🔎 Mercury 5 (4-STROKE) Reference Library — Exploded parts diagrams (28 diagrams), specifications, common issues, and maintenance checklist.
The Mercury 5 (4-STROKE) is a 4-Stroke, 1-Cylinder, OHV outboard motor. Designed for dinghies, inflatable boats, and small tenders where lightweight portability is essential.
Quick Reference Specifications
| Specification |
Value |
| Engine Type |
4-Stroke, 1-Cylinder, OHV |
| Horsepower |
5 HP |
| Displacement |
123 cc |
| Bore x Stroke |
59 mm x 45 mm |
| Spark Plug (Type & Gap) |
NGK DPR6EA-9 |
| Engine Oil Capacity |
0.45 L (15 fl oz) |
| Recommended Engine Oil |
SAE 10W-30 Mercury 4-Stroke Outboard Oil |
| Gear Case Oil Capacity |
189 mL (6 fl oz) |
| Idle Speed (in gear) |
1100 RPM (in gear) |
| Full Throttle RPM Range |
4500-5500 |
| 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 5 (4-STROKE):
-
Water Pump / Overheating: If the tell-tale stream is weak or absent, the water pump impeller likely needs replacement. Inspect annually or every 100 hours. → Recommended: Water Pump Impeller Kit
-
Engine Oil / Maintenance Light: 4-stroke engines require regular oil and filter changes. Use marine-grade oil rated for your engine. Change every 100 hours or annually. → Recommended: Oil Filter, Engine Oil
-
Fuel Injector Issues (EFI models): Rough idle or misfires may indicate clogged fuel injectors. Use fuel stabilizer and clean injectors periodically. → Recommended: Fuel Injector, Fuel Filter
-
Gear Case Oil Leak: Check lower unit seals if gear oil appears milky (water contamination). Replace seals and gaskets during lower unit service. → Recommended: Lower Unit Seal Kit, Drain Plug Gaskets
-
Anode Corrosion: Inspect sacrificial anodes regularly, especially in saltwater. Replace when 50% depleted to protect against galvanic corrosion. → Recommended: Zinc/Aluminum Anode Kit
Parts Diagrams & OEM Part Numbers
Expand the sections below to view detailed exploded parts diagrams and find the exact OEM replacement components for your Mercury 5 (4-STROKE).
▶Accessories (1 parts)
| Ref |
OEM Part # |
Part Name |
| - |
16839A4 |
GUIDE KIT, Vertical Rope |
▶Accessory Parts (20 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
16837A2 |
ALTERNATOR KIT |
| 2 |
16074T |
ALTERNATOR |
| 3 |
10-16059 |
SCREW |
| 4 |
54-16060 |
CLAMP |
| 5 |
10-16821 |
SCREW |
| 6 |
84-17175 |
HARNESS ASSEMBLY |
| 7 |
16838A4 |
CHARGING KIT, Battery, Rectifier Comment: (6 AMP) |
| 8 |
16076A1 |
RECTIFIER KIT Comment: (Use with 25 MM Screw) |
| 9 |
89-16077 |
FUSE |
| 10 |
10-16078 |
SCREW Comment: (20MM) |
| 11 |
13-16079 |
LOCKWASHER |
| 12 |
12-8M0108373 |
WASHER, Stainless Steel |
| 13 |
54-813275 |
CLAMP |
| 14 |
11-16081 |
NUT, Stainless Steel |
| 15 |
84-16082 |
