Mercury 45, 4.5 (1 CYL.) (8026540 THRU 8068064) Parts & Diagrams

🔎 Mercury 45, 4.5 (1 CYL.) Reference Library — Exploded parts diagrams (19 diagrams), specifications, common issues, and maintenance checklist.

The Mercury 45, 4.5 (1 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	45 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 45, 4.5 (1 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 45, 4.5 (1 CYL.).

▶BOTTOM COWL ASSEMBLY (23 parts)

Ref	OEM Part #	Part Name
-	27-78139A80	GASKET SET
1	187-7711A4	BOTTOM COWL
2	36187A1	LEVER ASSEMBLY, CLAMPING - PORT
3	36188A1	LEVER ASSEMBLY, CLAMPING - STARBOARD
4	53-55891	FASTENER, CLAMPING LEVER
5	84-60871A7	GROUND STRAP ASSEMBLY
6	24-63399	SPRING, GROUND STRAP
7	23-26819	BUSHING, NYLON - CLAMPING LEVER
8	23-31293	BUSHING, RUBBER - CLAMPING LEVER
9	17-58997	PIN, ROLL - CLAMPING LEVER
10	10-79953Q04	SCREW, BOTTOM COWL FLUSHING HOLE
11	12-191833	WAHSER, BOTTOM COWL FLUSHING HOLE SCREW
12	56712	NOZZLE, TELL TALE
13	10-35519	SCREW, TELLL TALE NOZZLE TO BOTTOM COWL
14	32-8M0108355	TUBE, TELL TALE (7 1/4")
15	22-996642	ELBOW, TELL TALE - HOSE TO CYLINDER BLOCK
16	27-89937	GASKET, POWERHEAD TO BOTTOM COWL
17	27-55847	GASKET Comment: EXHAUST RELIEF COVER TO BOTTOM COWL
18	55936	COVER, EXHAUST RELIEF
19	10-69079	SCREW, EXHUAST RELIEF COVER TO BOTTOM COWL (7/16")
20	87-69508A31	STOP SWITCH ASSEMBLY Comment: (INCLUDES A-87-69509A1 COVER)
21	13-69845	LOCKWASHER, STOP SWITCH
22	11-69844	NUT, STOP SWITCH

▶CARBURETOR ASSEMBLY (25 parts)

Ref	OEM Part #	Part Name
-	27-78139A80	GASKET SET
--	1395-92621	REPAIR PARTS KIT
1	1341-8740A1	CARBURETOR ASSEMBLY, COMPLETE Comment: UNITED STATES 5270784 AND UP AUSTRALIA 8059345 AND UP BELGIUM 9221756 AND UP CANADA 7128838 AND UP
2	1395-8673	FLOAT ASSEMBLY
6	1395-92581	INLET NEEDLE, SEAT AND GASKET
9	1399-1133	COVER, FLOAT BOWL
10	10-52195	SCREW, FLOAT BOWL COVER (SHORT)
11	10-52196	SCREW, FLOAT BOWL COVER (LONG)
12	13-26995	LOCKWASHER, FLOAT BOWL COVER SCREW
14	1399-3938	SCREEN, FILTER
16	1399-1135	COVER, STRAINER (90 DEG.) Comment: UNITED STATES 5270783 AND BELOW AUSTRALIA 8059344 AND BELOW BELGIUM 9221755 AND BELOW CANADA 7128837 AND BELOW
16A	1399-4791A1	COVER, STRAINER (45 DEG.) Comment: UNITED STATES 5270784 AND UP AUSTRALIA 8059345 AND UP BELGIUM 9221756 AND UP CANADA 7128838 AND UP
18	10-25822	SCREW, STRAINER COVER
19	1395-6027	SCREW, THROTTLE STOP LEVER
20	8146791	LEVER, THROTTLE STOP
21	1399-1716	SHAFT, THROTTLE
25	1399-3739	SHUTTER, THROTTLE
28	10-28845	SCREW, PLUG - BODY CHANNEL
30	10-23178	SCREW, PLUG - MAIN NOZZLE
31	1399-3252	JET, MAIN FUEL (.032)
34	10-28405	SCREW, PLUG - MAIN FUEL JET CHANNEL
35	1399-3740	SCREW, IDLE ADJUSTMENT
37	27-63309	GASKET, CARBURETOR TO REED BLOCK
38	12-20583	WASHER, CARBURETOR MOUNTING STUD
39	11-24652	NUT, CARBURETOR MOUNTING STUD

▶CARBURETOR CHOKE LINKAGE (9 parts)

Ref	OEM Part #	Part Name
1	59000	THROTTLE LEVER
2	10-20597	SCREW, THROTTLE LEVER TO CARBURETOR (3/8")
3	79092	SHUTTER AND SCREEN, CHOKE - CARBURETOR
4	24-53193	SPRING, CHOKE SHUTTER TO LEVER
5	24-55299A1	SPRING ASSEMBLY, CARBURETOR
6	10-55298	SCREW, SPRIING TO CARBURETOR
7	53187	LEVER, CHOKE
8	24-53190	SPRING, TENSION - CHOKE KNOB
9	53189	KNOB, CHOKE

▶CLAMP BRACKET ASSEMBLY (19 parts)

