR SUPPORT BRACKET
39	11-36069	NUT, RUBBER MOUNT
40	10-37562	SCREW, (.312-18 x 1.00) Stainless Steel
41	13-8M0204647	LOCKWASHER, (.312), REAR SUPPORT BRACKET SCREW
42	95967T	BRACKET, SUPPORT - TOP COWL (FRONT)
43	31014	MOUNT, RUBBER - FRONT SUPPORT BRACKET
44	12-69056	WASHER, (.255 x .625 x .0312), RUBBER MOUNT
45	13-26992	LOCKWASHER, (.250) Stainless Steel, RUBBER MOUNT
46	11-36069	NUT, RUBBER MOUNT
47	10-37562	SCREW, (.312-18 x 1.00) Stainless Steel
48	13-8M0204647	LOCKWASHER, (.312), FRONT SUPPORT BRACKET SCREW
49	90435	MOUNT, RUBBER - FRONT SUPPORT BRACKET
50	11-36069	NUT, RUBBER MOUNT

▶CARBURETOR ASSEMBLY (47 parts)

Ref	OEM Part #	Part Name
-	1395-51091	REPAIR PARTS KIT Comment: WMK-38
1	1368-7226A19	CARBURETOR ASSEMBLY Comment: WMK-38
2	1395-8673	FLOAT ASSEMBLY
3	NSS	NOT SOLD SEPARATE, PIN, FLOAT LEVER PINION
4	NSS	NOT SOLD SEPARATE, LEVER, FLOAT (LOWER)
5	NSS	NOT SOLD SEPARATE, LEVER, FLOAT (UPPER)
6	1395-83181	NEEDLE, Inlet
7	NSS	NOT SOLD SEPARATE, GASKET, INLET SEAT
8	NSS	NOT SOLD SEPARATE, GASKET, FLOAT BOWL COVER
9	1395-9016	COVER, FLOAT BOWL Comment: WMK-38
10	1395-5733	JET, Main (.092) Comment: WMK-38
11	1395-5734	HOSE, ECONOMIZER
12	10-52195	SCREW, FLOAT BOWL COVER
13	1395-4804	SCREW, FLOAT BOWL COVER
14	8,13-26995	LOCKWASHER, Stainless Steel, FLOAT BOWL COVER SCREW
15	92880	LEVER, THROTTLE Comment: SN# USA-5823918/Australia-8070640/Belgium-9298956/Canada-7169338 & Up
16	10-60293	SCREW, (#5-40 x .500), THROTTLE LEVER Comment: SN# USA-5823918/Australia-8070640/Belgium-9298956/Canada-7169338 & Up
17	11-92500	PUSH NUT, THROTTLE LEVER SCREW Comment: SN# USA-5823918/Australia-8070640/Belgium-9298956/Canada-7169338 & Up
18	1395-8641	SHAFT, Throttle Comment: SN# USA-5823918/Australia-8070640/Belgium-9298956/Canada-7169338 & Up
19	NSS	NOT SOLD SEPARATE, IDLE TUBE
20	1395-4540	SCREW, BODY (IDLE TUBE)
21	1395-9017	SHUTTER, Throttle Comment: WMK-38
22	NSS	NOT SOLD SEPARATE, SCREW, THROTTLE SHUTTER
23	NSS	NOT SOLD SEPARATE, SPRING, IDLE ADJUSTMENT SCREW
24	NSS	NOT SOLD SEPARATE, SCREW, IDLE ADJUSTMENT
25	NSS	NOT SOLD SEPARATE, MAIN NOZZLE
26	1395-4542	SCREW, PLUG - MAIN NOZZLE
27	1395-6030	JET, (.070), MAIN FUEL
28	1395-4541	SCREW, PLUG - MAIN FUEL JET CHANNEL
29	NSS	NOT SOLD SEPARATE, GASKET, JET CHANNEL PLUG SCREW
30	NSS	NOT SOLD SEPARATE, SPRING, THROTTLE SHAFT RETURN
31	1395-4543	SCREW, BODY CHANNEL
32	52106A1	VENTURI, Plastic
33	NSS	NOT SOLD SEPARATE, PLUG, BODY CHANNEL
34	27-481641	GASKET, CARBURETOR FLANGE
35	11-64809	NUT, CARBURETOR MOUNTING STUD
36	16-69016	STUD, CHOKE SHUTTER PIVOT (CARBURETOR)
37	55179	SHUTTER, Choke, CARBURETOR
38	24-55163	SPRING, TENSION - CHOKE SHUTTER
39	12-47960	WASHER, CHOKE SHUTTER CARBURETOR STUD
40	10-32,11-20110	NUT, , CHOKE SHUTTER TO CARBURETOR STUD
41	35-57819	SCREEN, CARBURETOR
42	10-58185	SCREW, (#10-32 x 1.00), SCREEN TO CARBURETOR
43	24-57818	SPRING, TENSION - SCREEN SCREW
44	12-30164	WASHER, SCREEN SCREW
45	10-32,11-20110	NUT, , SCREEN SCREW
46	22-19688	FITTING, ELBOW - CARBURETOR

▶CLAMP AND SWIVEL BRACKET ASSEMBLY (50 parts)