CABLE, Battery |
| 16 |
16839A4 |
GUIDE KIT, Vertical Rope |
| 17 |
NSS |
NOT SOLD SEPARATE, Guide |
| 18 |
16113 |
PLATE, Seal |
| 19 |
10-17173 |
SCREW |
| 20 |
8538281 |
HANDLE, (1.0 Meters) Comment: (1.0M) |
▶Carburetor (18 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-803508A05 |
GASKET SET, Powerhead Comment: SN# 0R057259 & Up |
| 1 |
3303-879660A1 |
CARBURETOR Comment: (6 HP-Bodensee) SN# 0R017220 & Up |
| 2 |
10-8035095 |
SCREW |
| 3 |
24-803554 |
SPRING |
| 4 |
8035241,40,40 |
PILOT JET Comment: (6 HP)(Bodensee) |
| 5 |
10-8035099 |
SCREW ASSEMBLY, Pilot Comment: (Bodensee) |
| 6 |
81265010 |
MAIN NOZZLE Comment: (6 HP-Bodensee) |
| 7 |
68,162507 |
JET, Main Comment: (6 HP - Bodensee) |
| 8 |
162543 |
FLOAT VALVE, Brass |
| 9 |
54-803525 |
CLIP, Stainless Steel |
| 10 |
17-162562 |
PIN, Float - Stainless Steel |
| 11 |
162533 |
FLOAT |
| 12 |
27-8035084 |
GASKET, Rubber |
| 13 |
16258T5 |
FLOAT BOWL |
| 14 |
10-16260 |
SCREW, (M4 x 12) |
| 15 |
10-8035093 |
SCREW, Drain (M5 x 6) |
| 16 |
25-8035131 |
O-RING, Rubber |
| 17 |
19-881836 |
PLUG Comment: (7.5MM)(MPE)(Use where Applicable) |
▶Clamp Brackets (43 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
3406-9622T6 |
CLAMP BRACKET, Starboard |
| 2 |
3406-96231 |
CLAMP BRACKET, Port |
| 3 |
10-898101337 |
BOLT |
| 4 |
12-95375 |
WASHER |
| 5 |
12-16192 |
WASHER |
| 6 |
11-95374 |
NUT, (M8) |
| 7 |
161931 |
DISTANCE PLATE |
| 8 |
10-16194 |
SCREW |
| 9 |
24-16212 |
SPRING |
| 10 |
8M0045584 |
STOPPER ASSEMBLY, Tilt |
| 11 |
8M0090337 |
GRIP |
| 12 |
10-8230427 |
BOLT |
| 13 |
16210002 |
SET PLATE |
| 14 |
825113 |
BUSHING |
| 15 |
10-16200 |
CLAMP SCREW ASSEMBLY |
| 16 |
12-95379 |
PAD |
| 17 |
16198004 |
THRUST ROD |
| 18 |
24-8150931 |
SPRING |
| 19 |
24-161951 |
SPRING |
| 20 |
12-16197 |
WASHER |
| 21 |
10-16196 |
SCREW |
| 22 |
3407-813029T9 |
SWIVEL BRACKET |
| 23 |
3407-883300T |
SWIVEL BRACKET Comment: SN# 0R023867 & Up |
| 24 |
23-8035674 |
BUSHING, Lower Comment: SN# 0R023867 & Up |
| 25 |
8M0124744 |
FRICTION BAND Comment: SN# 0R023867 & Up |
| 26 |
11-883302 |
WING NUT Comment: SN# 0R023867 & Up |
| 27 |
12-953921 |
WASHER, Stainless Steel Comment: SN# 0R023867 & Up |
| 28 |
24-953839 |
SPRING Comment: SN# 0R023867 & Up |
| 29 |
803582 |
THRUST PLATE |
| 30 |
23-8035672 |
BUSHING, Upper |
| 31 |
8035821 |
THRUST PLATE |
| 32 |
10-8M0102279 |
BOLT, Stainless Steel |
| 33 |
22-824969 |
FITTING, Grease |
| 34 |
162133 |
ARM, Reverse Lock |
| 35 |
10-82304223 |
BOLT |
| 36 |
24-16216 |
SPRING |
| 37 |
24-16215 |
SPRING |
| 38 |
808599 |
CAP Comment: (Use where Applicable) |
| 39 |
3407-813029T10 |
SWIVEL BRACKET Comment: SN# 0R023866 & Below |
| 40 |
23-8035673 |
BUSHING, Lower Comment: SN# 0R023866 & Below |
