Mercury 402, 40 (2 CYL.) (7112423 THRU 7144762) Parts & Diagrams

🔎 Mercury 402, 40 (2 CYL.) Reference Library — Exploded parts diagrams (19 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 ASSEMBLY (25 parts)

Ref	OEM Part #	Part Name
1	2139-7642A2	BOTTOM COWL
2	48472	COVER, PLUG - BOTTOM COWL HARNESS HOLE Comment: MANUAL
3	10-61802	SCREW, PLUG COVER TO BOTTOM COWL (7/8") Comment: MANUAL
4	27-628601	GASKET Comment: POWERHEAD TO EXHAUST EXTENSION PLATE
5	39622	SEAL, RUBBER Comment: EXHAUST PLATE TO BOTTOM COWL
6	42818A1	PLATE ASSEMBLY, EXHUAST EXTENSION Comment: SERIAL GROUP #1
7	23-71980	BUSHING, FLANGE EXHUAST PLATE
8	12-38453	WASHER, NYLON - WATER OUTLET TUBE
9	26-38452	SEAL, RUBBER - WATER OUTLET TUBE
10	38500	RETAINER, WATER OUTLET TUBE SEAL Comment: SERIAL GROUP #1
11	10-65414	SCREW RETAINER TO EXHAUST PLATE (3/4") Comment: SERIAL GROUP#1
12	79799	HOUSING, WATER INLET TUBE SEAL Comment: SERIAL GROUP #2
13	27-797971	GASKET, HOUSING Comment: SERIAL GROUP #2
14	10-79798	SCREW, HOUSING TO EXHAUST PLATE (1 3/8") Comment: SERIAL GROUP #2
15	27-385011	GASKET Comment: EXHAUST PLATE TO DRIVE SHAFT HOUSING
16	37637	BOOT, FUEL CONNECTOR - BOTTOM COWL
17	39616	BOOT, CONTROL CABLE - BOTTOM COWL
18	39555	COVER PLATE ASSEMBLY
19	39556	PAD, SOUND - COVER PLATE
20	10-8M0113176	SCREW, COVER PLATE TO BOTTOM COWL
21	87-69508A31	STOP SWITCH ASSEMBLY Comment: MANUAL
22	11-69844	NUT, STOP SWITCH Comment: MANUAL
23	76176	LEVER, FRONT COVER
24	17-26541	ROLL PIN, LEVER TO BOTTOM COWL
25	24-76177	SPRING, FRONT COVER LEVER

▶CARBURETOR ASSEMBLY (23 parts)

Ref	OEM Part #	Part Name
1	1368-7226A19	CARBURETOR ASSEMBLY
2	1395-8673	FLOAT ASSEMBLY
6	1395-83181	INLET NEEDLE, SEAT AND GASKET
10	1395-5680	COVER, FLOAT BOWL
11	1395-5733	JET, BOWL VENT (.092)
12	1395-5734	HOSE, ECONOMIZER
13	10-52195	SCREW, FLOAT BOWL COVER
14	1395-4804	SCREW, FLOAT BOWL COVER
15	13-26995	LOCKWASHER, FLOAT BOWL COVER SCREW
16	1395-4805	SCREEN, FILTER
17	74371	LEVER, THROTTLE
18	1395-6027	SCREW, THROTTLE STOP LEVER
19	1395-7942	SHAFT, THROTTLE
21	1395-4540	SCREW, BODY (IDLE TUBE)
22	1395-9017	SHUTTER, THROTTLE
25	1399-3515	SCREW, IDLE ADJUSTMENT
27	1395-4542	SCREW, PLUG - MAIN NOZZLE
28	1399-3794	JET, MAIN FUEL (.074)
29	1395-4541	SCREW, PLUG - MAIN FUEL JET CHANNEL
32	1395-4543	SCREW, BODY CHANNEL
33	1395-51091	REPAIR PARTS KIT (1PER CARBURETOR)
34	27-481641	GASKET, CARBURETOR FLANGE
35	11-64809	NUT, CARBURETOR MOUNTING STUD

▶CARBURETOR CHOKE LINKAGE (15 parts)

Ref	OEM Part #	Part Name
1	47969	KNOB AND SHAFT, CHOKE
2	12-30314	WASHER, CHOKE SHAFT
3	24-47968	SPRING, COMPRESSION - CHOKE SHAFT
4	55180	LEVER, CHOKE
5	1368-7226A19	CARBURETOR ASSEMBLY Comment: SEE CARBURETOR ASSEMBLY PAGES FOR BREAKDOWN
6	16-69016	STUD, CHOKE SHUTTER PIVOT (CARBURETOR)
7	55179	SHUTTER, CHOKE - CARBURETOR
8	24-55163	SPRING, TENSION - CHOKE SHUTTER
9	12-47960	WASHER, CHOKE SHUTTER CARBURETOR STUD
10	11-20110	NUT, CHOKE SHUTTER TO CARBURETOR STUD
11	35-57819	SCREEN, CARBURETOR
12	10-58185	SCREW, SCREEN TO CARBURETOR (1")
13	24-57818	SPRING, TENSION - SCREEN SCREW
14	12-30164	WASHER, SCREEN SCREW
15	11-20110	NUT, SCREEN SCREW

▶CLAMP AND SWIVEL BRACKET ASSEMBLY (45 parts)