Ref	OEM Part #	Part Name
1	1468-5570A3	CLAMP BRACKET ASSEMBLY (PORT) Comment: WASHER ATTACHED WITH A SCREW.
2	1467-5571A3	CLAMP BRACKET ASSEMBLY (STARBOARD) Comment: WASHER ATTACHED WITH A SCREW.
3	10-77190A3	THUMB SCREW ASSEMBLY Comment: WASHER ATTACHED WITH A SCREW.
4	12-73719	WASHER, THUMB SCREW Comment: WASHER ATTACHED WITH A SCREW.
4A	10-768042	SCREW, THUMB SCREW Comment: WASHER ATTACHED WITH A SCREW.
5	12-71421	WASHER, TILT TUBE Comment: UNITED STATES 4419187 AND UP AUSTRALIA 8039675 AND UP BELGIUM 9125665 AND UP CANADA 7080423 AND UP
6	96962	TILT TUBE Comment: UNITED STATES 4419187 AND UP AUSTRALIA 8039675 AND UP BELGIUM 9125665 AND UP CANADA 7080423 AND UP
7	19-39333	PLUG, TILT TUBE Comment: UNITED STATES 4419187 AND UP AUSTRALIA 8039675 AND UP BELGIUM 9125665 AND UP CANADA 7080423 AND UP
8	54-8M0085928	CLIP, SAFETY CHAIN - TILT TUBE (OPTIONAL)
9	11-858869	NUT, TILT TUBE FASTENING
10	16-71417	STUD, CLAMP BRACKET Comment: UNITED STATES 4419187 AND UP AUSTRALIA 8039675 AND UP BELGIUM 9125665 AND UP CANADA 7080423 AND UP
11	71420	HANDLE, CARRYING Comment: UNITED STATES 4419187 AND UP AUSTRALIA 8039675 AND UP BELGIUM 9125665 AND UP CANADA 7080423 AND UP
12	13-26992	LOCKWASHER, CLAMP BRACKET STUD
13	11-29598	NUT, CLAMP BRACKET STUD
14	24-62143	SPRING, TILT LOCK PIN
15	17-71418A2	TILT LOCK PIN ASSEMBLY Comment: UNITED STATES 4419187 AND UP AUSTRALIA 8039675 AND UP BELGIUM 9125665 AND UP CANADA 7080423 AND UP
16	10-67982	BOLT, CLAMP BRACKET TO BOAT
17	12-67983	WASHER, CLAMP BRACKET SCREW
18	11-8267098	NUT, CLAMP BRACKET SCREW

▶CRANKSHAFT, PISTON AND CONNECTING ROD ASSEMBLY (14 parts)

Ref	OEM Part #	Part Name
-	27-78139A80	GASKET SET
1	427-7334A2	CRANKSHAFT ASSEMBLY Comment: UNITED STATES 5397702 AND UP BELGIUM 9244406 AND UP CANADA 7137937 AND UP
3	26-72793	SEAL, CARRIER Comment: UNITED STATES 5397701 AND BELOW AUSTRALIA 8059594 AND BELOW BELGIUM 9244405 AND BELOW CANADA 7137937 AND BELOW
4	79952A1	CARRIER ASSEMBLY Comment: UNITED STATES 5397702 AND UP BELGIUM 9244406 AND UP CANADA 7137937 AND UP
5	12-79960	SEAL, BELT Comment: UNITED STATES 5397702 AND UP BELGIUM 9244406 AND UP CANADA 7137937 AND UP
6	608-7395A2	CONNECTING ROD ASSEMBLY Comment: UNITED STATES 5270784 AND UP AUSTRALIA 8059345 AND UP BELGIUM 9221756 AND UP CANADA 7128838 AND UP
7	10-87374	SCREW, CONNECTING ROD
8	29-26815	BEARING, NEEDLE - CRANKPIN
9	11-20061	NUT, CONNECTING ROD SCREW
10	12-65967	WASHER, NEEDLE BEARING RETAINING
11	29-31505	BEARING, NEEDLE - PISTON PIN
12	719-7391T3	PISTON AND PISTON PIN ASSEMBLY
13	40-21666	LOCK RING, PISTON PIN
14	39-21665A12	RING, PISTON

▶CYLINDER BLOCK AND CRANKCASE ASSEMBLY (43 parts)