Ref	OEM Part #	Part Name
1	1427-5611A4	CLAMP BRACKET ASSEMBLY Comment: (ELECTRIC)
2	10-78492A1	THUMB SCREW ASSEMBLY Comment: (ELECTRIC)
3	10-78495	SCREW, (.312-24 x .680), WASHER TO THUMB SCREW
4	12-78493	WASHER, THUMB SCREW
5	75043	CAP, THUMB SCREW Comment: (MANUAL)
6	17-8M0026068	PIN ASSEMBLY, Tilt Lock
7	23-59623	SPACER, CLAMP BRACKET STUD
8	16-59625	STUD, CLAMP BRACKET
9	13-8M0204647	LOCKWASHER, (.312), CLAMP BRACKET STUD
10	11-28770	NUT, (.312-24) Stainless Steel, CLAMP BRACKET STUD
11	8M0041936	TILT TUBE, CLAMP BRACKET TO SWIVEL BRACKET
12	12-52864	WASHER, CLAMP BRACKET TO SWIVEL BRACKET
13	11-858869	NUT, (.875-14), TILT TUBE
14	53078	CAP, PLASTIC - TILT TUBE
15	10-68298	BOLT, (.375-16 x 3.250)
16	12-68410	WASHER, CLAMP BRACKET BOLT (LOWER)
17	11-82671112	NUT, CLAMP BRACKET BOLT
18	69540A4	SWIVEL PIN ASSEMBLY Comment: ELECTRIC-LONG SHAFT
19	30711	BUMPER, STEERING ARM
20	10-66897	BOLT, (.437-20 x 5.250), UPPER MOUNT TO STEERING ARM
21	62297	BUMPER, STEERING ARM Comment: MANUAL
22	76535T	BRACKET, RIDE-GUIDE ATTACHING Comment: MANUAL
23	10-34352	SCREW, (.375-24 x .875), BRACKET TO STEERING ARM Comment: MANUAL
24	76533	STRAP, BRACKET SCREW Comment: MANUAL
25	12-52865	WASHER, SWIVEL PIN
26	1480-7655A1	SWIVEL BRACKET Comment: (LONG SHAFT)
27	26-32911	SEAL, Oil, SWIVEL BRACKET
28	22-8M0169589	FITTING, Grease, SWIVEL BRACKET
29	47913A2	LEVER ASSEMBLY, TILT LOCK - PORT SIDE
30	10-69087	SCREW, (.312-24 x .880)
31	11-29250	NUT, (.312-24), TILT LOCK AND STOP LEVER SCREW
32	47912A2	LEVER ASSEMBLY, TILT TOP - STARBOARD SIDE
33	23-47911	BUSHING, TILT LOCK AND STOP LEVER
34	13-34632	WASHER, WAVE - TILT LOCK AND STOP LEVER
35	12-56720	WASHER, (.330 x .750 x .060) Stainless Steel, TILT LOCK AND STOP LEVER
36	11-29250	NUT, (.312-24)
37	17-25598	PIN, REVERSE LOCK SPRING ATTACHING
38	56349	SHAFT, REVERSE LOCK TO SWIVEL BRACKET
39	14664A3	LOCK ASSEMBLY, Reverse Comment: SN# USA-5823918/Australia-8070640/Belgium-9298956/Canada-7169338 & Up
40	24-29821	SPRING, REVERSE LOCK TENSION
41	18-45882	COTTER PIN, REVERSE LOCK TO SHAFT
42	12-25176	WASHER, SWIVEL PIN TO BOTTOM YOKE (.060)
43	77416T1	YOKE, Bottom
44	53-77415	RETAINING RING, BOTTOM YOKE
45	89813	ROD END, PUSH ROD Comment: SN# USA-5823918/Australia-8070640/Belgium-9298956/Canada-7169338 & Up
46	43413A2	ROD, PUSH - REVERSE LOCK Comment: (LONG SHAFT) SN# USA-5823918/Australia-8070640/Belgium-9298956/Canada-7169338 & Up
47	11-28770	NUT, (.312-24) Stainless Steel, JAM - PUSH ROD Comment: SN# USA-5823918/Australia-8070640/Belgium-9298956/Canada-7169338 & Up
48	17-72524	PIN, REVERSE LOCK LEVER
49	18-25191	COTTER PIN, PUSH ROD TO REVERSE LOCK
50	933361	GUIDE, PUSH ROD

▶CRANKSHAFT, PISTONS AND CONNECTING RODS (21 parts)

Ref	OEM Part #	Part Name
1	454-9073A1	CRANKSHAFT ASSEMBLY
2	78308A1	RETAINER ASSEMBLY, BALL BEARING
3	30-63742T	BEARING, Ball, RETAINER (CRANKSHAFT)
4	53-63634	RING, Retaining, BALL BEARING
5	540-7238A2	BEARING ASSEMBLY, Main, VALVE TYPE
6	17-20032	PIN, Dowel, MAIN BEARING
7	10-45775	SCREW, (#12-28 x .560) , MAIN BEARING CLAMPING
8	11-45774	NUT, MAIN BEARING CLAMPING SCREW
9	34-56007A1	REED SET, MAIN BEARING (MATCHED)
10	34-56008	STOP, Reed, MAIN BEARING REED VALVES
11	10-20055	SCREW, (#10-32 x .375), REED STOP MOUNTING
12	624-8101A3	CONNECTING ROD ASSEMBLY
13	10-91012	SCREW, (.250-28 Special), CONNECTING ROD Comment: USE WITHOUT NUT
14	11-49091	NUT, CONNECTING ROD SCREW
15	31-62596A1	BEARING ASSEMBLY, CRANKPIN
16	29-8M0214934	BEARING, PISTON PIN
17	12-8M0032839	WASHER, NEEDLE BEARING RETAINING
18	774-9137A14	PISTON ASSEMBLY Comment: (.030 OVERSIZE)
19	53-857196	RING, Lock, PISTON PIN
20	39-88392A12	RING SET, Piston - .030 Oversize
21	28-45554	KEY, CRANKSHAFT

▶CYLINDER BLOCK AND THERMOSTAT (30 parts)

Ref	OEM Part #	Part Name
-	27-78028A78	GASKET SET
1	851-7940A6	CYLINDER BLOCK ASSEMBLY
2	66843T	BRACKET, COIL MOUNTING
3	99436A1	COVER, DIAPHRAGM Comment: WITH THERMOSTAT
4	648771	DIAPHRAGM, POPPET VALVE Comment: WITH THERMOSTAT
5	12-76451	WASHER, DIAPHRAGM Comment: WITH THERMOSTAT
6	10-69570	SCREW, (#10-16 x .750), WASHER AND DIAPHRAGM Comment: WITH THERMOSTAT
7	75692	THERMOSTAT Comment: WITH THERMOSTAT
8	27-8M0204714	GASKET, THERMOSTAT Comment: WITH THERMOSTAT
9	86596	POPPET VALVE, RELIEF VALVE Comment: WITH THERMOSTAT
10	24-66852	SPRING, COMPRESSION Comment: WITH THERMOSTAT
11	65848	CARRIER, POPPET VALVE Comment: WITH THERMOSTAT
12	25-64872	GROMMET, POPPET VALVE Comment: WITH THERMOSTAT
13	99436A1	COVER ASSEMBLY, COIL BRACKET Comment: W/O THERMOSTAT
14	25-823683	O-RING, COVER Comment: W/O THERMOSTAT
15	10-31984	SCREW, (.312-18 x 1.375)
16	10-88760	SCREW, (.312-18 x 1.250)
17	10-58414	SCREW (2-1/2")
18	13-8M0204647	LOCKWASHER, (.312), COIL MOUNTING BRACKET SCREW
19	25-39597	GROMMET, COIL MOUNTING BRACKET
20	27-66847	GASKET, COIL MOUNTING BRACKET TO BLOCK
21	32-9938779	HOSE, CYLINDER BLEED (8")
22	21-42866	CHECK VALVE, CYLINDER BLEED (TOP)
23	21-42863	FITTING, CYLINDER BLEED (BOTTOM)
24	58124A27	SWITCH ASSEMBLY, MERCURY Comment: SN# USA-5823918/Australia-8070640/Belgium-9298956/Canada-7169338 & Up
25	10-48409	SCREW, (#10-16 x .625) Stainless Steel
26	76184	INDICATOR, TIMING Comment: ELECTRIC
27	10-25299	SCREW, (.312-18 x .75), INDICATOR ATTACHING Comment: ELECTRIC
28	12-20084	WASHER, (.328 x .562 x .062), INDICATOR ATTACHING SCREW Comment: ELECTRIC
29	17-29908	PIN, INDICATOR LOCATING Comment: ELECTRIC