| 41 |
10-162061 |
SCREW, Adjusting Comment: SN# 0R023866 & Below |
| 42 |
24-953838 |
SPRING Comment: SN# 0R023866 & Below |
| 43 |
12-16826 |
WASHER, Stainless Steel Comment: SN# 0R023866 & Below |
▶Cowling (26 parts)
| Ref |
OEM Part # |
Part Name |
| - |
37-8240877 |
DECAL, Fuel Lever |
| 1 |
114-803580T5 |
TOP COWL ASSEMBLY Comment: (Silver)(Use With Integral Fuel Tank) |
| 2 |
8107512 |
SEAL |
| 3 |
25-162282 |
SEAL, Rubber |
| 4 |
4000-803578T1 |
BOTTOM COWL Comment: (Use With Integral Fuel Tank) |
| 5 |
37-8156931 |
DECAL, Fuel Lever, Remote Fuel Shut-Off Comment: (Use With Integral Fuel Tank) |
| 6 |
37-879706 |
DECAL, Fuel Lever Comment: (Use With Integral Fuel Tank) |
| 7 |
25-16226 |
GROMMET |
| 8 |
25-16225 |
GROMMET |
| 9 |
25-16231 |
GROMMET |
| 10 |
10-16832 |
BOLT, (M6 x 16) |
| 11 |
12-16826 |
WASHER, Stainless Steel |
| 12 |
25-953871 |
GROMMET |
| 13 |
803579 |
COVER HOOK |
| 14 |
10-8230427 |
BOLT |
| 15 |
12-953921 |
WASHER, Stainless Steel |
| 16 |
13-16221 |
WAVE WASHER |
| 17 |
23-16220 |
BUSHING |
| 18 |
26-16219 |
SEAL |
| 19 |
162181 |
HOOK LEVER |
| 20 |
16841Q02 |
FLUSHING ATTACHMENT |
| 21 |
91-803581 |
TOOL KIT |
| 22 |
50-16230 |
SAFETY ROPE |
| 23 |
37-804651A05 |
DECAL, EPA Label Information Comment: (2005) |
| 24 |
54-813275 |
CLAMP |
| 25 |
10-16827 |
SCREW |
▶Crankshaft, Piston and Connecting Rods (12 parts)
| Ref |
OEM Part # |
Part Name |
| - |
39-803518T02 |
RING SET, Piston Comment: (.5 Oversize) |
| 1 |
474-803515T |
CRANKSHAFT |
| 2 |
12-803516 |
WASHER |
| 3 |
28-16053 |
KEY |
| 4 |
600-8M0124936 |
CONNECTING ROD |
| 5 |
10-8035092 |
BOLT |
| 6 |
779-804768T4 |
PISTON Comment: (.5 Oversize) (6 HP)(Bare Piston) SN# 0R028047 & Below |
| 7 |
53-160573 |
E RING |
| 8 |
41-898103113 |
PIN, Piston |
| 9 |
39-8035181 |
RING, Piston - Top Comment: (.5 Oversize) |
| 10 |
39-8035191 |
RING, Piston - Second Comment: (.5 Oversize) |
| 11 |
26-8035201 |
RING, Oil Comment: (.5 Oversize) |
▶Cylinder Block (29 parts)
| Ref |
OEM Part # |
Part Name |
| - |
804797T1 |
POWERHEAD ASSEMBLY Comment: (6 H.P.) |
| 1 |
878-815013T2 |
CYLINDER BLOCK |
| 2 |
22-8M0071347 |
FITTING |
| 3 |
26-898101285 |
SEAL, Oil |
| 4 |
30-161324 |
BEARING, Ball |
| 5 |
803512 |
CAP, Filler |
| 6 |
25-803513 |
O-RING |
| 7 |
803511 |
CAP |
| 8 |
27-80350811 |
GASKET |
| 9 |
10-8230319 |
BOLT |
| 10 |
17-804369 |
BREATHER TUBE |
| 11 |
12-804370 |
WASHER |
| 12 |
32-952235 |
TUBING |
| 13 |
54-952245 |
CLAMP |
| 14 |
900-8M0119549 |
CYLINDER HEAD Comment: (6 H.P.) |
| 15 |
27-803508 |
GASKET |
| 16 |
17-16119 |
PIN, Dowel |
| 17 |
27-803508012 |
GASKET |
| 18 |
853705006 |
COVER, Thermostat Comment: (Design II) |
| 19 |
27-8M0214960 |
GASKET |
| 20 |
8M0228409 |