Ref	OEM Part #	Part Name
-	27-78139A80	GASKET SET
1	843-8694A3	CYLINDER BLOCK AND CRANKCASE ASSEMBLY Comment: UNITED STATES 5270784 AND UP AUSTRALIA 8059345 AND UP BELGIUM 9221756 AND UP CANADA 7128838 AND UP
2	16-66021	STUD, CYL. BLOCK, CRANKCASE AND CARBURETOR
4	17-8M0084726	PIN, DOWL - CRANKCASE TO CYLINDER BLOCK
5	21-428671	FITTING ASSEMBLY, BLEED DRAIN
7	32-9938779	HOSE, BLEED DRAIN (7 1/2")
8	54-56223	CLAMP, BLEED HOSE ATTACHING
9	22-78916	ELBOW, BLEED DRAIN
10	22-996642	ELBOW (90 - 1/8" MALE (TEL TALE)
11	10-73280	SCREW, CRANKCASE TO CYLINDER BLOCK (1 1/2") Comment: UNITED STATES 4597262 AND UP AUSTRALIA 8044350 AND UP BELGIUM 9139800 AND UP CANADA 7091998 AND UP
12	10-76621	SCREW, CRANKCASE TO CYLINDER BLOCK (1") Comment: UNITED STATES 4597262 AND UP AUSTRALIA 8044350 AND UP BELGIUM 9139800 AND UP CANADA 7091998 AND UP
13	11-8M0207775	NUT, CRANKCASE FASTENING SCREW Comment: UNITED STATES 4597261 AND BELOW AUSTRALIA 8044349 AND BELOW BELGIUM 9139799 AND BELOW CANADA 7091997 AND BELOW
14	70726	REED BLOCK
15	34-35836	REED, INLET VALVE
16	34-22215	RETAINER, REED
17	10-28430	SCREW, REED AND RETAINER TO BLOCK (1/4")
18	27-357391	GASKET, REED BLOCK TO CRANKCASE
19	30-72961	BEARING, BALL - CRANKCASE (LOWER)
20	26-56397	OIL SEAL, CRANKCASE (LOWER)
21	15-31412A1	SHIM ASSEMBLY Comment: UPPER HOUSING TO BLOCK (.002-3-5-10)
22	1132-6352A1	BEARING HOUISNG ASSEMBLY, UPPER Comment: UNITED STATES 4597262 AND UP AUSTRALIA 8044350 AND UP BELGIUM 9139800 AND UP CANADA 7091998 AND UP
23	30-72961	BEARING, BALL - UPPER BEARING HOUSING
24	31-31410	BEARING, ROLLER - UPPER BEARING HOUSING
25	26-66301	OIL SEAL, UPPER BEARING HOUSING Comment: UNITED STATES 4597262 AND UP AUSTRALIA 8044350 AND UP BELGIUM 9139800 AND UP CANADA 7091998 AND UP
26	25-20863	"O" RING, UPPER BEARING HOUSING
27	54-34598	CLAMP, HOLD DOWN RING
28	10-36205	SCREW Comment: HOLD DOWN RING CLAMP TO BEARING HSG. (9/16")
29	24-34731	SPRING, HOLD DOWN RING CLAMP
30	10-39002	SCREW, UPPER BEARING HOUSING (#12-24 X 1/2)
31	35658	COVER, TRANSFER COVER
32	27-35657	GASKET, TRANSFER PORT COVER
33	10-20720	SCREW Comment: TRANSFER PORT COVER TO CYLINDER BLOCK (5/8")
34	1016-7070A1	COVER ASSEMBLY, CLYINDER BLOCK Comment: UNITED STATES 4869518 AND UP AUSTRALIA 8052880 AND UP BELGIUM 9186201 AND UP CANADA 7112923 AND UP
35	66019	MOUNT, RUBBER - COVER TO TOP COWL
36	13-20202	LOCKWASHER, RUBBER MOUNT 2
38	27-416151	GASKET, COVER TO CYLINDER BLOCK
39	10-8M0214943	SCREW, CYLINDER BLOCK COVER TO CYLINDER BLOCK (1") Comment: UNITED STATES 4597262 AND UP AUSTRALIA 8044350 AND UP BELGIUM 9139800 AND UP CANADA 7091998 AND UP
40	11-8M0207775	NUT, CYLINDER BLOCK COVER MOUNTING SCREW Comment: UNITED STATES 4597261 AND BELOW AUSTRALIA 8044349 AND BELOW BELGIUM 9139799 AND BELOW CANADA 7091997 AND BELOW
41	27-416141	GASKET, CYLINDER BLOCK TO BAFFLE PLATE
42	46234	PLATE, BAFFLE - EXHAUST MANIFOLD
43	27-416141	GASKET Comment: BAFFLE PLATE TO EXHAUST MANIFOLD COVER
44	46171	COVER, EXHAUST MANIFOLD
45	10-49668	SCREW, PALTE/MANIFOLD COVER TO BLOCK (3/4")

▶DRIVE SHAFT HOUSING ASSEMBLY (22 parts)

Ref	OEM Part #	Part Name
-	27-78139A80	GASKET SET
1	1542-8452A1	DRIVE SHAFT HOUSING ASSEMBLY (LONG SHAFT)
2	16-66373	STUD, DRIVE SHAFT HOUSING TO GEAR HOUSING
3	11-82670911	NUT Comment: DRIVE SHAFT HOUSING TO GEAR HOUSING STUD
4	11-8M0204726	NUT Comment: GEAR HOUSING TO DRIVE SHFT HOUSING STUD
5	1539-8450A1	SADDLE ASSEBMLY Comment: UNITED STATES 4869518 AND UP AUSTRALIA 8052880 AND UP BELGIUM 9186201 AND UP CANADA 7112923 AND UP
6	64076	BUMPER, THRUST - SADDLE
7	79896A1	MOUNT ASSEMBLY, LOWER Comment: UNITED STATES 5270784 AND UP AUSTRALIA 8059345 AND UP BELGIUM 9221756 AND UP CANADA 7128838 AND UP
8	79985A1	MOUNT ASSEMBLY, UPPER (SEE NOTE BELOW) Comment: UNITED STATES 5270784 AND UP AUSTRALIA 8059345 AND UP BELGIUM 9221756 AND UP CANADA 7128838 AND UP
9	53-26406	RING, RETAINING - UPPER AND LOWER MOUNT
10	79907	COVER, UPPER AND LOWER MOUNT Comment: UNITED STATES 5270784 AND UP AUSTRALIA 8059345 AND UP BELGIUM 9221756 AND UP CANADA 7128838 AND UP
11	10-48408	SCREW Comment: UPPER AND LOWER MOUNT COVER RETAINING (1/2") UNITED STATES 5270783 AND BELOW AUSTRALIA 8059344 AND BELOW BELGIUM 9221755 AND BELOW CANADA 7128837 AND BELOW
12	55435	BLOCK, BEARING - DRIVE SHAFT (LONG SHAFT0
13	27-59079	GASKET, BOTTOM COWL TO DRIVE SHFT HOUSING
14	11-24652	NUT Comment: DRIVE SHAFT HOUSING TO POWERHEAD STUDS
15	32-32077	TUBE, WATER OUTLET (LONG SHAFT)
16	26-36556	SEAL, RUBBER - WATER OUTLET TUBE
17	23-13127	BEARING, NYLON - OUTLET TUBE SEAL
18	71057	LINK ROD, REVERSE LOCK
19	10-65414	SCREW Comment: CAM RETAINER TO DRIVE SHAFT HOUSING (3/4")
21	65216	CAM, REVERSE LOCK
22	72007	RETAINER, REVERSE LOCK CAM