▶CYLINDER BLOCK CRANKCASE AND COVERS (45 parts)

Ref	OEM Part #	Part Name
-	61779A87	POWERHEAD ASSEMBLY
1	1167-8277A1	END CAP ASSEMBLY, Upper Comment: SN# USA-5823918/Australia-8070640/Belgium-9298956/Canada-7169338 & Up
2	25-47254	O-RING, UPPER END CAP
3	31-62066T	BEARING, Roller, UPPER END CAP
4	26-41953	SEAL, UPPER END CAP
5	10-30225	SCREW AND LOCKWASHER, (.312-18 x 1.00), UPPER END CAP MOUNTING
6	851-7940A6	CYLINDER BLOCK ASSEMBLY
7	16-64936	STUD, CARBURETOR MOUNTING (1-1/4")
8	16-68165	STUD (1-5/8")
9	16-87901	STUD (4-3/8")
10	16-68166	STUD, (.312 x 2.125)
11	16-68167	STUD, (.312-18/.312-24 x 2.560)
12	66517	RESTRICTOR, CYLINDER BLOCK (BLEED)
13	17-23784	PIN, Dowel, CRANKCASE TO CYLINDER BLOCK
14	17-20323	PIN, Dowel, CYLINDER BLOCK TO MAIN BEARING
15	27-55158	GASKET, SEALING - CYLINDER BLOCK
16	22-328022	PLUG, Pipe (.125-27), CYLINDER BLOCK Comment: SN# USA-6228284/Australia-8075392/Belgium-9365540/Canada-7202537 & Below
17	62064	BRACKET, STARTER MOTOR
18	10-21339	SCREW, (.312-24 x 1.375)
19	11-29250	NUT, (.312-24), STARTER MOTOR BRACKET SCREW
20	10-74824	SCREW, (.312-18 x 1.250)
21	1152-7267A1	END CAP ASSEMBLY, Lower
22	26-41953	SEAL, LOWER END CAP
23	25-823683	O-RING, LOWER END CAP
24	10-63365	SCREW, END CAP TO CYLINDER BLOCK (1-1/2")
25	25-64068	O-RING, LOWER END CAP SCREW
26	27-854891	GASKET, CYLINDER BLOCK TO BAFFLE PLATE
27	55190	PLATE, DIVIDER - EXHAUST MANIFOLD
28	27-854882	GASKET, BAFFLE PLATE TO EXHAUST COVER
29	551572	COVER, EXHAUST MANIFOLD
30	10-31984	SCREW (1-3/8")
31	10-64021	SCREW, ADJUSTING - EXHAUST COVER (1-7/8")
32	11-64015	NUT, (.250-20), ADJUSTING SCREW
33	26852	CAP, Nylon, ADJUSTING SCREW
34	1024-91101	COVER, CYLINDER BLOCK
35	27-856729	GASKET, CYLINDER BLOCK COVER
36	10-76213	SCREW, (.250-20 x 1.120)
37	46933A3	STRAP ASEMBLY, Ground, POWERHEAD TO BOTTOM COWL
38	22-328022	PLUG, Pipe (.125-27), CYLINDER BLOCK COVER
39	63970	COVER, TRANSFER PORT
40	27-552791	GASKET, TRANSFER PORT COVER
41	10-8M0214943	SCREW, TRANSFER PORT COVER MOUNTING (1")
42	54-54457	J CLIP, COIL HARNESS
43	92059	BRACKET, FUEL FILTER AND HARNESS
44	10-76213	SCREW, (.250-20 x 1.120), BRACKET MOUNTING

▶DRIVESHAFT HOUSING ASSEMBLY (37 parts)

Ref	OEM Part #	Part Name
1	1593-7513A12	HOUSING ASSEMBLY, Driveshaft Comment: (LONG SHAFT)
2	16-97460	STUD, (.375 x 6.75), DRIVESHAFT HOUSING Comment: (X-LONG)
3	16-96124	STUD, (.4375 x 8.03) , DRIVESHAFT HOUSING Comment: (X-LONG)
4	19-64649	PLUG, PLASTIC - WATER PICK-UP HOLE
5	22-390721	PLUG, (1/8 Inch Brass), DRIVESHAFT HOUSING
6	12-65791	WASHER, GEAR HOUSING STUDS
7	11-8M0204653	NUT, (.437-20) Stainless Steel, GEAR HOUSING STUDS
8	60769	COVER, TRIM - DRIVESHAFT HOUSING
9	10-57807	SCREW, (#10-16 x .750) Stainless Steel, TRIM COVER TO DRIVESHAFT HOUSING
10	25-92012	GROMMET, TRIM COVER SCREW
11	32-98856	TUBE, WATER OUTLET Comment: (X-LONG SHAFT)
12	695441	TUBE, EXHAUST Comment: (LONG SHAFT)
13	11-64809	NUT, POWERHEAD STUDS
14	923373	MOUNT, RUBBER - UPPER
15	96401	SEAL, BELLOWS - UPPER MOUNT
16	12-27727	WASHER, UPPER MOUNT BOLT (37/64 ID)
17	12-66966	WASHER, RUBBER - UPPER MOUNT BOLT
18	12-30514	WASHER, UPPER MOUNT BOLT
19	11-8M0204653	NUT, (.437-20) Stainless Steel, UPPER MOUNT BOLT
20	87883	COVER, UPPER MOUNT
21	10-8M0214943	SCREW, (.250-20 x 1.00), UPPER MOUNT COVER
22	12-8M0204649	WASHER, (.281 x .500 x .060) Stainless Steel, UPPER MOUNT COVER SCREW
23	10-75284	SCREW, (.500-20 x 5.500), LOWER MOUNT
24	12-28051	WASHER, LOWER MOUNT SCREW
25	12-28053	WASHER, RUBBER - LOWER MOUNT SCREW
26	75302T1	MOUNT, RUBBER - LOWER
27	12-30119	WASHER, (.875 Inch Outside Diameter), LOWER MOUNT SCREW
28	11-25096	NUT, LOWER MOUNT SCREW
29	69592F1	CLAMP, LOWER MOUNT TO DRIVESHAFT HOUSING
30	10-29256	SCREW, (.312-18 x .875), LOWER MOUNT CLAMP
31	24-35522	SPRING, TENSION - LOWER MOUNT CLAMP
32	88238A10	CABLE ASSEMBLY, Ground
33	35474T	COVER, LOWER MOUNT CLAMP
34	10-87884	SCREW, (#12-14 x .920), COVER TO LOWER CLAMP
35	11-35521	NUT, LOWER MOUNT CLAMP COVER
36	98858A1	EXTENSION ASSEMBLY Comment: (X-LONG SHAFT)
37	37721001	SEAL, EXTENSION Comment: (X-LONG SHAFT)