THERMOSTAT (126 Degrees F)(52 Degrees C) |
| 21 |
10-803509 |
BOLT, (M8 x 90) |
| 22 |
10-855677002 |
BOLT, (M8 x 60) |
| 23 |
33-8M0204682 |
SPARK PLUG, NGK#DCPR6E (NGK#DCPR6E) |
| 24 |
803510 |
COVER |
| 25 |
27-8035082 |
GASKET |
| 26 |
10-168283 |
BOLT, (M6 x 20) |
| 27 |
12-953921 |
WASHER, Stainless Steel |
| 28 |
8537052 |
CAP Comment: (Design I) |
▶Driveshaft Housing (15 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-803508A05 |
GASKET SET, Powerhead Comment: SN# 0R057259 & Up |
| 1 |
1599-803591T2 |
HOUSING, Driveshaft Comment: (Long) |
| 2 |
23-16114 |
BUSHING |
| 3 |
19-803593 |
PLUG |
| 4 |
27-803508016 |
GASKET |
| 5 |
17-16119 |
PIN, Dowel |
| 6 |
10-879194264 |
BOLT |
| 7 |
19-879194296 |
FLUSH PLUG |
| 8 |
27-95220 |
GASKET |
| 9 |
25-161181 |
GROMMET |
| 10 |
25-16117 |
GROMMET |
| 11 |
827663A1 |
HOUSING ASSEMBLY |
| 12 |
23-811214 |
BUSHING Comment: (Long) |
| 13 |
16121 |
RETAINER |
| 14 |
10-16123 |
SCREW, (25 mm) Comment: (Long) |
▶Electrical Components (22 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
11-16071 |
NUT |
| 2 |
12-16072 |
WASHER |
| 3 |
262-803557T |
FLYWHEEL |
| 4 |
54-16060 |
CLAMP |
| 5 |
10-16821 |
SCREW |
| 6 |
803844T |
COIL, Exciter |
| 7 |
10-16059 |
SCREW |
| 8 |
339-803559T1 |
COIL, Ignition |
| 9 |
85-803560001 |
BOOT |
| 10 |
10-167051 |
BOLT, (M6 x 20) |
| 11 |
878062 |
DAMPER |
| 12 |
803558T02 |
CD UNIT Comment: SN# 0R036272 & Up |
| 13 |
878061 |
FRONT DAMPER |
| 14 |
23-879705 |
SLEEVE |
| 15 |
54-813275 |
CLAMP Comment: (80 MM) |
| 16 |
10-16827 |
SCREW |
| 17 |
803562 |
WARNING LAMP |
| 18 |
87-823037A05 |
SWITCH ASSEMBLY, Stop Comment: SN# 0R036272 & Up |
| 19 |
823054 |
LANYARD |
| 20 |
25-16068 |
GROMMET |
| 21 |
803561 |
COIL, Pulser |
| 22 |
10-82303110 |
SCREW, (M5 x 16) |
▶Engine Gasket Set Components (1 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-803508016 |
GASKET, DriveShaft Housing |
▶Fuel System (34 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-803508A05 |
GASKET SET, Powerhead Comment: SN# 0R057259 & Up |
| 1 |
803530 |
MANIFOLD, Inlet |
| 2 |
25-8035133 |
O-RING |
| 3 |
10-8150684 |
BOLT, (M6 x 25) |
| 4 |
27-80350810 |
GASKET, Insulator |
| 5 |
27-803508013 |
GASKET |
| 6 |
32-8M0057113 |
LINE, Fuel (1000 mm) Comment: (To Carburetor) |
| 7 |
54-95395 |
CLIP, Stainless Steel |
| 8 |
803529T06 |
PUMP, Fuel Comment: SN# 0R036272 & Up |
| 9 |
25-803513 |
O-RING |
| 10 |
10-8555448 |
SCREW, (M6 x 25) |
| 11 |
8M0155131 |
ROD, Choke |
| 12 |
23-8M0047187 |
BUSHING |
| 13 |
10-16223 |
BOLT, (M6 x 14) |
| 14 |
12-161404 |
WASHER |
| 15 |
54-953951 |
CLAMP |
| 16 |
8276225 |
LINK WIRE, Choke |
| 17 |
10-16832 |
BOLT, (M6 x 16) |
| 18 |
803528 |
BRACKET |
| 19 |
23-804371001 |