▶FLYWHEEL AND IGNITION COIL (18 parts)

Ref	OEM Part #	Part Name
-	27-78139A80	GASKET SET
1	236-4475A1	FLYWHEEL ASSEMBLY
2	28-20094	KEY, FLYWHEEL DRIVE
3	25-62701	"O" RING, FLYWHEEL NUT Comment: UNITED STATES 4377556 AND BELOW AUSTRALIA 8037074 AND BELOW BELGIUM 9110488 AND BELOW CANADA 7072372 AND BELOW
4	12-36245	WASHER, FLYWHEEL NUT
5	11-20696	NUT, FLYWHEEL
6	13-35629	WASHER, WAVE - CAM TENSION
7	336-4465	CAM, BREAKER
8	336-4528T2	COIL ASSEMBLY, IGNITION
9	13-26996	LOCKWASHER, IGNITION COIL TERMINAL
10	11-45076	NUT, IGNITION COIL TERMINAL
11	66355	COVER, IGNITION COIL
12	10-61530	SCREW Comment: COIL COVER TO REAR SUPPRT BRACKET (3 3/4")
13	11-27164	NUT, COIL COVER SCREW
14	84-813715A1	LEAD ASSEMBLY, HIGH TENSION
15	332-2854T01	NIPLE, IGNITION COIL
16	85-63709A1	PROTECTOR ASSEMBLY, SPARK PLUG
17	33-896329833	SPARK PLUG (AC#40FFK) Comment: CANADA AND BELGIUM USE C-33-75739

▶FUEL PUMP AND FUEL LINE ASSEMBLY (SERIAL GROUP #14) (20 parts)

Ref	OEM Part #	Part Name
-	27-78139A80	GASKET SET
1	89977A1	FUEL PUMP ASSEMBLY (SEE NOTE)
2	21-30430A2	CHECK VALVE ASSEMBLY
3	53245A1	DIAPHRAGM KIT, FUEL PUMP
6	53241	BASE, FUEL PUMP Comment: UNITED STATES 5270783 AND BELOW AUSTRALIA 8059344 AND BELOW BELGIUM 9221755 AND BELOW CANADA 7128837 AND BELOW
7	61541	COVER, FUEL PUMP
8	10-32627	SCREW, FUEL PUMP TO BASE (1 1/2")
9	12-847883	WASHER, FUEL PUMP SCREWS
10	22-61544	ELBOW, HOSE TO FUEL PUMP (45 DEG.)
11	22-39079	ELBOW, FUEL PUMP TO CARBURETOR
12	32-9912688	HOSE ASSEMBLY Comment: FUEL PUMP TO CYLINDER BLOCK (4 1/2")
13	22-33373001	ELBOW, HOSE TO CYLINDER BLOCK (90 DEG.)
14	54-20387	CLAMP, FUEL PUMP HOSE TO ELBOWS
15	32-61642	FUEL LINE, INLET - ADAPTOR TO FUEL PUMP
16	30188	CUP WASSHER, ADAPTOR
17	24-23067T	SPRING, ADAPTOR STEM
18	25-16524	"O" RING, ADAPTOR STEM
19	23069	STEM, CHECK UNIT ADAPTOR
20	22833	ADAPTOR, CHECK UNIT
21	10-37923	SCREW Comment: CHECK UNIT ADAPTOR TO BOTTOM COWL (1 1/4")

▶FUEL PUMP AND FUEL LINE ASSEMBLY (SERIAL GROUP #15) (15 parts)

Ref	OEM Part #	Part Name
-	27-78139A80	GASKET SET
1	89977A1	FUEL PUMP ASSEMBLY
2	32-8M0108355	FUEL LINE (3 1/4" AND 1 1/2")
3	54-20387	CLAMP, FUEL LINE
4	22-19688	FITTING, FUEL LINE TO CARBURETOR
5	22-63981	FITTING, FUEL LINE TO ADAPTOR
6	32-9912688	HOSE ASSEMBLY Comment: FUEL PUMP TO CYLINDER BLOCK (4 1/2")
7	22-33373001	ELBOW, HOSE TO CYLINDER BLOCK (90)
8	54-20387	CLAMP, FUEL HOSE TO ELBOWS
9	30188	CUP WASHER, ADAPTOR
10	24-23067T	SPRING, ADAPTOR STEM
11	25-16524	"O" RING, ADAPTOR STEM
12	23069	STEM, CHECK UNIT ADAPTOR
13	22833	ADAPTOR, CHECK UNIT
14	10-37923	SCREW Comment: CHECK UNIT ADAPTOR TO BOTTOM COWL (1 1/4")

▶GEAR HOUSING ASSEMBLY, COMPLETE (PAGE 1) (45 parts)