▶FLYWHEEL, IGNITION COIL AND SWITCH BOX (35 parts)

Ref	OEM Part #	Part Name
1	11-8M0214915	NUT, (.625-18), FLYWHEEL
2	12-33001	WASHER, (.641 x 1.250 x .190), FLYWHEEL NUT
3	242-4764A25	FLYWHEEL ASSEMBLY Comment: (ELECTRIC)
4	10-32417	SCREW, (.250-28 x .625)
5	50-65213	RATCHET, FLYWHEEL Comment: MANUAL
6	10-69088	SCREW Comment: MANUAL
7	13-20202	LOCKWASHER, RATCHET SCREW Comment: MANUAL
8	398-5255	STATOR, ALTERNATOR Comment: ELECTRIC
9	10-56787	SCREW, STATOR TO UPPER END CAP (2")
10	10,13-26996	LOCKWASHER, Stainless Steel, STATOR SCREW
11	61830	SUPPORT, Stator
12	338-4731A8	TRIGGER PLATE ASSEMBLY
13	24-62095	SPRING, COMPRESSION
14	17-62768	PIN, SPRING RETENTION
15	12-62133	WASHER (UPPER)
16	13-61983	WASHER, CENTER)
17	12-61982	WASHER (LOWER)
18	54-54457	J CLIP
19	61990	TIE STRAP, (14.00 Inches), STATOR LEADS
20	300-8M0166172	COIL ASSEMBLY, Ignition, COMPLETE
21	10-32,11-45076	NUT, Brass, COIL TERMINALS
22	84-60466A1	CABLE ASSEMBLY, Black (2.50 Inches)
23	76254	COVER, IGNITION COIL
24	10-60194	SCREW (2-1/8")
25	84-813715A1	LEAD ASSEMBLY, SPARK PLUG (HIGH TENSION)
26	85-63709A1	BOOT/TERMINAL KIT, SPARK PLUG
27	332-2854T01	BOOT, LEAD TO IGNITION COIL
28	33-896329827	SPARK PLUG (AV#V-40FFM)
29	332-4911A8	SWITCHBOX ASSEMBLY, COMPLETE
30	54-54457	J CLIP, SWITCH BOX LEADS
31	10-69067	SCREW, (.250-20 x 1.375)
32	10-45218	SCREW, (#10-32 x .380)
33	86-66754	TERMINAL BLOCK, SWITCH BOX LEAD
34	10-38055	SCREW, (.190-32 x .62), TERMINAL BLOCK ATTACHING
35	10-32,11-8267086	NUT,

▶FUEL PUMP AND FUEL LINE (40 parts)

Ref	OEM Part #	Part Name
-	27-78028A78	GASKET SET
1	62973A4	PUMP ASSEMBLY, Fuel
2	21-8M0084275	CHECK VALVE ASSEMLBY
3	55278A1	DIAPHRAGM KIT
4	NSS	NOT SOLD SEPARATE, GASKET, CHECK VALVE
5	NSS	NOT SOLD SEPARATE, GASKET, FUEL PUMP
6	23004	RETAINER, CHECK VALVE
7	10-43725	SCREW, RETAINER TO HOUSING
8	10-69093	SCREW, (.250-20 x 1.50), FUEL PUMP MOUNTING
9	22-328022	PLUG, Pipe (.125-27), FUEL PUMP
10	69791A2	HOSE AND NOZZLE, TELL TALE Comment: SN# USA-6228284/Australia-8075392/Belgium-9365540/Canada-7202537 & Below
11	66849	CLAMP, HOSE AND NOZZLE Comment: SN# USA-6228284/Australia-8075392/Belgium-9365540/Canada-7202537 & Below
12	10-48409	SCREW, (#10-16 x .625) Stainless Steel, CLAMP TO BOTTOM COWL Comment: SN# USA-6228284/Australia-8075392/Belgium-9365540/Canada-7202537 & Below
13	32-8M0108355	HOSE, BLOCK TO PUMP (11") Comment: SN# USA-6228284/Australia-8075392/Belgium-9365540/Canada-7202537 & Below
14	22-328022	PLUG, Pipe (.125-27), CYLINDER BLOCK Comment: SN# USA-6228285/Belgium-9365541/Canada-7202538 & Up
15	22-64705	FITTING, PUMP INLET
16	32-8M0108355	LINE, (57.00 Inches Bulk), FUEL FILTER TO PUMP (9")
17	35-889527A07	FILTER ASSEMBLY, Fuel
18	35-87946Q04	FILTER ASSEMBLY
19	25-897536	SEAL, FUEL FILTER
20	32-8M0108355	LINE, (57.00 Inches Bulk), ADAPTOR TO FUEL FILTER (11")
21	22-63187	FITTING, Barb (.250-18), FUEL LINE TO ADAPTOR
22	30188	WASHER, ADAPTOR
23	24-23067T	SPRING, ADAPTOR STEM
24	25-16524	O-RING, ADAPTOR STEM
25	23069	STEM, CHECK UNIT ADAPTOR
26	22833	ADAPTOR, CHECK UNIT (FUEL PUMP)
27	10-56500	SCREW, (.250-28 x 1.250), ADAPTOR TO BOTTOM COWL
28	11-36069	NUT, ADAPTOR SCREW
29	11-400212	NUT, (M6) Stainless Steel, FUEL FILTER
30	22-64705	FITTING, PUMP OUTLET
31	32-8M0108355	LINE, (57.00 Inches Bulk), PUMP TO CARBURETOR (12-3/4")
32	54-68424	CLAMP, FUEL LINE ATTACHING
33	22-782792	ELBOW, TELL TALE HOSE TO BLOCK Comment: SN# USA-6228285/Belgium-9365541/Canada-7202538 & Up
34	32-7568058	HOSE, TELL TALE (6") Comment: SN# USA-6228285/Belgium-9365541/Canada-7202538 & Up
35	69791	NOZZLE, TELL TALE HOSE TO COWL Comment: SN# USA-6228285/Belgium-9365541/Canada-7202538 & Up
36	23-90882	SLEEVE, NOZZLE Comment: SN# USA-6228285/Belgium-9365541/Canada-7202538 & Up
37	66849	CLAMP, NOZZLE Comment: SN# USA-6228285/Belgium-9365541/Canada-7202538 & Up
38	10-48409	SCREW, (#10-16 x .625) Stainless Steel, CLAMP TO BOTTOM COWL Comment: SN# USA-6228285/Belgium-9365541/Canada-7202538 & Up
39	56762	TIE STRAP, (4.00 Inches), NOZZLE Comment: SN# USA-6228285/Belgium-9365541/Canada-7202538 & Up