COLLAR |
| 20 |
23-952868 |
COLLAR |
| 21 |
11-400212 |
NUT, (M6) Stainless Steel |
| 22 |
803526T |
SILENCER, Air |
| 23 |
803527 |
FLAME TRAP |
| 24 |
10-855809003 |
BOLT, (M6 x 85) |
| 25 |
12-16826 |
WASHER, Stainless Steel |
| 26 |
54-95395 |
CLIP, Stainless Steel |
| 27 |
32-8M0079503 |
TUBING, (170 mm) |
| 28 |
35-8M0157133 |
FILTER, Fuel |
| 29 |
32-878054 |
TUBING |
| 30 |
22-8M0182334 |
CONNECTOR, Fuel - Brass |
| 31 |
10-4000333 |
SCREW, (M6 x 40) |
| 32 |
12-16826 |
WASHER, Stainless Steel |
| 33 |
878311 |
CAP |
▶Gear Housing(Driveshaft) (42 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-8M0188431 |
SEAL KIT, Gear Housing |
| 1 |
1668-9621T6 |
GEAR HOUSING ASSEMBLY, Basic Comment: (Sailpower/Sailmate) |
| 2 |
23-16124 |
BUSHING |
| 3 |
22-8M0229353 |
PLUG |
| 4 |
27-95220 |
GASKET |
| 5 |
10-8M0063198 |
BOLT |
| 6 |
12-16826 |
WASHER, Stainless Steel |
| 7 |
43-16138 |
GEAR |
| 8 |
16133 |
STRAINER, Water |
| 9 |
10-16134 |
SCREW |
| 10 |
10-16126 |
BOLT |
| 11 |
12-16192 |
WASHER |
| 12 |
45-8M0076368 |
DRIVESHAFT Comment: (Long) |
| 13 |
30-95347 |
BEARING |
| 14 |
28-16155 |
KEY |
| 15 |
27-16164003 |
GASKET |
| 16 |
15-8132761 |
SHIM, (0.15) Comment: (0.15) |
| 17 |
26-16162 |
SEAL, Oil |
| 18 |
46-826053T |
HOUSING |
| 19 |
27-16160004 |
GASKET |
| 20 |
16159 |
PLATE |
| 21 |
27-8M0155369 |
GASKET |
| 22 |
47-8M0204676 |
IMPELLER |
| 23 |
16157 |
LINER |
| 24 |
46-16156 |
HOUSING, Upper Water Pump |
| 25 |
26-16168 |
SEAL |
| 26 |
32-16167 |
HOSE |
| 27 |
10-8M0063198 |
BOLT |
| 28 |
12-16826 |
WASHER, Stainless Steel |
| 29 |
26-16171 |
SEAL |
| 30 |
32-16169 |
TUBE, Water Comment: (Short) |
| 31 |
32-16170 |
TUBE, Water Comment: (Long) |
| 32 |
25-18876 |
GROMMET |
| 33 |
8M0058365 |
CAM ROD Comment: (Long) |
| 34 |
17-16179 |
PIN |
| 35 |
16165 |
RETAINER |
| 36 |
10-823042 |
BOLT |
| 37 |
25-161771 |
O-RING |
| 38 |
23-16176 |
BUSHING |
| 39 |
25-16178 |
O-RING |
| 40 |
8M0090459 |
CAM |
| 41 |
17-16175 |
PIN |
▶Gear Housing, Propeller Shaft (25 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-8M0188431 |
SEAL KIT, Gear Housing |
| 1 |
1668-9621T6 |
GEAR HOUSING ASSEMBLY, Basic Comment: (Sailpower/Sailmate) |
| 42 |
30-16128 |
BEARING, Ball |
| 43 |
15-813277 |
SHIM, (0.15) |
| 44 |
43-812944 |
GEAR |
| 45 |
16152 |
FOLLOWER, Cam |
| 46 |
16153 |
RETAINER |
| 47 |
52-812946 |
CLUTCH |
| 48 |
17-16150 |
PIN, Clutch |
| 49 |
24-17667 |
SPRING |
| 50 |
44-195133 |
PROPELLER SHAFT |
| 51 |
12-16140 |
WASHER |
| 52 |
43-8129451 |
GEAR, Reverse |
| 53 |
30-16132 |
BEARING, Ball |
| 54 |
26-16130 |
SEAL, Oil |
| 55 |
25-16131 |
O-RING |
| 56 |
825118T |
HOUSING |
| 57 |
10-8248324 |
BOLT, Stainless Steel |
| 58 |
16145Q01 |
THRUST HOLDER |
| 59 |