Ref	OEM Part #	Part Name
1	1427-5611A4	CLAMP BRACKET ASSEMBLY
2	10-78492A1	THUMB SCREW ASSEMLBY
2A	10-78495	SCREW, WASHER TO THUMB SCREW
2B	12-78493	WASHER, THUMB SCREW
3	75043	CAP, THUMB SCREW
4	17-8M0026068	TILT LOCK PIN ASSEMBLY
5	23-59623	SPACER, CLAMP BRACKET STUD
6	16-59625	STUD, CLAMP BRACKET
7	13-8M0204647	LOCKWASHER, CLAMP BRACKET STUD
8	11-28770	NUT, CLAMP BRACKET STUD
9	8M0041936	TUBE, TILT - CLAMP BRACKET TO SWIVEL BRACKET
10	12-52864	WASHER, CLAMP BRACKET TO SWIVEL BRACKET
11	11-858869	NUT, TILT TUBE
12	69540A4	SWIVEL PIN ASSEMBLY (LONG SHAFT) Comment: ELECTRIC
13	30711	BUMPER, STEERING ARM
14	10-33986	SCREW, UPPER MOUNT TO STEERING ARM
15	62297	BUMPER, STEERING ARM Comment: MANUAL
16	76535T	BRACKET, RIDE-GUIDE ATTACHING Comment: MANUAL
19	10-34352	SCREW, BRACKET TO STEERING ARM (7/8") Comment: MANUAL
20	76533	STRAP, BRACKET SCREW Comment: MANUAL
21	12-52865	WASHER, SWIVEL PIN
22	10-68299	BOLT, CLAMP BRACKET TO BOAT TRANSOM Comment: (UPPER)
23	12-68300	WASHER, CLAMP BRACKET BOLT Comment: (UPPER)
24	11-82670912	NUT, CLAMP BRACKET BOLT
25	53078	CAP, PLASTIC - TILT TUBE
26	56349	SHAFT, REVERSE LOCK TO SWIVEL BRACKET
27	17-25598	ROLL PIN, REVERSE LOCK SPRING ATTACHING
28	87430	REVERSE LOCK ASSEMBLY
29	24-29821	SPRING, REVERSE LOCK TENSION
30	18-45882	COTTER PIN, REVERSE LOCK TO SHAFT
31	47912A2	LEVER ASSEMBLY, TILT STOP - STARBOARD SIDE
32	1480-7655A1	SWIVEL BRACKET ASSEMBLY (LONG SHAFT)
33	26-32911	OIL SEAL, SWIVEL BRACKET
34	22-8M0169589	FITTING, GREASE - SWIVEL BRACKET
35	19-77633Q	LUBRICAP, SWIVEL BRACKET GREASE FITTING
36	12-26837	WASHER, SWIVEL PIN TO BOTTOM YOKE (.065)
37	77416T1	YOKE, BOTTOM
38	53-77415	RETIANING RING, BOTTOM YOKE
39	47913A2	LEVER ASSEMBLY, TILT LOCK - PORT SIDE
40	10-69087	SCREW, TILT LOCK AND STOP LEVER TO SWIVEL BRACKET
41	11-29250	NUT, TILT LOCK AND STOP LEVER SCREW
42	23-47911	BUSHING, TILT LOCK AND STOP LEVER
43	13-34632	WASHER, WAVE - TILT LOCK AND STOP LEVER
44	12-56720	WASHER, TILT LOCK AND STOP LEVER
45	11-29250	NUT, TILT LOCK AND STOP LEVER TO CLAMP BRACKET

▶COWLING AND FRONT COVER (7 parts)

Ref	OEM Part #	Part Name
--	92-86166Q1	GLUE, ADHESIVE - BLANKET FASTENING
1	2161-6347A20	COWL FRONT COVER ASSEMBLY Comment: WITHOUT DECALS
2	76450	BLANKET, COWL FRONT COVER
3	2137-3878A6	WRAP AROUND COWL ASSEMBLY Comment: WITHOUT DECALS
4	46785A1	COWL LATCH ASSEMBLY
5	30413	HOOK, COWL LATCH FASTENING
6	76259	BLANKET, SOUND ABSORBING Comment: WRAP AROUND COWL

▶CRANKSHAFT, PISTON AND CONNECTING ROD ASSEMBLY (22 parts)

Ref	OEM Part #	Part Name
1	454-9073A1	CRANKSHAFT ASSEMBLY
2	78308A1	RETAINER ASSEMBLY, BALL BEARING
3	30-63742T	BALL BEARING, RETAINER (CRANKSHAFT)
4	53-63634	RETAINING RING, BALL BEARING
5	540-7238A2	MAIN BEARING ASSEMBLY, VALVE TYPE
6	10-22032	DOWEL PIN, MAIN BEARING
7	10-45775	SCREW, MAIN BEARING CLAMPING (9/16")
8	11-45774	NUT, MAIN BEARING CLAMPING SCREW
9	34-56007A1	REED SET, MAIN BEARING (MATCHED)
10	34-56008	REED STOP, MAIN BEARING REED VALVES
11	10-20055	SCREW, REED STOP MOUNTING (3/8")
12	60834A3	CARRIER ASSEMBLY, SEAL Comment: METAL SEAL CARRIER PRESSED IN CRANKSHAFT.
13	64254001	SEAL, CARRIER Comment: METAL SEAL CARRIER PRESSED IN CRANKSHAFT.
14	624-8101A3	CONNECTING ROD ASSEMBLY
15	10-54803	SCREW, CONNECTING ROD
16	11-49091	NUT, CONNECTING ROD SCREW
17	31-62596A1	BEARING, ASSEMBLY, CRANKPIN
18	29-8M0214934	BEARING, NEEDLE - PISTON PIN
19	12-8M0032839	WASHER, NEEDLE BEARING RETAINING
20	774-9137A12	PISTON AND PISTON PIN ASSEMBLY
21	53-857196	LOCK RING, PISTON PIN
22	39-78811A12	RING, PISTON (.015 OVERSIZE)

▶CYLINDER BLOCK AND COIL MOUNTING BRACKET (31 parts)