▶GEAR HOUSING(DRIVESHAFT) (51 parts)

Ref	OEM Part #	Part Name
-	27-78028A78	GASKET SET
1	1643-9539T1	GEAR HOUSING ASSEMBLY, Mercury, Basic
2	22-85822A10	CONNECTOR ASSEMBLY, SPEEDOMETER
3	17-8M0084726	PIN, Dowel (.187 x .530), GEAR HOUSING
4	16-33778	STUD, WATER PUMP/BASE (2-5/8")
5	16-96126	STUD, (.4375 x 7.22), GEAR HOUSING Comment: (X-LONG SHAFT)
6	31-62091T	BEARING, Roller, DRIVESHAFT
7	72849A1	SCREEN ASSEMBLY, WATER INTAKE
8	10-36070	SCREW, (#10-32 x 1.250)
9	10-32,11-859124	NUT, Stainless Steel, WATER INTAKE SCREEN SCREW
10	92815	PLATE, SUPPORT - EXHAUST TUBE
11	37721001	SEAL, EXHAUST TUBE
12	43-98097T	GEAR, Pinion, DRIVESHAFT
13	11-55910	NUT, (.437-20), PINION GEAR TO DRIVESHAFT
14	27-19552	GASKET, WATER PUMP BASE TO GEAR HOUSING
15	25-26722	O-RING, WATER PUMP BASE
16	46-77177A1	BASE ASSEMBLY, Water Pump
17	26-79831	SEAL, Oil, WATER PUMP BASE
18	26-90562	SEAL, (1.254 x .312), WATER PUMP BASE
19	17-35973	PIN, Dowel, WATER PUMP BASE
20	27-19553	GASKET, LOWER - WATER PUMP BASE TO FACE PLATE
21	32768	FACE PLATE, WATER PUMP BASE
22	27-19551	GASKET, UPPER - FACE PLATE TO WATER PUMP BODY
23	47-89983T	IMPELLER, WATER PUMP
24	28-8M0032837	KEY, IMPELLER DRIVE
25	46-77822A1	BODY ASSEMBLY, Water Pump
26	48753	INSERT, WATER PUMP BODY
27	26-38452	SEAL, RUBBER - WATER INLET TUBE
28	12-38453	WASHER, NYLON - WATER PUMP BODY
29	12-8M0204649	WASHER, (.281 x .500 x .060) Stainless Steel, WATER PUMP BODY AND BASE STUDS
30	11-35888	NUT, (.250-28) Stainless Steel, WATER PUMP BODY AND BASE STUDS
31	25-20273	O-RING, RUBBER - CENTRIFUGAL SLINGER (DRIVE SHAFT)
32	88868A1	SEAT ASSEMBLY, DRIVESHAFT
33	86304	SEAL, SPLINED - DRIVESHAFT
34	10-79953Q04	SCREW, (.375-16 x .250), GREASE FILLER
35	22-8M0058389	SCREW, Magnetic, DRAIN
36	12-191833	WASHER, FILLER/DRAIN SCREW
37	88181	SLEEVE, LUBRICATION - DRIVESHAFT
38	15-92881A1	SHIM SET, BEARING TO GEAR HOUSING (.002-3-5-10-20)
39	31-8M0166756	BEARING ASSEMBLY, Roller, TAPERED - DRIVESHAFT
40	45-97442A2	DRIVESHAFT ASSEMBLY Comment: (X-LONG SHAFT)
41	24-20254	SPRING, COMPRESSION - DRIVESHAFT
42	17-30545	PIN, DRIVESHAFT
43	97443A1	SHAFT ASSEMBLY, SHIFT Comment: (X-LONG SHAFT)
44	53-29641	E RING, SHIFT SHAFT
45	25-25439	O-RING, (.862 x .103), SHIFT SHAFT BUSHING
46	23-77631A2	BUSHING ASSEMBLY, SHIFT SHAFT
47	26-892361	SEAL, Oil, SHIFT SHAFT BUSHING
48	12-77674	WASHER, RUBBER - SHIFT SHAFT BUSHING
49	78036	BASE, REVERSE LOCKING
50	43308T1	CAM, REVERSE LOCKING

▶GEAR HOUSING(PROPELLER SHAFT) (34 parts)

Ref	OEM Part #	Part Name
-	27-78028A78	GASKET SET
1	1643-9539T1	GEAR HOUSING ASSEMBLY, Mercury, Basic
51	760394	CAM, Shift Control
52	15-38374A1	SHIM SET, BEARING CUP TO GEAR HOUSING (.002-3-5-10)
53	31-38356A1	BEARING SET
54	43-55608T4	GEAR ASSEMBLY, Forward
55	31-21739	BEARING, Roller, FORWARD GEAR
56	38441	FOLLOWER, Cam
57	20843	SLIDE, CROSS PIN
58	24-38114	SPRING, RETAINING - CROSS PIN
59	52-92911T	RATCHET, SLIDING CLUTCH
60	17-8M0020942	PIN, Cross, RATCHET TO PROPELLER SHAFT
61	24-39845	SPRING, COMPRESSION - CAM FOLLOWER
62	44-75365	PROPELLER SHAFT
63	43-79158T	GEAR, Reverse
64	12-32004	WASHER, THRUST - REVERSE GEAR
65	30-20839T	BEARING, Ball, REVERSE GEAR
66	25-31986	O-RING, BEARING CARRIER
67	69386T1	CARRIER ASSEMBLY, Bearing
68	31-21700	BEARING, Needle, BEARING CARRIER
69	26-8M0205511	SEAL, Oil, BEARING CARRIER
70	26-8M0203757	SEAL, Oil, BEARING CARRIER
71	28-30281	KEY, LOCATING - BEARING CARRIER
72	14-53012	TAB WASHER, GEAR HOUSING COVER
73	11-87763	NUT, GEAR HOUSING
74	97-31640Q4	TRIM TAB ASSEMBLY, GEAR HOUSING
75	10-66024	SCREW, (.437-14 x 1.75), TRIM TAB TO GEAR HOUSING
76	12-8M0214963	WASHER, (.406 x .750 x .104), DRIVESHAFT HOUSING STUD
77	11-8M0204726	NUT, (.375-24), DRIVE SHAFT HOUSING STUD
78	12-65791	WASHER, HOUSING TO STUD (7/16")
79	11-8M0204653	NUT, (.437-20) Stainless Steel, STUD
80	73345A1	THRUST HUB, FRONT
81	14-8M0214942	TAB WASHER, PROPELLER NUT
82	11-69578Q1	PROP NUT KIT

▶MISCELLANEOUS PARTS/ACCESSORIES (1 parts)

Ref	OEM Part #	Part Name
-	27-78028A78	GASKET SET

▶PROPELLERS (1 parts)