48-812950A03 |
PROPELLER Comment: (9 Pitch) |
| 60 |
12-16146 |
WASHER |
| 61 |
11-16147 |
PROP NUT |
| 62 |
18-815026 |
COTTER PIN |
| 63 |
10-16832 |
BOLT, (M6 x 16) |
| 64 |
97-875208 |
ANODE Comment: (Square) |
▶Intake/Exhaust Valves (14 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
400-8M0147019 |
CAMSHAFT Comment: (6 H.P.) |
| 2 |
803546 |
LIFTER |
| 3 |
803547 |
PUSH ROD |
| 4 |
803548 |
PLATE |
| 5 |
10-8035097 |
BOLT |
| 6 |
8M0056319 |
ROCKER ARM |
| 7 |
803550 |
PIVOT |
| 8 |
11-803551 |
NUT |
| 9 |
8M0056316 |
VALVE, Exhaust |
| 10 |
8M0056312 |
VALVE, Intake |
| 11 |
8M0158660 |
SEAT |
| 12 |
24-898101214 |
SPRING |
| 13 |
803555 |
RETAINER |
| 14 |
28-803556 |
KEEPER, Valve |
▶Intergral Fuel Tank (38 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
1258-878355A2 |
TANK ASSEMBLY, Fuel Comment: (Bodensee) |
| 2 |
36-8M0058610 |
CAP ASSEMBLY, Fuel Comment: (Bodensee) |
| 3 |
27-878353 |
GASKET |
| 4 |
26-878354 |
SEAL |
| 5 |
10-8M0204707 |
SCREW, (M6 x 25) |
| 6 |
12-161404 |
WASHER |
| 7 |
23-8537437 |
MOUNT, Rubber |
| 8 |
23-853715007 |
SPACER |
| 9 |
10-16705 |
BOLT |
| 10 |
10-8M0051381 |
SCREW, Stainless Steel |
| 11 |
54-813275 |
CLAMP |
| 12 |
25-881305 |
MOUNT, Rubber |
| 13 |
11-400212 |
NUT, (M6) Stainless Steel |
| 14 |
878350 |
BRACKET |
| 15 |
878351 |
BRACKET Comment: (Use where Applicable) |
| 16 |
32-8M0057113 |
LINE, Fuel (1000 mm) (9.875 Inch) |
| 17 |
54-95395 |
CLIP, Stainless Steel |
| 18 |
32-8M0057113 |
LINE, Fuel (1000 mm) (14.00 Inch) |
| 19 |
22-878387 |
FUEL COCK ASSEMBLY |
| 20 |
10-815046 |
SCREW, Stainless Steel |
| 21 |
32-8M0057113 |
LINE, Fuel (1000 mm) (1.375 Inch) |
| 22 |
32-8M0057113 |
LINE, Fuel (1000 mm) (8.50 Inch) |
| 23 |
22-73318 |
TEE, Plastic |
| 24 |
32-8M0057113 |
LINE, Fuel (1000 mm) (5.25 Inch) |
| 25 |
54-816311T |
TIE STRAP, (8.00 Inches) |
| 26 |
22-815048 |
CONNECTOR, Plastic |
| 27 |
32-8M0168427 |
HOSE, Rubber (1.75 Inch) |
| 28 |
22-8M0182334 |
CONNECTOR, Fuel - Brass |
| 29 |
10-4000333 |
SCREW, (M6 x 40) |
| 30 |
12-16826 |
WASHER, Stainless Steel |
| 31 |
878311 |
CAP |
| 32 |
35-8M0157133 |
FILTER, Fuel |
| 33 |
32-17668 |
HOSE (7.125 Inch) |
| 34 |
23-8797051 |
SLEEVE |
| 35 |
10-82304221 |
BOLT Comment: (M6 x 40) |
| 36 |
10-8230421 |
BOLT Comment: (M6 x 25) |
| 37 |
881306 |
PLATE |
| 38 |
23-881307001 |
SPACER |
▶Lube Chart (0 parts)
▶Oil Pan (41 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-803508A05 |
GASKET SET, Powerhead Comment: SN# 0R057259 & Up |
| 1 |
10-82303110 |
SCREW, (M5 x 16) |
| 2 |
54-803543 |
STOPPER |
| 3 |
32-952237 |
TUBING |
| 4 |
26-8035202 |
SEAL |
| 5 |
10-855558 |
SCREW, (M5 x 16) |
| 6 |
12-160721 |
WASHER |
| 7 |
803540 |
HOUSING, Strainer |
| 8 |
803542 |