Ref	OEM Part #	Part Name
1	851-7940A6	CYLINDER BLOCK AND CRANKCASE ASSEMBLY
2	66843T	BRACKET, COIL MOUNTING
3	99436A1	COVER, DIAPHRAGM
4	10-31984	SCREW, COIL MOUNTING BRACKET TO BLOCK Comment: (1 3/8")
5	10-31984	SCREW, STARTER BRACKET AND COVER TO BLOCK Comment: (1 3/8")
6	10-58414	SCREW, COVER AND COIL BRACKET TO BLOCK Comment: (2 1/2")
7	13-8M0204647	LOCKWASHER, COIL MOUNTING BRACKET SCREW
8	648771	DIAPHRAGM, POPPET VALVE
9	12-76451	WASHER, DIAPHRAGM
10	10-69570	SCREW Comment: WASHER AND DIAPHRAGM TO POPPET VALVE
11	25-39597	GROMMET, COIL MOUNTING BRACKET
12	27-66847	GASKET, COIL MOUNTING BRACKET TO BLOCK
13	75692	THERMOSTAT
14	27-8M0204714	GASKET, THERMOSTAT
15	86596	POPPET, RELIEF VALVE
16	24-66852	SPRING, COMPRESSION - POPPET RELIEF VALVE
17	65848	CARRIER, POPPET VALVE
18	25-64872	GROMMET, POPPET VALVE
19	32-9938779	HOSE, CYLINDER BLEED (8")
20	21-42866	FITTING, CYLINDER BLEED (TOP)
21	21-42863	ELBOW, CYLINDER BLEED (BOTTOM)
22	58124A17	SWITCH ASSEMBLY, MERCURY
23	10-48409	SCREW, MERCURY SWITCH TO EXHAUST COVER Comment: (5/8")
24	54-26550	CLIP, MERCURY SWITCH LEAD
25	10-62568	SCREW, MERCURY SWITCH CLIP (3/8")
26	8M0084613	"D" WASHER, CLIP SCREW
27	76184	INDICATOR, TIMING Comment: ELECTRIC
28	10-25299	SCREW, INDICATOR ATTACHING (3/4") Comment: ELECTRIC
29	12-20084	WASHER, INDICATOR ATTACHING SCREW Comment: ELECTRIC
30	23-62769	SPACER, INDICATOR ATTACHING SCREW Comment: ELECTRIC
31	17-29908	ROLL PIN, INDICATOR LOCATING Comment: ELECTRIC

▶CYLINDER BLOCK AND CRANKCASE ASSEMBLY (42 parts)

Ref	OEM Part #	Part Name
1	1151-4732A1	END CAP ASSEMBLY, UPPER
2	25-47254	"O" RING, UPPER END CAP
3	31-62066T	ROLLER BEARING, UPPER END CAP
4	26-41953	OIL SEAL, UPPER END CAP
5	10-30225	SCREW, UPPER END CAP MOUNTING (1")
6	851-7940A6	CYLINDER BLOCK AND CRANKCASE ASSEMBLY
7	16-64936	STUD, CARBURETOR MOUNTING (1 1/4") Comment: (1 1/4")
8	16-68165	STUD, CRANKCASE TO DRIVE SHAFT HOUSING Comment: (1 5/8")
9	16-68168	STUD, CYLINDER BLOCK TO DRIVE SHAFT HOUSING Comment: (3 11/16")
10	16-68166	STUD, CYLINDER BLOCK TO DRIVE SHAFT HOUSING Comment: (2 7/64")
11	16-68167	STUD, CYLINDER BLOCK TO DRIVE SHAFT HOUSING Comment: (2 9/16")
12	66517	RESTRICTOR, CYLINDER BLOCK (BLEED)
13	17-23784	DOWEL PIN, CRANKCASE TO CYLINDER BLOCK
14	17-20323	DOWEL PIN, CYLINDER BLOCK TO MAIN BEARING
15	27-55158	GASKET, SEALING - CYLINDER BLOCK
15A	22-328022	PIPE PLUG, CYLINDER BLOCK
16	62064	BRACKET, STARTER MOTOR
17	10-21339	SCREW, STARTER MOTOR BRACKET TO BLOCK Comment: (1 3/8")
18	11-29250	NUT, STARTER MOTOR BRACKET SCREW
19	10-74824	SCREW, CRANKCASE TO CYLINDER BLOCK (1 1/4")
21	1152-7267A1	END CAP ASSEMBLY, LOWER
22	26-41953	OIL SEAL, LOWER END CAP
23	25-64068	"O" RING, LOWER END CAP SCREW
24	25-823683	"O" RING, LOWER END CAP
25	10-63365	SCREW Comment: LOWER END CAP TO CYLINDER BLOCK AND CRANKCASE (1 1/2")
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, MANIFOLD COVER TO CYLINDER BLOCK Comment: (1 3/8")
31	10-64021	SCREW, ADJUSTING - EXHAUST COVER (1 7/8")
32	11-64015	NUT, ADJUSTING SCREW
33	26852	CAP, NYLON - ADJUSTING SCREW
34	1024-91101	COVER, CYLINDER BLOCK
35	27-85490	GASKET, CYLINDER BLOCK COVER
36	10-76213	SCREW, CYLINDER BLOCK COVER MOUNTING Comment: (1 1/8")
38	46933A3	GROUND STRAP, POWERHEAD TO Comment: BOTTOM COWL
39	22-328022	PLUG, PIPE - CYLINDER BLOCK COVER
40	63970	COVER, TRANSFER PORT
41	27-552791	GASKET, TRANSFER PORT COVER
42	54-54457	"J" CLIP, COIL HARNESS
43	10-8M0214943	SCREW, TRANSFER PORT COVER MOUNTING (1")

▶DRIVE SHAFT HOUSING ASSEMBLY (48 parts)