Ref	OEM Part #	Part Name
-	48-73144A45	PROPELLER (PITCH 17")(ALUMINUM)

▶SHIFT CONTROL LINKAGE (27 parts)

Ref	OEM Part #	Part Name
1	87876A2	BRACKET, SHIFT ANCHOR - UPPER
2	10-73657	SCREW, (.312-18 x 1.50)
3	10-67450	SCREW, (.312-18 x 2.250)
4	10-35385	SCREW, (.312-18 x 1-3/4)
5	87874	SLIDE, SHIFT ACTUATING
6	56193	LATCH, SHIFT ACTUATING SLIDE (SHIFT CABLE)
7	10-39620	SCREW, LATCH TO SHIFT ACTUATING SLIDE
8	24-27087	SPRING, COMPRESSION - LATCH SCREW
9	75717	SLIDE, NYLON - ANCHOR BRACKET
10	39515	END CAP, NYLON - ANCHOR BRACKET SLIDE
11	87876A2	BRACKET, SHIFT ANCHOR - LOWER
12	10-20012	SCREW, (.250-28 x 1.62)
13	11-826709109	NUT, (.250-28), UPPER ANCHOR BRACKET SCREW
14	39519	CUP Comment: RETAINER - ANCHOR BRACKET (SHIFT CABLE BARREL)
15	87609A1	LEVER
16	17-47175	PIN, LOCKING LEVER AND COVER FASTENING
17	90211	COVER, NYLON - SHIFT CABLE
18	87609A1	LINK, LOCKING LEVER TO COVER
19	75104A8	SHIFT SHAFT ASSEMBLY Comment: (LONG SHAFT)
20	12-37998	WASHER, UPPER SHIFT SHAFT Comment: (MANUAL)
21	18-26811	COTTER PIN, UPPER SHIFT SHAFT Comment: (MANUAL)
22	87-88096A1	SWITCH ASSEMBLY, NEUTRAL START Comment: (ELECTRIC TILLER HANDLE MODELS)
23	10-30902	SCREW, (#6-32 x .750), SWITCH ATTACHING Comment: (ELECTRIC TILLER HANDLE MODELS)
24	86-45915	TERMINAL BLOCK Comment: (ELECTRIC TILLER HANDLE MODELS)
25	10-25764	SCREW, (.190-32 x .50), TERMINAL BLOCK ATTACHING Comment: (ELECTRIC TILLER HANDLE MODELS)
26	10-32,11-27164	NUT AND LOCKWASHER, , TERMINAL BLOCK SCREW Comment: (ELECTRIC TILLER HANDLE MODELS)
27	10-69079	SCREW, (#10-16 x .440), SWITCH LEADS TO TERMINAL BLOCK Comment: (ELECTRIC TILLER HANDLE MODELS)

▶STARTER HOUSING ASSEMBLY (36 parts)

Ref	OEM Part #	Part Name
1	11-20166	NUT, SHEAVE SHAFT (LEFT HAND THREAD)
2	14-61004	TAB WASHER, SHEAVE SHAFT NUT
3	25-39597	GROMMET, STARTER HOUSING
4	76141	CABLE ASSEMBLY, INTERLOCK Comment: MANUAL
5	10-32228	SCREW, (#10-32 x .625), CABLE TO EXHAUST PLATE Comment: MANUAL
6	10-69022	SCREW, (#10-32 x .500) Stainless Steel Comment: MANUAL
7	428201	CAM, INTERLOCK Comment: MANUAL
8	10-76138	SCREW, (.312-18 x 1.120) Comment: MANUAL
9	24-761401	SPRING Comment: MANUAL
10	79371	ACTUATOR, INTERLOCK Comment: MANUAL
11	10-76137	SCREW (1-5/8") Comment: MANUAL
12	24-76139	SPRING, INTERLOCK ACTUATOR SCREW - MANUAL Comment: MANUAL
13	12-30191	WASHER, INTERLOCK CABLE Comment: MANUAL
14	18-26811	COTTER PIN, INTERLOCK CABLE TO ACTUATOR Comment: MANUAL
15	93695	PULLEY, STARTER SCREW
16	10-45210	SCREW, (.190-32 x 1.250), PULLEY TO STARTER HOUSING
17	12-22887	WASHER, PULLEY SCREW
18	23-309772	SPACER, PULLEY SCREW
19	94121	RETAINER, STARTER ROPE
20	11-24656	NUT, PULLEY SCREW
21	76079A8	HOUSING ASSEMBLY, Starter
22	10-88759	SCREW, STARTER HOUSING TO CRANKCASE (1")
23	13-8M0204647	LOCKWASHER, (.312), STARTER HOUSING SCREW
24	61002	PLATE, STARTER REWIND
25	24-39502T02	SPRING, STARTER REWIND
26	23-87649	BUSHING, SPRING GUIDE
27	50-94338A1	SHEAVE ASSEMBLY, Starter
28	91936	PAWL, Starter
29	24-87651	SPRING, STARTER PAWL
30	53-87706	E RING, STARTER PAWL
31	23-63061	SPACER, SHEAVE SHAFT
33	94962A1	LEVER ASSEMBLY
34	13-20160	WAVE WASHER
35	87656	SHEAVE SHAFT
36	47341A11	ROPE AND HANDLE KIT, Manual/Emergency Start (FOR MANUAL STARTING)
37	79470A1	RETAINER KIT, Rope, STARTER ROPE

▶STARTER MOTOR ASSEMBLY (12 parts)

Ref	OEM Part #	Part Name
-	50-41583T	STARTER MOTOR ASSEMBLY Comment: (10 PINION TEETH)
1	90642	DRIVE KIT
2	43076T	DRIVE ASSEMBLY Comment: (10 PINION TEETH)
3	68584	PLATE ASSEMBLY, DRIVE END
5	13-26992	LOCKWASHER, (.250) Stainless Steel
7	57384	ARMATURE
8	898265016	BRUSH/SPRING KIT
9	23-57387	BUSHING, INSULATING
11	12-38013	WASHER, INPUT STUD
12	13-26992	LOCKWASHER, (.250) Stainless Steel
13	11-20890	NUT, (.250-20)
14	57389	END CAP ASSEMBLY, W/BRUSH HOLDER

▶STARTER MOTOR, RECTIFIER AND WIRING HARNESS (ELECTRIC ONLY) (42 parts)