Ref	OEM Part #	Part Name
-	27-78139A80	GASKET SET
--	23-13127	BEARING, NYLON - WATER PUMP COVER
1	1630-7360A11	GEAR HOUSING ASSEMBLY Comment: UNITED STATES 5270784 AND UP AUSTRALIA 8059345 AND UP BELGIUM 9221756 AND UP CANADA 7128838 AND UP
2	16-58138	STUD Comment: GEAR HOUSING TO DRIVE SHAFT HOUSING (3 1/2")
3	16-58136	STUD Comment: WATER PUMP HOUSING TO GEAR HOUSING (2 3/4")
4	31-22756	BEARING, ROLLER - DRIVE SHAFT
5	17-20032	PIN, DOWEL - LOCATING
6	26-33613	SEAL, RUBBER - WATER INTAKE TUBE
7	35-33425	SCREEN, WATER INTAKE
8	10-28642	SCREW Comment: WATER INTAKE SCREEN TO GEAR HOUSING
9	12-191833	WASHER, GREASE FILLER HOLE SCREW
10	10-79953Q04	SCREW, GREASE FILLER HOLE
11	19643	WASHER, GREASE VENT HOLE SCREW
12	10-28653	SCREW, GREASE VENT HOLE
13	71658A1	SHAFT ASSEMBLY, SHIFT(LONG SHAFT)
14	53-22899	RING, RETAINING - SHIFT SHAFT
15	23-30676A1	BUSHING ASSEMBLY, SHIFT SHAFT
16	25-26802	"O" RING, SHIFT SHAFT BUSHING
17	26-30696	OIL SEAL, SHIFT SHAFT BUSHING
18	10-39149	SCREW, SHIFT SHAFT BUSHING RETAINER (1/2")
19	43-98696	GEAR, PINION
20	14-30377	TAB WASHER, PINION GEAR SCREW
21	10-30376	SCREW, PINION GEAR TO DRIVE SHAFT (3/4")
22	45-95874A1	DRIVE SHAFT(LONG SHAFT) Comment: UNITED STATES 5397702 AND UP BELGIUM 9244406 AND UP CANADA 7137937 AND UP
23	15-30527A1	SHIM ASSEMBLY Comment: BALL BEARING TO GEAR HOUSING (.002-3-5-10)
24	30-70944	BEARING, BALL - DRIVE SHAFT
25	53-30523	RING, RETAINING - BALL BEARING
26	15-30527A1	SHIM ASSEMBLY Comment: BALL BEARING TO PUMP HOUSING (.002-3-5-10)
27	46-70941T01	WATER PUMP HOUSING ASSEMBLY
28	25-29439	"O" RING, WATER PUMP HOUSING
29	26-30900T	OIL SEAL, WATER PUMP HOUSING
30	26-33613	SEAL, WATER INTAKE TUBE
31	32-34293	TUBE, WATER INTAKE
32	70977T	INSERT, WATER PUMP HOUSING
33	28-8M0032835	KEY, IMPELLER DRIVE
34	47-89981	IMPELLER, WATER PUMP
35	46895	PLATE, FACE - WATER PUMP HOUSING TO COVER
36	93224A1	WATER PUMP COVER ASSEMBLY
37	26-36558	SEAL, WATER PUMP COVER
38	26-30913	OIL SEAL, WATER PUMP COVER
39	12-20533	WASHER Comment: WATER PUMP HOUSING AND COVER STUD
40	11-35888	NUT, WATER PUMP HOUSING STUD
41	25-30526	RING, RUBBER - CENTRIFUGAL SLINGER
43	23-31792T	SLEEVE, GUIDE - INLET TUBE
43A	25-62704	"O" RING, DRIVE SHAFT Comment: UNITED STATES 5397702 AND UP BELGIUM 9244406 AND UP CANADA 7137937 AND UP

▶GEAR HOUSING ASSEMBLY, COMPLETE (PAGE 2) (29 parts)

Ref	OEM Part #	Part Name
-	27-78139A80	GASKET SET
--	66606	THRUST HUB (USED WITH NYLON PROP ONLY)
1	1630-7360A11	GEAR HOUSING ASSEMBLY Comment: SEE "GEAR HOUSING ASSEMBLY, COMPLETE" (PAGE 1) FOR PARTS BREAKDOWN UNITED STATES 5270784 AND UP AUSTRALIA 8059345 AND UP BELGIUM 9221756 AND UP CANADA 7128838 AND UP
44	44434	CAM, SHAFT
45	31334	FOLLOWER, CAM
46	24-76298	SPRING, COMPRESSION - CAM FOLLOWER Comment: UNITED STATES 4597262 AND UP AUSTRALIA 8044350 AND UP BELGIUM 9139800 AND UP CANADA 7091998 AND UP
47	15-30522A1	SHIM ASSEMBLY Comment: BEARING TO GEAR HOUSING (.002-3-5-10)
48	30-21889	BEARING, BALL - FORWARD GEAR
49	43-48577A3	FORWARD GEAR ASSEMBLY
50	31-22458	BEARING, ROLLER - FORWARD GEAR
51	52-63314	RATCHET, SLIDING CLUTCH
52	53-32449	RING, RETIANING, CROSS PIN
53	17-30535	PIN, CROSS - RATCHET TO PROPELLER SHAFT
54	44-75667A2	SHAFT ASSEMBLY, PROPELLER Comment: UNITED STATES 4597262 AND UP AUSTRALIA 8044350 AND UP BELGIUM 9139800 AND UP CANADA 7091998 AND UP
55	43-63316	REVERSE GEAR ASSEMBLY
56	71479	SLEEVE, THRUST - REVERSE GEAR Comment: UNITED STATES 4377557 AND UP AUSTRALIA 8037075 AND UP BELGIUM 9110489 AND UP CANADA 7072373 AND UP
57	30-21889	BEARING, BALL - REVERSE GEAR
58	15-30532A1	SHIM ASSEMBLY Comment: THRUST WASHER TO HOUSING (.002-3-5-10)
59	25-30529	"O" RING, BEARING CARRIER
60	72673T1	BEARING CARRIER ASSEMBLY Comment: UNITED STATES 4377557 AND UP AUSTRALIA 8037075 AND UP BELGIUM 9110489 AND UP CANADA 7072373 AND UP
61	31-22458	BEARING, ROLLER - BEARING CARRIER
62	26-66022	OIL SEAL, BEARING CARRIER
63	12-30528	WASHER, GEAR HOUSING COVER Comment: UNITED STATES 4377556 AND BELOW AUSTRALIA 8037074 AND BELOW BELGIUM 9110488 AND BELOW CANADA 7072372 AND BELOW
64	86236	COVER, GEAR HOUSING Comment: UNITED STATES 4377557 AND UP AUSTRALIA 8037075 AND UP BELGIUM 9110489 AND UP CANADA 7072373 AND UP
65	86665A1	GUIDE COLLAR, PROPELLER
66	48-65010A1	PROPELLER ASSEMBLY Comment: (2 BLADE - 8 1/4" DIA. ) - NYLON
67	11-64075A1	SPACER, SPLINED - PROPELLER NUT
68	12-79552	WASHER, PROPELLER SHAFT
69	11-64075A1	NUT, PROPELLER