Ref	OEM Part #	Part Name
1	1593-7513A12	DRIVE SHAFT HOUSING ASSEMBLY (LONG SHAFT)
2	16-8M0022145	STUD, DRIVE SHAFT HOUSING TO GEAR HOUSING Comment: (1 3/4")
3	16-57935	STUD, DRIVE SHAFT HOUSING TO GEAR HOUSING Comment: (3")
4	19-64649	PLUG, PLASTIC - WATER PICK-UP HOLES
9	12-65791	WASHER, DRIVE SHAFT HOUSING TO GEAR HOUSING STUDS
10	60769	COVER, TRIM - DRIVE SHAFT HOUSING
11	10-57807	SCREW, TRIM COVER TO DRIVE SHAFT HOUSING
12	25-92012	GROMMET, TRIM COVER SCREW
13	32-45679	TUBE, WATER OUTLET (LONG SHAFT)
14	695441	TUBE, EXHAUST (LONG SHAFT)
15	11-64809	NUT, POWERHEAD STUDS
16	46933A2	GROUND STRAP Comment: BOTTOM COWL TO DRIVE SHAFT HOUSING
17	10-48408	SCREW, GROUND STRAP ATTACHING (1/2")
18	13-69432	LOCKWASHER, GROUND STRAP SCREW
19	27-385011	GASKET, EXHAUST PLATE TO DRIVE SHAFT HOUSING
20	11-23161	NUT, UPPER MOUNT BOLT
21	12-30519	WASHER, UPPER MOUNT BOLT (3/8 ID)
22	12-66966	WASHER, RUBBER - UPPER MOUNT BOLT
23	12-27727	WASHER, UPPER MOUNT BOLT (37/64 ID)
24	79680A1	COVER, UPPER MOUNT - OUTSIDE HALF Comment: SERIAL GROUP #2
25	79681	COVER, UPPER MOUNT - INSIDE HALF Comment: SERIAL GROUP #2
26	96401	SEAL, BELLOWS - UPPER MOUNT Comment: SERIAL GROUP #2
27	25-65936	"O" RING, UPPER MOUNT Comment: SERIAL GROUP #1
28	75301	MOUNT, RUBBER - UPPER
29	10-67916	SCREW, UPPER MOUNT COVER - REAR (2")
30	10-69029	SCREW, UPPER MOUNT COVER - FRONT (1 3/4")
30A	12-8M0204649	WASHER, UPPER MOUNT COVER SCREW
31	11-36069	NUT, UPPER MOUNT COVER SCREW
32	25067	BUMPER, LOWER MOUNT (T 1/2")
33	10-75284	SCREW, LOWER MOUNT (5 1/2")
34	12-28051	WASHER, LOWER MOUNT SCREW
35	12-28053	WASHER, RUBBER - LOWER MOUNT SCREW
36	75302T1	MOUNT, RUBBER - LOWER
37	12-30119	WASHER, LOWER MOUNT SCREW
38	11-25096	NUT, LOWER MOUNT SCREW
39	69592F1	CLAMP, LOWER MOUNT TO DRIVE SHAFT HOUSING
40	10-29256	SCREW, LOWER MOUNT CLAMP Comment: TO DRIVE SHAFT HOUSING (7/8")
41	24-35522	SPRING, TENSION - LOWER MOUNT CLAMP
42	35474T	COVER, LOWER MOUNT CLAMP
43	10-29722	SCREW, COVER TO LOWER CLAMP (5/8")
44	11-35521	NUT, LOWER MOUNT CLAMP COVER
45	11-8M0204653	NUT Comment: GEAR HOUSING TO DRIVE SHAFT HOUSING STUDS
46	933361	GUIDE, PUSH ROD
47	59720	ROD, PUSH - REVERSE LOCK (LONG SHAFT)
48	11-28770	NUT, JAM - PUSH ROD
49	59722	ROD END, PUSH ROD
50	17-72524	PIN, REVERSE LOCK LEVER
51	18-25191	COTTER PIN, PUSH ROD TO REVERSE LOCK

▶FLYWHEEL, IGNITION COIL AND SWITCH BOX (36 parts)

Ref	OEM Part #	Part Name
1	11-8M0214915	NUT, FLYWHEEL
2	12-36258	WASHER, FLYWHEEL NUT
3	28-45554	KEY, FLYWHEEL DRIVE
4	242-4764A25	FLYWHEEL ASSEMBLY (ELECTRIC) Comment: SERIAL CROUP #2
5	10-32417	SCREW, FLEXIBLE PLATE TO FLYWHEEL (9/16")
6	50-65213	RATCHET, FLYWHEEL Comment: MANUAL
7	10-69088	SCREW, RATCHET TO FLYWHEEL (7/8") Comment: MANUAL
8	13-20202	LOCKWASHER, RATCHET SCREW Comment: MANUAL
9	398-5255	STATOR, ALTERNATOR Comment: ELECTRIC
10	10-56787	SCREW, STATOR TO UPPER END CAP (2")
11	13-26996	LOCKWASHER, STATOR SCREW
12	61830	STATOR SUPPORT
13	12-62133	WASHER, TRIGGER TO STATOR SUPPORT Comment: UPPER
14	13-61983	WASHER, WAVE - TRIGGER TO STATOR SUPPORT Comment: CENTER
15	12-61982	WASHER, TRIGGER TO STATOR SUPPORT (LOWER)
16	338-4731A8	TRIGGER PLATE ASSEMBLY
17	24-62095	SPRING, COMPRESSION
18	17-62768	PIN, SPRING RETENTION
19	54-54457	"J" CLIP, TRIGGER LEADS TO RUBBER SUPPORT Comment: MOUNT
20	300-8M0166172	IGNITION COIL ASSEMBLY, COMPLETE
23	11-45076	NUT, COIL TERMINALS
24	84-60466A1	GROUND WIRE Comment: COIL GROUND TO COIL COVER SCREW
25	76254	COVER, IGNITION COIL
26	10-60194	SCREW, COIL COVER TO COIL BRACKET (2 1/8")
27	84-813715A1	LED ASSEMBLY, SPARK PLUG (HIGH TENSION)
28	33-896329827	SPARK PLUG (AC#V-R0FFM) Comment: FOR CANADA AND BELGIUM, USE C-33-68098 (CHAMPION #QL-76V)
29	85-63709A1	PROTECTOR ASSEMLBY, SPARK PLUG
30	332-2854T01	BOOT, LEAD TO IGNITION COIL
31	332-4911A8	SWITCH BOX ASSEMBLY, COMPLETE
32	54-54457	"J" CLIP, SWITCH BOX LEADS
33	10-69067	SCREW, SWITCH BOX AND "J" CLIP TO BRACKET
34	10-45218	SCREW, TERMINAL BLOCK AND SWITCH BOX (3/8")
35	86-66754	TERMINAL BLOCK, SWITCH BOX LEAD
36	10-38055	SCREW, TERMINAL BLOCK ATTACHING
37	11-8267086	NUT, TERMINAL BLOCK ATTACHING SCREWS
38	61990	STA-STRAP, STATOR LEADS

▶FUEL PUMP ASSEMBLY AND FUEL LINES (35 parts)