Ref	OEM Part #	Part Name
1	8M0058226	RECTIFIER
2	10-38055	SCREW, (.190-32 x .62)
3	10-32,11-27164	NUT AND LOCKWASHER, , RECTIFIER FASTENING SCREW
4	10-32,11-45076	NUT, Brass, RECTIFIER TERMINAL
5	89-889274	SOLENIOD ASSEMBLY, Choke
6	10-25299	SCREW, (.312-18 x .75)
7	10,13-26996	LOCKWASHER, Stainless Steel, CHOKE SOLENOID TERMINAL
8	10-32,11-45076	NUT, Brass, CHOKE SOLENOID TERMINAL
9	89008A2	PLUNGER ASSEMBLY, CHOKE SOLENOID
10	19-35827	PLUG, BOTTOM COWL (PART OF BOTTOM COWL ASSEMBLY)
11	11-30428	FASTENER (PART OF BOTTOM COWL ASSEMBLY)
12	84-96219A8	HARNESS ASSEMBLY Comment: SN# USA-6052943/Australia-8075323/Belgium-9340336/Canada-7186623 & Up
13	88-8M0207796	FUSE, 20 Ampere Comment: SN# USA-6052943/Australia-8075323/Belgium-9340336/Canada-7186623 & Up
14	84-95084A2	CABLE ASSEMBLY, FUSE Comment: SN# USA-6052943/Australia-8075323/Belgium-9340336/Canada-7186623 & Up
15	54-88167	CLAMP, WIRING HARNESS Comment: SN# USA-6052943/Australia-8075323/Belgium-9340336/Canada-7186623 & Up
16	10-23702	SCREW, (.190-32 x 1.12), WIRING HARNESS CLAMP
17	24-28357	SPRING, WIRING HARNESS CLAMP SCREW
18	12-72761	WASHER, (.203 x .562 x .060) Stainless Steel, WIRING HARNESS CLAMP SCREW
19	84-88439A4	CABLE ASSEMBLY, Battery - Negative
20	886201	BRACKET, HARNESS SUPPORT
21	10-73280	SCREW, HARNESS SUPPORT BRACKET
22	88617	COVER, HARNESS SUPPORT BRACKET
23	10-28635	SCREW, (.250-20 x .620) Stainless Steel, HARNESS SUPPORT BRACKET COVER
24	50-41583T	STARTER MOTOR ASSEMBLY Comment: (10 PINION TEETH)
25	10-35213	SCREW, STARTER MOTOR TO CRANKCASE (1-5/8")
26	27-86663	GASKET, STARTER MOTOR
27	13-26992	LOCKWASHER, (.250) Stainless Steel, CABLE TO STARTER MOTOR NUT
28	11-20890	NUT, (.250-20), CABLE TO STARTER MOTOR
29	84-88809A9	CABLE ASSEMBLY, STARTER TO SOLENOID (YELLOW) Comment: SN# USA-5823918/Australia-8070640/Belgium-9298956/Canada-7169338 & Up
30	10-69035	SCREW AND LOCKWASHER, (.250-20 x .625) Stainless Steel
31	8M0185622	SOLENOID, Starter Comment: SN# USA-5823918/Australia-8070640/Belgium-9298956/Canada-7169338 & Up
32	10-98253	SCREW, (.250-20 x .500), SOLENOID TO BRACKET
33	13-26992	LOCKWASHER, (.250) Stainless Steel, STARTER SOLENOID SCREW
34	85-78866	INSULATOR, STARTER SOLENOID Comment: SN# USA-5823917/Australia-8070639/Belgium-9298955/Canada-7169337 & Below
35	10,13-26996	LOCKWASHER, Stainless Steel Comment: SN# USA-5823917/Australia-8070639/Belgium-9298955/Canada-7169337 & Below
36	8-32,11-26419	NUT, Brass Comment: SN# USA-5823918/Australia-8070640/Belgium-9298956/Canada-7169338 & Up
37	13-8M0204647	LOCKWASHER, (.312) Comment: SN# USA-5823917/Australia-8070639/Belgium-9298955/Canada-7169337 & Below
38	11-94330	NUT, (.250-20) Brass Comment: SN# USA-5823918/Australia-8070640/Belgium-9298956/Canada-7169338 & Up
39	42729A1	BRACKET, STARTER MOTOR TO CRANKCASE
40	10-32079	SCREW, (.250-20 x .560)
41	10-69022	SCREW, (#10-32 x .500) Stainless Steel, BRACKET TO CRANKCASE
42	12-89302	WASHER, (.203 x .406 x .040), BRACKET SCREW

▶STEERING HANDLE ASSEMBLY (47 parts)

Ref	OEM Part #	Part Name
-	52148A1	CO-PILOT KIT
1	48416	CAP, STEERING HANDLE GRIP
2	11-826709109	NUT, (.250-28), STEERING HANDLE ARM
3	12-69056	WASHER, (.255 x .625 x .0312), STEERING HANDLE ARM
4	58192A1	GRIP, STEERING HANDLE ARM
5	48414	HOUSING, DRIVE WHEEL - STEERING ARM HANDLE
6	48516A1	DRIVE WHEEL/ROD ASSEMBLY
7	48405A2	ARM, STEERING HANDLE
8	48519	PLATE, COVER - DRIVE WHEEL
9	27-48518	GASKET, COVER PLATE
10	10-72169	SCREW, (#10-24 x .50)
11	8885242	CONDUIT, CABLE
12	48520	CABLE, Throttle
13	89578	BARREL, CONTROL LINKAGE
14	10-824081	SCREW, SET - THROTTLE CABLE GUIDE TUBE
15	8M0026078	TUBE, THROTTLE CABLE GUIDE
16	8M0204660	GUIDE, THROTTLE CABLE
17	20007	ANCHOR, THROTTLE CABLE
18	8-32,10-8M0204644	SET SCREW, , THROTTLE CABLE ANCHOR
19	48404T8	BRACKET, STEERING HANDLE
20	48416	CAP, STEERING HANDLE BRACKET
21	10-823597	SCREW
22	12-48477	WASHER, STEERING HANDLE BRACKET (.505 I.D.)
23	12-48526	WASHER, NYLON - HANDLE BRACKET (.630 I.D.)
24	23-28919	BUSHING, NYLON - HANDLE BRACKET (5/8" I.D.)
25	23-48525	SPACER, STEERING HANDLE BRACKET
26	12-38000	WASHER, NYLON - HANDLE BRACKET (1-35/64" O.D.)
27	13-48478	WAVE WASHER, STEERING HANDLE BRACKET
28	12-49636	WASHER, NYLON - HANDLE BRACKET (1-3/4 O.D.)
29	11-82671317	NUT, (.500-20), STEERING HANDLE BRACKET SCREW
30	10-35786	SCREW, (.375-24 x 1.00), BRACKET TO ENGINE
31	14-43589	TAB WASHER, BRACKET SCREW
32	78812A1	DETENT, SHIFT LEVER
33	10-48409	SCREW, (#10-16 x .625) Stainless Steel
34	485681	LEVER, Shift
35	23-48237	BUSHING, NYLON - SHIFT LEVER (3/8" I.D.)
36	12-34931	WASHER, (.406 x .734 x .063) Stainless Steel, SHIFT LEVER
37	11-8M0204726	NUT, (.375-24), SHIFT LEVER TO STEERING HANDLE BRACKET
38	8128061	SHIFT ROD, SHIFT
39	48419T	ROD END, SHIFT ROD
40	23-48475	BUSHING, NYLON - SHIFT ROD (1/4" I.D.)
41	12-35950	WASHER, (.273 x .437 x .031) Stainless Steel, SHIFT ROD
42	18-25191	COTTER PIN, SHIFT ROD
43	98530	KNOB, SHIFT LEVER
44	45064	COVER, BOTTOM COWL - SHORTING SWITCH
45	19-35827	PLUG, BOTTOM COWL - SHORTING SWITCH HOLE
46	11-30428	FASTENER, PLUG TO BOTTOM COWL