▶MISCELLANEOUS PARTS/ACCESSORIES (1 parts)

Ref	OEM Part #	Part Name
-	37-43154A84	DECAL SET - SERIAL GROUP #15

▶SHIFT CONTROL LINKAGE (16 parts)

Ref	OEM Part #	Part Name
1	93730T	HANDLE, SHIFT CONTROL
2	66378	SHAFT, SHIFT - CONTROL HANDLE
3	23-66375	BUSHING, NYLON - SHIFT CONTROL HANDLE
4	66414	CAM, DETENT - SHIFT SHAFT
5	43-66377	GEAR, HORIZONTAL - SHIFT CONTROL HANDLE
6	12-8M0204649	WASER, SHIFT CONTROL HANDLE TO SHAFT
7	11-826709109	NUT, SHIFT CONTROL HANDLE TO SHAFT
8	17-25905	PIN, DETENT CAM TO SHIFT SHAFT
9	12-8M0204649	WASHER, SHIFT CONTROL HANDLE
10	11-8267089	NUT Comment: HORIZONTAL GEAR TO SHIFT CONTROL HANDLE
11	24-39627	SPRING, DETENT - CRANKCASE
12	39601	PLATE, DETENT SPRING
13	10-25764	SCREW, PLATE AND PRING TO CRANKCASE (1/2")
14	71660	SHIFT SHAFT, UPPER Comment: UNITED STATES 4270055 AND UP AUSTRALIA 8032490 AND UP BELGIUM 9099814 AND UP CANADA 7059233 AND UP
15	23-30677	BUSHING, NYLON - SHIF CONTROL SHAFT
16	43-86686A1	GEAR, SECTOR - SHIFT SHAFT Comment: UNITED STATES 5270784 AND UP AUSTRALIA 8059345 AND UP BELGIUM 9221756 AND UP CANADA 7128838 AND UP

▶STATOR AND IGNITION COMPONENTS (29 parts)

Ref	OEM Part #	Part Name
1	336-4524A1	COVER ASSEMBLY
2	10-60491	SCREW, COVER TO MODULE (5/8")
3	336-4516A2	IGNITION MODULE ASSEMBLY
4	10-59800	SCREW, MODULE TO STATOR (9/16")
5	10-36046	SCREW, MODULE- COIL LEAD (1/4")
6	13-26996	LOCKWASHER, MODULE Comment: IGNITION COIL LEAD TERMINALS
7	11-45076	NUT, MODULE - IGNITION COIL LEAD TERMINALS
8	336-4470A1	COIL, HIGH SPEED
9	54-59538	CLIP, COIL RETAINING
10	54-59539	CLIP, COIL RETAINING
11	336-4463	CONDENSER ASSEMBLY
12	10-62269	SCREW, CONDENSER ATTACHING (7/16")
13	336-4476A6	STATOR ASSEMBLY
14	336-4458	PLATE, STATOR HOLD DOWN
15	10-35400	SCREW, HOLD DOWN PLATE TO STATOR (7/16")
16	15-33910015	SHIM, STATOR PLATE TO UPPER END CAP
17	336-3989	WICK, CAM WIPER -STATOR ASSEMBLY
18	336-4318A2	MAKER ASSEMBLY, STATOR HOUSING
19	10-56266	SCREW, MAKER TO STATOR HOUSING (3/8")
20	56520	CAM, THROTTLE
21	10-69054	SCREW, THROTTLE CAM TO CONTACT HOUSING
22	12-37998	WASHER, THROTTLE CAM ATTACHING SCREW
23	56757A5	JUMPER WIRE ASS'Y Comment: CONDENSER TO COVER (BLACK-4 1/4")
24	56318A11	LEAD ASSEMBLY Comment: MODULE TO IGNITION COIL (GREEN - 12 1/4")
25	38938	BOOT, LEAD ASSEMBLY
26	56316A4	CABLE ASSEMBLY Comment: STATOR HOUSING (WHITE - 10 3/4")
27	38938	BOOT, CABLE
28	336-4460	INSULATOR, CABLE TO CONTACT HOUSING
29	11-56325	NUT, CABLE INSULATOR

▶STEERING HANDLE ASSEMBLY (21 parts)