Ref	OEM Part #	Part Name
1	62973A4	FUEL PUMP ASSEMBLY
2	21-30430A3	CHECK VALVE ASSEMBLY
3	55278A1	DIAPHRAGM KIT
6	23004	RETAINER, CHECK VALVE
7	10-43725	SCREW, RETAINER TO HOUSING
8	10-69093	SCREW, FUEL PUMP MOUNTING (1 1/2")
9	22-328022	PLUG, PIPE - FUEL PUMP
10	69791A2	HOSE AND NOZZLE, TELL TALE Comment: PART OF BOTTOM COWL ASSEMBLY
11	66849	CLAMP, TELL TALE HOSE AND NOZZLE Comment: PART OF BOTTOM COWL ASSEMBLY
12	32-8M0108355	HOSE ASSEMBLY, CYLINDER BLOCK TO FUEL PUMP Comment: (11")
14	22-291112	FITTING, BLOCK TO FUEL PUMP HOSE
15	22-64705	FITTING, PUMP INLET
17	22-63187	FITTING, FUEL LINE TO ADAPTOR
18	32-8M0108355	FUEL LINE, FUEL PUMP TO ADAPTOR (12 1/4")
19	22833	ADAPTOR, CHECK UNIT (FUEL PUMP)
20	23069	STEM, CHECK UNIT ADAPTOR
21	25-16524	"O" RING, ADAPTOR STEM
22	24-23067T	SPRING, ADAPTOR STEM
23	30188	CUP WASHER, ADAPTOR
24	10-56500	SCREW, ADAPTOR TO BOTTOM COWL (1 1/4")
25	11-36069	NUT, ADAPTOR SCREW
26	22-19688	ELBOW, PUMP OUTLET (90)
27	54-68424	CLAMP, FUEL LINE ATTACHING
28	32-8M0108355	FUEL LINE, FUEL PUMP TO FILTER COVER (4 1/2")
29	70929	BASE, FUEL PUMP
30	10-71913	SCREW, BASE TO TRANSFER PORT COVER
31	35-59072	SCREEN, FILTER - INLET
32	25-35480	"O" RING, COVER TO HOUSING
33	35-91078A1	COVER, FUEL INLET
34	27-25848	GASKET, NYLON - FILTER COVER SCREW
35	10-37370	SCREW, COVER TO FUEL PUMP (5/8")
36	22-64705	FITTING, FILTER BASE
37	32-8M0108355	FUEL LINE, FILTER COVER TO PUMP (6")
38	22-19688	FITTING, ELBOW - CARBURETOR
39	10-48409	SCREW, CLAMP TO BOTTOM COWL

▶GEAR HOUSING ASSEMBLY, COMPLETE (PAGE 1 OF 2) (50 parts)

Ref	OEM Part #	Part Name
-	26-79831A1	SEAL KIT
1	1643-9539T1	GEAR HOUSING ASSEMBLY Comment: SERIAL GROUP #2
1A	22-85822A10	CONNECTOR ASSEMBLY, SPEEDOMETER Comment: SERIAL GROUP #2
2	17-8M0084726	PIN, DOWEL - GEAR HOUSING
3	16-33778	STUD, WATER PUMP BODY/BASE TO GEAR HSG. Comment: (2 5/8")
4	16-8M0034453	STUD, GEAR HOUSING TO DRIVE SHAFT HOUSING
5	31-62091T	BEARING, ROLLER - DRIVE SHAFT
6	72849A1	SCREEN, WATER INTAKE - PORT
7	10-36070	SCREW Comment: WATER INTAKE SCREEN TO GEAR HOUSING
8	11-859124	NUT, WATER INTAKE SCREEN SCREW
9	92815	PLATE, SUPPORT - EXHAUST TUBE
10	37721001	SEAL, EXHAUST TUBE
11	43-55607	GEAR, PINION - DRIVE SHAFT
12	11-55910	NUT, PINION GEAR TO DRIVE SHAFT
13	27-19552	GASKET, WATER PUMP BASE TO GEAR HOUSING
14	25-26722	,"O" RING, WATER PUMP BASE
15	46-77177A1	WATER PUMP BASE ASSEMBLY
16	26-79831	OIL SEAL, WATER PUMP BASE
17	26-90562	OIL SEAL, WATER PUMP BASE
18	17-35973	DOWEL PIN Comment: WATER PUMP BASE TO WATER PUMP BODY
19	27-19553	GASKET, LOWER Comment: WATER PUMP BASE TO FACE PLATE
20	32768	PLATE, FACE Comment: WATER PUMP BASE TO WATER PUMP BODY
21	27-19551	GASKET, UPPER Comment: FACE PLATE TO WATER PUMP BODY
22	47-89983T	IMPELLER, WATER PUMP
23	28-8M0032837	KEY, IMPELLER DRIVE
24	46-77822A1	WATER PUMP BODY ASSEMBLY
25	48753	INSERT, WATER PUMP BODY
26	12-8M0204649	WASHER, WATER PUMP BODY AND BASE STUDS
27	11-35888	NUT, WATER PUMP BODY AND BASE STUDS
28	26-38452	SEAL, RUBBER - WATER INLET TUBE (WATER PUMP BODY)
29	12-38453	WASHER, NYLON - WATER PUMP BODY
30	25-20273	RING, RUBBER - CENTRIFUGAL SLINGER (DRIVE SHAFT)
31	22-8M0058389	SCREW, DRAIN (MAGNETIC)
32	12-191833	WASHER, GREASE FILLER AND DRAIN SCREW
35	76063A1	SHAFT ASSEMBLY, SHIFT - LOWER
36	53-29641	CLIP, RETAINING - SHIFT SHAFT
37	25-25439	"O" RING, SHIFT SHAFT BUSHING
38	23-77631A2	BUSHING ASSEMBLY, SHIFT SHAFT
39	26-8M0204708	OIL SEAL, SHIFT SHAFT BUSHING
41	12-77674	WASHER, RUBBER - SHIFT SHAFT BUSHING
42	78036	BASE, REVERSE LOCKING
43	43308T1	CAM, REVERSE LOCKING
44	45-77389A2	DRIVE SHAFT ASSEMBLY (LONG SHAFT) Comment: UNITED STATES 5174088 AND BELOW AUSTRALIA 8052649 AND BELOW BELGIUM 9214055 AND BELOW CANADA 7123912 AND BELOW
45	24-20254	SPRING, COMPRESSION - DRIVE SHAFT
46	17-30545	PIN, DRIVE SHAFT
47	88181	SLEEVE, LUBRICATION - DRIVE SHAFT
48	15-92881A1	SHIM, BEARING TO GEAR HOUSING (.002-3-5-10-20)
49	31-8M0166756	ROLLER BEARING ASSEMBLY, TAPERED - DRIVE SHAFT
49A	78654A1	SEAT ASSEMBLY, DRIVE SHAFT Comment: SPLINED NYLON SEAL SEAT ON DRIVE SHAFT.
49B	86304	SEAL, SPLINED - DRIVE SHAFT Comment: SPLINED NYLON SEAL SEAT ON DRIVE SHAFT.