STRAINER |
| 9 |
803541 |
CUP |
| 10 |
17-16119 |
PIN, Dowel |
| 11 |
84-803539 |
LEAD WIRE |
| 12 |
87-8M0163139 |
SWITCH |
| 13 |
25-8035135 |
GROMMET |
| 14 |
10-810755007 |
BOLT, (M6 x 20) |
| 15 |
803532 |
PLATE, Exhaust |
| 16 |
27-803508015 |
GASKET |
| 17 |
803531T |
PAN, Oil Comment: SN# 0R057259 & Up |
| 18 |
10-168306 |
BOLT, (M6 x 40) |
| 19 |
8035331 |
ROTOR, Outer |
| 20 |
17-162563 |
PIN |
| 21 |
803533 |
ROTOR, Inner |
| 22 |
25-803513010 |
O-RING Comment: SN# 0R057259 & Up |
| 23 |
803534 |
COVER |
| 24 |
10-168287 |
BOLT, (M6 x 16) |
| 25 |
10-167051 |
BOLT, (M6 x 20) |
| 26 |
8150162 |
HOUSING |
| 27 |
26-8M0101649 |
SEAL, Oil |
| 28 |
23-815018 |
SPACER |
| 29 |
27-8M0152378 |
GASKET |
| 30 |
26-8M0056308 |
SEAL, Oil |
| 31 |
10-803509021 |
BOLT |
| 32 |
12-8035161 |
WASHER |
| 33 |
10-8150685 |
BOLT, (M8 x 40) |
| 34 |
27-803508014 |
GASKET |
| 35 |
803535 |
CONTROL PLUNGER |
| 36 |
24-8035541 |
SPRING |
| 37 |
25-168231 |
O-RING |
| 38 |
803536 |
SEAT |
| 39 |
803537 |
COVER |
| 40 |
10-168287 |
BOLT, (M6 x 16) |
▶Recoil Starter (30 parts)
| Ref |
OEM Part # |
Part Name |
| - |
803576T02 |
STARTER ASSEMBLY, Recoil Comment: SN# 0R051740 & Up |
| 1 |
8M0227442 |
HOUSING, Starter Comment: SN# 0R051740 & Up |
| 2 |
24-812645T10 |
SPRING SET, Starter Comment: SN# 0R051740 & Up |
| 3 |
812633002 |
SHEEVE, Starter Comment: SN# 0R051740 & Up |
| 4 |
24-812634003 |
SPRING, Return Comment: SN# 0R051740 & Up |
| 5 |
24-812636001 |
SPRING Comment: SN# 0R051740 & Up |
| 6 |
812635002 |
RATCHET Comment: SN# 0R051740 & Up |
| 7 |
812638001 |
FRICTION PLATE Comment: SN# 0R051740 & Up |
| 8 |
10-812637001 |
BOLT Comment: SN# 0R051740 & Up |
| 9 |
16110004 |
PLATE, Seal Comment: SN# 0R051740 & Up |
| 10 |
50-12066Q10 |
ROPE |
| 11 |
804363001 |
HANDLE, Starter Comment: SN# 0R051740 & Up |
| 12 |
8M0084137 |
ROPE ANCHOR Comment: SN# 0R051740 & Up |
| 13 |
812642002 |
PULLEY, Starter Comment: SN# 0R051740 & Up |
| 14 |
10-168281 |
SCREW AND LOCKWASHER |
| 15 |
8M0169412 |
SNAP, Link Rod |
| 16 |
803577 |
LOCK ROD, Starter |
| 17 |
812643002 |
CAM, Starter Lock Comment: SN# 0R051740 & Up |
| 18 |
10-855544 |
SCREW Comment: SN# 0R051740 & Up |
| 19 |
23-855545001 |
COLLAR Comment: SN# 0R051740 & Up |
| 20 |
12-16826 |
WASHER, Stainless Steel |
| 21 |
24-804366001 |
SPRING, Starter Lock Cam Comment: SN# 0R051740 & Up |
| 22 |
17634001 |
LOCK, Starter Comment: SN# 0R051740 & Up |
| 23 |
10-8555449 |
SCREW |
| 24 |
24-812645007 |
SPRING Comment: SN# 0R051740 & Up |
| 25 |
23-895130 |
COLLAR Comment: SN# 0R051740 & Up |
| 26 |
10-810755 |
SCREW |
| 27 |
13-400256 |
LOCKWASHER, (M6) |
| 28 |
54-8M0130961 |
CLAMP Comment: SN# 0R051740 & Up |
| 29 |
17643002 |