Ref	OEM Part #	Part Name
-	60850A6	STEERING HANDLE ASSEMBLY, COMPLETE
1	60854	GRIP, HANDLE - THROTTLE
2	62251	CAP, HANDLE THROTTLE
3	66393	SHAFT, THROTTLE
4	66394A1	HANDLE ASSEMBLY, THROTTLE SHAFT
5	17-46152	PIN, THROTTLE HADNLE
6	12-62252	WASHER, THROTTLE HANDLE TO STEERING ARM
7	60850	ARM, STEERING HANDLE
8	43-60852	GEAR, BALL THROTTLE SHAFT
9	17-27088	PIN, BALL GEAR TO THROTTLE SHAFT
10	48003	PIVOT, STEERING HANDLE TO BRACKET
11	15-48002015	SHIM, HANDLE PIVOT TO BRACKET (.015)
12	10-64074	SCREW, HANDLE TO ARM BRACKET (5/8")
13	60857A2	UNIVERSAL JOINT ASSEMBLY
14	43-60852	GEAR, BALL - UNIVERSAL JOINT
15	17-77564	PIN, BALL GEAR TO UNIVERSAL JOINT
16	96130A1	BRACKET, STEERING ARM
17	10-62233	SCREW Comment: DETENT SPRING TO STEERING ARM BRACKET (5/8")
18	24-72847	SPRING, DETENT - STEERING HANDLE
19	10-78038	SCREW, BRACKET TO SADDLE (1 3/4") Comment: UNITED STATES 4869518 AND UP AUSTRALIA 8052880 AND UP BELGIUM 9186201 AND UP CANADA 7112923 AND UP
20	11-8M0207775	NUT, BRACKET SCREW Comment: UNITED STATES 4869517 AND BELOW AUSTRALIA 8052879 AND BELOW BELGIUM 9186200 AND BELOW CANADA 7112922 AND BELOW

▶SWIVEL BRACKET ASSEMBLY (32 parts)

Ref	OEM Part #	Part Name
1	1471-7324A1	SWIVEL BRACKET ASSEMBLY Comment: UNITED STATES 5270784 AND UP AUSTRALIA 8059345 AND UP BELGIUM 9221756 AND UP CANADA 7128838 AND UP
2	19-77633Q	LUBRICAP, GREASE FITTING - SWIVEL BRACKET Comment: UNITED STATES 4419186 AND BELOW AUSTRALIA 8039674 AND BELOW BELGIUM 9125664 AND BELOW CANADA 7080422 AND BELOW
3	22-8M0169589	FITTING, GREASE - SWIVEL BRACKET Comment: UNITED STATES 4419187 AND UP AUSTRALIA 8039675 AND UP BELGIUM 9125665 AND UP CANADA 7080423 AND UP
4	23-64028	BUSHING, SWIVEL BRACKET
5	23-26841	BUSHING, NYLON - REVERSE LOCK LEVER ROD
6	71419	ROD, REVERSE LOCK TO SWIVEL BRACKET Comment: UNITED STATES 4419187 AND UP AUSTRALIA 8039675 AND UP BELGIUM 9125665 AND UP CANADA 7080423 AND UP
7	10-45582	COTTER PIN, REVERSE LOCK LEVER TO ROD
8	63628T	LEVER, REVERSE LOCK
9	61007	RETAINER, ROD - REVERSE LOCK
10	63559T	BRACKET, TROLL
11	24-63630	SPRING, EXTENSION - TROLL BRACKET
12	63554	GUIDE, SPRING
13	17-25319	ROLL PIN, SPRING GUIDE
14	79744	LEVER, CONTROL - BRACKET Comment: UNITED STATES 4869518 AND UP AUSTRALIA 8052880 AND UP BELGIUM 9186201 AND UP CANADA 7112923 AND UP
15	13-63631	WASHER, WAVE - TROLL BRACKET LEVER
16	66559	SWIVEL PIN, SWIVEL BRACKET TO SADDLE
17	77334	CO-PILOT DISC Comment: UNITED STATES 4869518 AND UP AUSTRALIA 8052880 AND UP BELGIUM 9186201 AND UP CANADA 7112923 AND UP
18	10-78038	SCREW, CO-PILOT DISC TO SADDLE (1 3/4") Comment: UNITED STATES 4869518 AND UP AUSTRALIA 8052880 AND UP BELGIUM 9186201 AND UP CANADA 7112923 AND UP
19	11-8M0207775	NUT, CO-PILOT DISC FASTENING SCREW Comment: UNITED STATES 4869517 AND BELOW AUSTRALIA 8052879 AND BELOW BELGIUM 9186200 AND BELOW CANADA 7112922 AND BELOW
20	20203	DISC Comment: FRICTION - CLAMP PLATE AND SWIVEL BRACKET
21	72845A1	PLATE ASSEMBLY, CLAMP - CO-PILOT Comment: UNITED STATES 4419187 AND UP AUSTRALIA 8039675 AND UP BELGIUM 9125665 AND UP CANADA 7080423 AND UP
22	10-36154	SCREW, CLAMP PLATE ADJUSTING 1 Comment: UNITED STATES 4419187 AND UP AUSTRALIA 8039675 AND UP BELGIUM 9125665 AND UP CANADA 7080423 AND UP
23	12-35462	WASHER, CLAMP PLATE ADJUSITNG SCREW
24	87984A1	LEVER ASSEMBLY, TILT STOP Comment: UNITED STATES 5270784 AND UP AUSTRALIA 8059345 AND UP BELGIUM 9221756 AND UP CANADA 7128838 AND UP
25	10-41433	SCREW, TILT STOP LEVER
26	13-31030	WASHER, WAVE - LEVER ANCHOR SCREW
27	11-35888	NUT, TILT STOP LEVER SCREW
28	10-36398	SCREW, SWIVEL BRACKET (1/4") Comment: UNITED STATES 4869517 AND BELOW AUSTRALIA 8052879 AND BELOW BELGIUM 9186200 AND BELOW CANADA 7112922 AND BELOW
29	72794	STOP, REVERSE LOCK Comment: UNITED STATES 4419187 AND UP AUSTRALIA 8039675 AND UP BELGIUM 9125665 AND UP CANADA 7080423 AND UP
30	10-71056	SCREW, REVERSE STOP TO SWIVEL BRACKET Comment: UNITED STATES 4419187 AND UP AUSTRALIA 8039675 AND UP BELGIUM 9125665 AND UP CANADA 7080423 AND UP
31	13-26992	LOCKWASHER, REVERSE STOP SCREW Comment: UNITED STATES 4419187 AND UP AUSTRALIA 8039675 AND UP BELGIUM 9125665 AND UP CANADA 7080423 AND UP
32	12-71055	WASHER, REVERSE STOP SCREW Comment: UNITED STATES 4419187 AND UP AUSTRALIA 8039675 AND UP BELGIUM 9125665 AND UP CANADA 7080423 AND UP