▶THROTTLE AND SPARK ADVANCE LINKAGE (40 parts)

Ref	OEM Part #	Part Name
1	44405	CAM, Throttle, ACTUATOR Comment: SN# USA-6052943/Australia-8075323/Belgium-9340336/Canada-7186623 & Up
2	10-63102	SCREW, (.250-20 x 1.250), ADJUSTING - THROTTLE CAM
3	11-64015	NUT, (.250-20), JAM - ADJUSTING SCREW
4	26852	CAP, Nylon, ADJUSTING SCREW
5	39522T	BRACKET, THROTTLE CONTROL SHAFT
6	10-64021	SCREW
7	11-64015	NUT, (.250-20), JAM - ADJUSTING SCREW
8	26852	CAP, Nylon, ADJUSTING SCREW
9	10-20639	SCREW, (.312-24 x 1.12)
10	11-29250	NUT, (.312-24), THROTTLE CONTROL BRACKET SCREW
11	10-34438	SCREW
12	12-25893	WASHER
13	13-62172	WAVE WASHER
14	11-29250	NUT, (.312-24)
15	62171	BALL JOINT, THROTTLE CAM Comment: SN# USA-6052942/Australia-8075322/Belgium-9340335/Canada-7186622 & Below
16	11-20013	NUT, (.250-28) Comment: SN# USA-6052942/Australia-8075322/Belgium-9340335/Canada-7186622 & Below
17	62174	TURNBUCKLE, SPARK ADVANCE LINKAGE Comment: SN# USA-6052942/Australia-8075322/Belgium-9340335/Canada-7186622 & Below
18	11-20754	NUT, (.250-28) Comment: SN# USA-6052942/Australia-8075322/Belgium-9340335/Canada-7186622 & Below
19	62173	ROD, UPPER Comment: SN# USA-6052942/Australia-8075322/Belgium-9340335/Canada-7186622 & Below
20	57440	SWIVEL, UPPER LINK ROD Comment: SN# USA-6052942/Australia-8075322/Belgium-9340335/Canada-7186622 & Below
21	95044	LINK ROD Comment: SN# USA-6052943/Australia-8075323/Belgium-9340336/Canada-7186623 & Up
22	95045	SWIVEL, LINK ROD Comment: SN# USA-6052943/Australia-8075323/Belgium-9340336/Canada-7186623 & Up
23	95049	LEVER, THROTTLE CONTROL Comment: SN# USA-6052943/Australia-8075323/Belgium-9340336/Canada-7186623 & Up
24	10-818165	SCREW, (.375-16 x 1.75)
25	23-55164	BUSHING, THROTTLE CONTROL LEVER SCREW
26	23-55171	BUSHING, THROTTLE CONTROL LEVER SCREW
27	24-55162	SPRING, RETURN - SPARK ADVANCE LEVER
28	95051	LEVER, SPARK ADVANCE Comment: SN# USA-6052943/Australia-8075323/Belgium-9340336/Canada-7186623 & Up
29	10-32627	SCREW, (.190-32 x 1.50), ADJUSTING - ADVANCE LEVER Comment: SN# USA-6052943/Australia-8075323/Belgium-9340336/Canada-7186623 & Up
30	10-32,11-68219	NUT, Stainless Steel, JAM - ADJUSTING SCREW Comment: SN# USA-6052943/Australia-8075323/Belgium-9340336/Canada-7186623 & Up
31	48039	CAP, NYLON - ADJUSTING SCREW Comment: SN# USA-6052943/Australia-8075323/Belgium-9340336/Canada-7186623 & Up
32	12-68410	WASHER, THROTTLE CONTROL LEVER SCREW
33	39483	LATCH
34	10-69026	SCREW, (.250-28 x .880)
35	24-20099	SPRING, COMPRESSION - LATCH SCREW
36	11-826709109	NUT, (.250-28), LATCH SCREW
37	62459T	BALL JOINT ASSEMBLY, SPARK ADVANCE LEVER
38	10-32,11-46438	NUT, , BALL JOINT TO SPARK ADVANCE LEVER
39	61940	LINK ROD
40	61939	PIVOT, THREADED - TRIGGER PLATE TO LINK ROD

▶TOP COWL AND COWLING (21 parts)

Ref	OEM Part #	Part Name
1	2138-6340A2	TOP COWL ASSEMBLY Comment: (MANUAL)
2	58657	ROPE GUIDE, STARTER ROPE Comment: (PLASTIC)
3	53-72168	RING, RETAINING - ROPE GUIDE Comment: (PLASTIC)
4	62236	SHILD, REAR - TOP COWL
5	10-48409	SCREW, (#10-16 x .625) Stainless Steel, REAR SHIELD TO TOP COWL
6	12-26014	WASHER, REAR SHIELD SCREW
7	55455	HOOK, TOP COWL LATCH - REAR
8	10-22956	SCREW, (.250-28 x .880), REAR HOOK TO TOP COWL
9	13-26992	LOCKWASHER, (.250) Stainless Steel, REAR HOOK SCREW
10	75973	PLATE, HINGE
11	10-32228	SCREW, (#10-32 x .625), HINGE PLATE
12	10,13-26996	LOCKWASHER, Stainless Steel, HINGE PLATE SCREW
13	94918F1	LEVER, COWL LATCH
14	52739	HINGE, COWL LATCH LEVER
15	17-58998	PIN, HINGE TO LEVER
16	2137-3878A6	WRAP AROUND COWL ASSEMBLY
17	76259	BLANKET, SOUND ABSORBING Comment: (EARLY STYLE ENGINES)
18	46785A1	LATCH ASSEMBLY, Cowl
19	30413	HOOK, COWL LATCH FASTENING
20	2161-6347A20	COVER ASSEMBLY, Cowl - Front
21	76450	BLANKET, COWL FRONT COVER

100-Hour / Annual Service Checklist

Regular maintenance keeps your Mercury 402, 40 (2 CYL.) running reliably season after season. Most of these tasks can be performed with basic tools and the factory service manual.

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

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

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Mercury 402, 40 (2 CYL.) (5556230 & Up) Parts & Diagrams

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