▶GEAR HOUSING ASSEMBLY, COMPLETE (PAGE 2 OF 2) (33 parts)

Ref	OEM Part #	Part Name
1	1643-9539T1	GEAR HOUSING ASS'Y Comment: SEE GEAR HOUSING ASSEMBLY, COMPLETE FOR BREAKDOWN SERIAL GROUP #2
51	760394	CAM, SHIFT Comment: SERIAL GROUP #2
52	38441	FOLLOWER, CA
53	20843	SLIDE, CROSS PIN
54	24-39845	SPRING, COMPRESSION - CAM FOLLOWER
55	15-38374A1	SHIM, BEARING CUP TO GEAR HOUSING Comment: (.002-3-5-10)
56	31-38356A1	TAPERED ROLLER BEARING ASSEMBLY
57	31-21739	BEARING, ROLLER - FORWARD GEAR
58	43-55608T4	FORWARD GEAR ASSEMBLY
59	52-92911T	RATCHET, SLIDING CLUTCH
60	17-8M0020942	PIN, CROSS - RATCHET TO PROPELLER SHAFT
61	24-38114	SPRING, RETAINING - CROSS PIN
62	44-75365	SHAFT, PROPELLER
63	43-79158T	REVERSE GEAR ASSEMBLY
65	12-32004	WASHER, THRUST - REVERSE GEAR
66	30-20839T	BEARING, BALL - REVERSE GEAR
67	25-31986	"O" RING, BEARING CARRIER
68	69386T1	BEARING CARRIER ASSEMBLY
69	31-21700	BEARING, ROLLER - BEARING CARRIER
70	26-8M0205511	OIL SEAL, BEARING CARRIER
71	26-8M0203757	OIL SEAL, BEARING CARRIER
72	28-30281	KEY, LOCATING - BEARING CARRIER
73	14-53012	TAB WASHER, GEAR HOUSING COVER
74	11-87763	COVER, GEAR HOUSING
75	97-31640Q4	TRIM TAB ASSEMBLY, GEAR HOUSING
76	10-66024	SCREW, TRIM TAB TO GEAR HOUSING
77	12-8M0214963	WASHER, DRIVE SHAFT HOUSING STUD (3/8")
78	11-8M0204726	NUT, DRIVE SHAFT HOUSING STUD (3/8")
79	12-65791	WASHER Comment: DRIVE SHAFT HOUSING TO GEAR HOUSING STUD (7/16")
80	11-8M0204653	NUT Comment: DRIVE SHAFT HOUSING TO GEAR HOUSING STUD (7/16")
81	73345A1	THRUST HUB, FRONT
84	14-8M0214942	TAB WASHER, PROPELLER
85	11-69578Q1	NUT, PROPELLER

▶MISCELLANEOUS PARTS/ACCESSORIES (1 parts)

Ref	OEM Part #	Part Name
-	37-89325A80	DECAL SET -SERIAL GROUP #2

▶SHIFT CONTROL LINKAGE (19 parts)

Ref	OEM Part #	Part Name
1	87876A2	BRACKET, SHIFT ANCHOR - UPPER
2	10-67450	SCREW, ANCHOR BRACKET TO CYLINDER BLOCK Comment: (2 1/8")
3	10-35385	SCREW, BRACKET TO CRANKCASE Comment: (1 3/4")
5	87874	SLIDE, SHIFT ACTUATING
6	56193	LATCH, SHIFT ACTUATING SLIDE (SHIFT CABLE)
8	10-39620	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, UPPER BRACKET TO LOWER BRACKET Comment: (1 5/8")
13	24-20856	NUT, UPPER ANCHOR BRACKET SCREW
14	75104A8	SHIFT SHAFT ASSEMBLY (LONG SHAFT)
16	12-37998	WASHER, UPPER SHIFT SHAFT Comment: MANUAL
17	18-26811	COTTOER PIN, UPPER SHIFT SHAFT Comment: MANUAL
18	39519	CUP, RETAINER - ANCHOR BRACKET Comment: (SHIFT CABLE BARREL)
19	87609A1	LEVER, NYLON - SHIFT CABLE LOCKING Comment: (UPPER BRACKET)
20	17-47175	PIN, LOCKING LEVER AND COVER FASTENING
21	39667	COVER, NYLON - SHIFT CABLE
22	87609A1	LINK, LOCKING LEVER TO COVER

▶STARTER HOUSING (41 parts)