▶THROTTLE CONTROL LINKAGE (15 parts)

Ref	OEM Part #	Part Name
1	43-60856	GEAR, HORIZONTAL - THROTTLE CONTROL
2	60885T	HOUSING, HORIZONTAL GEAR
3	10-96138	SCREW Comment: THROTTLE CONTROL HOUSING TO BOTTOM COWL (5/8")
4	15-64653A1	SHIM, PINION GEAR TO BOTTOM COWL
5	42666A3	GEAR AND SHAFT ASS"Y, THROTTLE CONTROL
6	62099T	BRACKET, THROTTLE CONTROL LEVER
7	10-23015	SCREW, ADJUSTING - THROTTLE (1")
8	11-68219	NUT, LOCK - THROTTLE ADJUSITNG SCREWS
9	17-27088	PIN, ROLL - LEVER TO VERTICAL SHAFT
10	60920	LINK, THROTTLE LEVER TO STATOR PLATE
11	10-34696	SCREW Comment: THROTTLE LINK TO THROTTLE LEVER (3/4")
12	12-34392	WASHER, THROTTLE LINK SCREW
13	13-29720	WASHER, WAVE - THROTTLE LINK SCREW
14	11-28656	NUT, THROTTLE LINK SCREW
15	10-56027	SCREW, THROTTLE LINK TO STATOR PLATE (7/8")

▶TOP COWL AND STARTER ASSEMBLY (35 parts)

Ref	OEM Part #	Part Name
1	191-7668A2	TOP COWL ASSEMBLY Comment: UNITED STATES 4597262 AND UP AUSTRALIA 8044350 AND UP BELGIUM 9139800 AND UP CANADA 7091998 AND UP
2	39538	STRIP, SOUND SEAL - REAR
3	39537	STRIP, SOUND SEAL - FORWARD
4	66018	MOUNT, RUBBER - TOP COWL
5	89096	COVER, TRIM - TOP COWL
6	10-64652	SCREW, TRIM COVER TO TOP COWL
7	14-20165	TAB WASHER, SHEAVE SHAFT NUT
8	11-20166	NUT, SHEAVE SHAFT (LEFT HAND THREAD)
9	64601	COVER, VENT - COP COWL
10	10-35519	SCREW, VENT SCREEN TO TOP COWL (3/8")
11	39258	BRACKET, STARBOARD - TOP COWL FASTENING
12	10-39514	SCREW, BRACKET TO TOP COWL (1 1/8")
13	12-39143	WASHER, BRACKET SCREW (1/16")
14	20155	RETAINER, STARTER SPRING
15	24-29340T02	SPRING ASSEMBLY, STARTER REWING
16	23-28912	BUSHING, SPRING GUIDE
17	50-93696A2	STARTER SHEAVE ASSEMBLY
18	17-22896	PIN, RETAINER - STARTER CABLE
19	30596	PAWL, STARTER
20	13-36206	WASHER, WAVE - STARTER PAWL
21	23-28919	BUSHING, NYLON - SHEAVE SHAFT SPACER
22	23-61005	SPACER, SHEAVE SHAFT
23	26179	RETAINER, SHEAVE SHAFT TO STARTER SHEAVE
24	12-35559	WASHER, SHEAVE SHAFT RETAINER
25	13-20160	WASHER, WAVE - RETAINER TENSION
26	30595	PLATE, RETAINER - STARTER PAWL
27	35558	SHAFT, SHEAVE
28	55860	PULLEY, STARTER CABLE
29	23-309772	SPACER, CABLE PULLEY
30	12-22887	WASHER, PULLEY FASTENING SCREW
31	10-28789	SCREW, PULLEY TO TOP COWL (3/4")
32	50-12066Q10	STARTER CABLE ASSEMBLY
33	79470A1	RETAINER ASSEMBLY, STARTER CABLE Comment: UNITED STATES 4869518 THRU 5270783 AUSTRALIA 8052880 THRU 8059344 BELGIUM 9186201 THRU 9221755 CANADA 7112923 THRU 7128837
33&34	79470A1	HANDLE AND RETAINER ASSEMBLY Comment: UNITED STATES 5270784 AND UP AUSTRALIA 8059345 AND UP BELGIUM 9221756 AND UP CANADA 7128838 AND UP
34	77998	HANDLE, STARTER CABLE Comment: UNITED STATES 4869518 THRU 5270783 AUSTRALIA 8052880 THRU 8059344 BELGIUM 9186201 THRU 9221755 CANADA 7112923 THRU 7128837

100-Hour / Annual Service Checklist

Regular maintenance keeps your Mercury 45, 4.5 (1 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 45, 4.5 (1 CYL.) (8026540 THRU 8068064) Parts & Diagrams

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