Ref	OEM Part #	Part Name
1	14-61004	TAB, WASHER, SHEAVE SHAFT NUT
2	11-20166	NUT, SHEAVE SHAFT (LEFT HAND THREAD)
3	25-39597	GROMMET, STARTER HOUSING
4	76141	CALBE ASSEMBLY, INTERLOCK Comment: MANUAL
5	10-32228	SCREW, CABLE TO EXHAUST PLATE (5/8") Comment: MANUAL
6	10-69022	SCREW, CABLE TO STARTER HOUSING (1/2") Comment: MANUAL
7	428201	CAM, INTERLOCK Comment: MANUAL
8	10-76138	SCREW, INTERLOCK CAM ATTACHING (1 1/8") Comment: MANUAL
9	24-761401	SPRING, INTERLOCK CAM SCREW Comment: MANUAL
10	79371	ACTUATOR, INTERLOCK Comment: MANUAL
11	10-76137	SCREW, INTERLOCK ACTUATOR ATTACHING (1 5/8") Comment: MANUAL
12	24-76139	SPRING, INTERLOCK ACTUATOR SCREW Comment: MANUAL
13	12-30191	WSHER, INTERLOCK CABLE Comment: MANUAL
14	18-26811	COTTER PIN, INTERLOCK CABLE TO ACTUATOR Comment: MANUAL
15	55860	PULLEY, STARTER SCREW
16	10-45210	SCREW, PULLEY TO STARTER HOUSING (1 1/4")
17	12-22887	WASHER, PULLEY SCREW
18	23-309772	SPACER, PULLEY SCREW
19	11-24656	NUT, PULLEY SCREW
20	76079A8	HOUSING, STARTER
21	10-37562	SCREW, STARTER HOUSING TO CRANKCASE (1")
22	10-37562	LOCKWASHER, STARTER HOUSING SCREW
23	61002	RETAINER, STARTER REWIND
24	24-39502T02	SPRING, STARTER REWIND
25	23-63100	BUSHING, SPRING GUIDE
26	76053A1	STARTER SHEAVE ASSEMBLY
27	30596	PAWL, STARTER
28	13-36206	WASHER, WAVE - STARTER PAWL
29	23-63061	SPACER, SHEAVE SHAFT
30	39840	RETAINER, WAVE WASHER
31	12-57837	WASHER, WAVE WASHER RETAINER
32	12-57837	WASHER, WAVE - RETAINER TENSION
33	66845	PLATE, RETAINER - STARTER PAWL
34	24-66853	SPRING, RETAINER TO STARTER SHEAVE
35	66848	RETAINER, SPRING
36	12-57860	WASHER, SHEAVE SHAFT
37	61003	SHAFT, SHEAVE
38	47341A11	STARTER ROPE ASSEMBLY Comment: FOR MANUAL STARTING
39	79470A1	RETAINER, STARTER ROPE Comment: SERIAL GROUP #1
39&40	79470A1	RETAINER ASSEMBLY, STARTER ROPE Comment: SERIAL GROUP #2
40	77998	HANDLE, STARTER ROPE Comment: SERIAL GROUP #1

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

Ref	OEM Part #	Part Name
1	8M0058226	RECTIFIER ASSEMBLY
2	10-25764	SCREW, RECTIFIER TO FRONT SUPPORT BRACKET Comment: (1/2")
3	11-27164	NUT, RECTIFIER FASTENING SCREW
5	11-45076	NUT, RECTIFIER TERMINAL (10-32)
6	89-889274	CHOKE SOLENOID ASSEMBLY
7	10-25299	SCREW Comment: CHOKE SOLENOID FRONT SUPPORT BRACKET (3/4")
9	13-26996	LOCKWASHER, CHOKE SOLENOID TERMINAL
10	11-45076	NUT, CHOKE SOLENOID TERMINAL
11	89008A2	PLUNGER ASSEMBLY, CHOKE SOLENOID
12	84-61393A1	LEAD ASSEMBLY Comment: RECTIFIER TO STARTER SOLENOID (4 7/8")
13	85-62453	BOOT, LEAD WIRE
14	19-35827	PLUG, BOTTOM COWL Comment: PART OF BOTTOM COWL ASSEMBLY
15	11-30428	FASTENER, PLUG TO BOTTOM COWL Comment: PART OF BOTTOM COWL ASSEMBLY
16	34228	SUPPORT, EXTERNAL WIRING HARNESS
17	10-67917	SCREW, SUPPORT TO BOTTOM COWL (5/8")
18	52907	INSULATOR, SUPPORT TO BOTTOM COWL
19	11-35888	NUT, SUPPORT FASTENING SCREW
20	10-98256	SCREW Comment: WIRING HARNESS GROUND TO BOTTOM COWL (1/2")
21	13-24669	LOCKWASHER, WIRING HARNESS GROUND SCREW
22	84-73826A1	WIRING HARNESS (INTERNAL)
23	54-76368	CLAMP, WIRING HARNESS ATTACHING
24	10-69013	SCREW Comment: WIRING HARNESS CLAMP TO BOTTOM COWL (7/8")
25	24-28975	SPRING, GARTER - INTERNAL WIRING HARNESS
26	50-55601A2	STARTER MOTOR ASSEMBLY
27	10-35213	SCREW, STARTER MOTOR TO CRANKCASE (1 5/8")
28	13-8M0204647	LOCKWASHER, CABLE TO STARTER MOTOR NUT
29	11-20890	NUT, CABLE TO STARTER MOTOR
30	84-93389A3	CABLE, STARTER MOTOR TO STARTER SOLENOID Comment: (YELLOW)
31	84-93388A14	GROUND WIRE Comment: STARTER MOTOR TO FRONT SUPPORT BRACKET
32	10-69035	SCREW, GROUND WIRE TO STARTER MOTOR (5/8")
33	25661T1	SOLENOID, STARTER
34	10-69028	SCREW, STARTER SOLENOID TO FRONT Comment: SUPPORT BRACKET (3/4")
35	13-26992	WASHER, STARTER SOLENOID SCREW
36	13-26996,10,10	LOCKWASHER, STARTER SOLENOID TERMINAL Comment:
37	11-68219,10,10	NUT, STARTER SOLENOID TERMINAL Comment:
38	38938	BOOT, RUBBER - STARTER SOLENOID TERMINAL Comment: (SMALL)
39	13-8M0204647	LOCKWASHER, STARTER SOLENOID TERMINAL Comment: (5/16")
40	11-22053	NUT, STARTER SOLENOID TERMINAL (5/16")
41	46265	BOOT, RUBBER - STARTER SOLENOID TERMINAL Comment: (LARGE)
42	54-24871	CLAMP, CHOKE SOLENOID LEAD WIRE
43	8M0084613	"C" WASHER, LEAD WIRE CLAMP
44	10-62568	SCREW, CLAMP ATTACHING (3/8")

▶THROTTLE CONTROL LINKAGE AND SPARK ADVANCE (35 parts)

Ref	OEM Part #	Part Name
1	95044A1	THROTTLE CAM ACTUATOR
2	10-63102	SCREW, ADJUSTING - THROTTLE CAM
3	11-64015	NUT, JAM - ADJUSTING SCREW
4	26852	CAP, NYLON - ADJUSTING SCREW
5	39522T	BRACKET, THROTTLE CONTROL SHAFT Comment: (NOT AS SHOWN)
6	10-64021	SCREW, ADJUSTING - THROTTLE CONTROL BRACKET Comment: (1 7/8")
7	11-64015	NUT, JAM - ADJUSTING SCREW
8	26852	CAP, NYLON - ADJUSTING SCREW
9	10-20639	SCREW, THROTTLE CONTROL BRACKET (1 1/8")
10	11-29250	NUT, THROTTLE CONTROL BRACKET SCREW
11	10-34438	SCREW Comment: THROTTLE CONTROL BRACKET TO THROTTLE CAM (2 3/8")
12	12-25893	WASHER Comment: THROTTLE CONTROL BRACKET TO THROTTLE CAM SCREW
13	13-62172	WAVE WASHER Comment: THROTTLE BRACKET/THROTTLE CAM SCREW
14	11-29250	NUT Comment: THROTTLE CONTROL BRACKET TO THROTTLE CAM SCREW
15	62171	BALL JOINT, THROTTLE CAM
16	11-20013	NUT, JAM - BALL JOINT TO TURNBUCKLE
17	62174	TURNBUCKLE, SPARK ADVANCE LINKAGE
18	11-20754	NUT, JAM - UPPER LINK ROD TO TURNBUCKLE
19	62173	ROD, LINK - UPPER
20	57440	SWIVEL, UPPER LINK ROD Comment: THROTTLE CONTROL LEVER
21	55187	LEVER, THROTTLE CONTROL
22	10-818165	SCREW Comment: THROTTLE CONTROL LEVER TO CYLINDER BLOCK (1 3/4")
23	23-55164	BUSHING, THROTTLE CONTROL LEVER SCREW
24	23-55171	BUSHING, THROTTLE CONTROL LEVER SCREW
25	24-55162	SPRING, RETURN - SPARK ADVANCE LEVER
26	61831	LEVER, SPARK ADVANCE
27	12-68410	WASHER, THROTTLE CONTROL LEVER SCREW
28	39483	LATCH, THROTTLE CONTROL LEVER Comment: (THROTTLE CABLE)
29	10-69026	SCREW, LATCH TO THROTTLE CONTROL LEVER Comment: (7/8")
30	24-20099	SPRING, COMPRESSION - LATCH SCREW
31	11-826709109	NUT, LATCH SCREW
32	62459T	BALL JOINT, SPARK ADVANCE LEVER
33	11-46438	NUT, BALL JOINT TO SPARK ADVANCE LEVER
35	61940	LINK ROD
36	61939	PIVOT, TREADED - TRIGGER PLATE TO LINK ROD

▶TOP COWL ASSEMBLY (37 parts)

Ref	OEM Part #	Part Name
1	2138-6340A2	TOP COWL ASSEMBLY (MANUAL)
2	77859	GUIDE, STARTER ROPE Comment: SERIAL GROUP #2
3	77860	RING, RETAINING - GUIDE Comment: SERAIL GROUP #2
4	62236	SHEILD, REAR - TOP COWL
5	10-38055	SCREW, REAR SHIEL TO TOP COWL (5/8")
6	12-26014	WASHER, REAR SHIELD SCREW
7	76132	BRACKET, SUPPORT - TOP COWL (REAR)
8	60577	MOUNT, RUBBER - REAR SUPPORT BRACKET
9	12-26014	WASHER, RUBBER MOUNT
10	12-69056	WASHER, RUBBER MOUNT
11	13-26992	LOCKWASHER, RUBBER MOUNT
12	11-36069	NUT, RUBBER MOUNT
13	90435	MOUNT, RUBBER - REAR SUPPORT BRACKET
14	11-36069	NUT, RUBBER MOUNT TO CYLINDER BLOCK COVER Comment: LOWER
15	11-36069	NUT, RUBBER MOUNT TO REAR SUPPORT BRACKET Comment: UPPER
16	10-37562	SCREW,REAR SUPPORT BRACKET TO BOTTOM COWL Comment: (1")
17	13-8M0204647	LOCKWASHER, REAR SUPPORT BRACKET SCREW
18	95967T	BRACKET, SUPPORT - TOP COWL (FRONT)
19	31014	MOUNT, RUBBER - FRONT SUPPORT BRACKET
20	12-26014	WASHER, RUBBER MOUNT
21	12-69056	WASHER, RUBBER MOUNT
22	13-26992	LOCKWASHER, RUBBER MOUNT
23	11-36069	NUT, RUBBER MOUNT
24	10-37562	SCREW Comment: FRONT SUPPORT BRACKET TO BOTTOM COWL (1")
25	13-8M0204647	LOCKWASHER, FRONT SUPPORT BRACKET SCREW
26	90435	MOUNT, RUBBER - FRONT SUPPORT BRACKET
27	11-36069	NUT, RUBBER MOUNT TO CRANKCASE (LOWER)
28	11-36069	NUT, RUBBER MOUNT TO FRONT SUPPORT BRACKET Comment: UPPER
29	55455	HOOK, TOP COWL LATCH - REAR
30	10-22956	SCREW, REAR HOOK TO TOP COWL (7/8")
31	13-26992	LOCKWASHER, REAR HOOK SCREW
32	75973	PLATE, HINGE
33	10-32228	SCREW, HINGE PLATE (5/8")
34	13-26996	LOCKWASHER, HINGE PLATE SCREW
35	94918F1	LEVER, COWL LATCH
36	52739	HINGE, COWL LATCH LEVER
37	17-58998	ROLL PIN, HINGE TO LEVER

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.) (7112423 THRU 7144762) Parts & Diagrams

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