SNAP, Link Rod Comment: SN# 0R051740 & Up |
▶Remote Control (52 parts)
| Ref |
OEM Part # |
Part Name |
| - |
8M0178530 |
REMOTE CONTROL Comment: (Manual Start) |
| 1 |
16910A1 |
HOUSING KIT, Front, With Decals-Front |
| 2 |
19-89774 |
PLUG |
| 3 |
17192 |
PLUG, Stop Switch Hole |
| 4 |
17191 |
PLUG, Wire Harness Hole |
| 5 |
16917 |
COVER |
| 6 |
16899T |
HOLDER, Neutral Lock |
| 7 |
10-40118107 |
SCREW, (M5 x 18) |
| 8 |
13-16923 |
LOCKWASHER, External |
| 9 |
16913T |
LEVER |
| 10 |
16916A1 |
CAP ASSEMBLY, With Decal |
| 11 |
16921 |
BRACKET, Lock Bar Support |
| 12 |
10-4005685 |
SCREW, (M4 x 10) |
| 13 |
16915 |
LOCK ARM |
| 14 |
10-40056105 |
SCREW, (M5 x 10) |
| 15 |
24-16924 |
SPRING |
| 16 |
16914 |
GRIP |
| 17 |
17016 |
PLUG |
| 18 |
10-40116110T |
SCREW, (M6 x 110) |
| 19 |
12-35280 |
WASHER, (.255 x .620 x .030) Stainless Steel |
| 20 |
11-401196 |
NUT, (M6) |
| 21 |
16920 |
BRAKE ADJUSTER |
| 22 |
12-16896 |
WASHER |
| 23 |
53-13194 |
RING, Retaining |
| 24 |
16895 |
ARM ASSEMBLY, Brake |
| 25 |
23-16875 |
BEARING, (1.750 Inside Diameter) (1.750 ID) |
| 26 |
12-16874 |
WASHER |
| 27 |
16892T |
GEAR, Drive |
| 28 |
850724A2 |
PLATE/STUD ASSEMBLY |
| 29 |
16873 |
ROLLER, Cam |
| 30 |
10-4007154 |
SCREW, (M8 x 30) |
| 31 |
12-8M0207778 |
WASHER |
| 32 |
54-85899A1 |
CLIP ASSEMBLY |
| 33 |
11-401386 |
NUT, (M6) Stainless Steel |
| 34 |
16918A3 |
GEAR SHIFT ASSEMBLY |
| 35 |
23-16868 |
BEARING, (.750 Inside Diameter) (.750 ID) |
| 36 |
12-16870 |
WASHER |
| 37 |
24-16882 |
SPRING |
| 38 |
16879 |
ROLLER, Detent |
| 39 |
16880 |
CLIP |
| 40 |
10-4005683 |
SCREW, (M4 x 6) |
| 41 |
24-16888 |
SPRING |
| 42 |
16886 |
CLIP |
| 43 |
16884 |
ROLLER |
| 44 |
16883 |
DRUM ASSEMBLY |
| 45 |
13-16922 |
WAVE WASHER |
| 46 |
16912T |
COVER, Bottom |
| 47 |
16911T |
COVER, Top |
| 48 |
23-16887 |
BEARING, (.810 Inside Diameter) (.810 ID) |
| 49 |
16919A1 |
LEVER ASSEMBLY, With Decal |
| 50 |
10-40118106 |
SCREW, (M5 x 12) |
| 51 |
17063T |
SPACER |
▶Remote Control 4000 Side Mount (57 parts)
| Ref |
OEM Part # |
Part Name |
| - |
8M0178530 |
REMOTE CONTROL, Manual Start - Non Power Trim Comment: (Manual Start - No Ignition Switch) |
| 1 |
NSS |
NOT SOLD SEPARATE, Housing-Front |
| 2 |
NSS |
NOT SOLD SEPARATE, Decal-F-N-R |
| 3 |
NSS |
NOT SOLD SEPARATE, Decal-Throttle Friction |
| 4 |
NSS |
NOT SOLD SEPARATE, Decal-Run/Off |
| 5 |
19-89774 |
PLUG, Key Swith Hole |
| 6 |
17192 |
PLUG, Stop Switch Hole |
| 7 |
17191 |
PLUG, Wire Harness Hole |
| 8 |
10-4005685 |
SCREW, (M4 x 10) |
| 9 |
16921 |
BRACKET, Lock Bar Support |
| 10 |
10-87775510 |
SCREW, (M4 x 10) |
| 11 |
8M0207317 |
LOCK BAR, Red |
| 12 |
24-16924 |
SPRING |
| 13 |
881139T2 |
HUB, Handle |
| 14 |
8811411 |
GRIP |
| 15 |
881146 |
PLUG |
| 16 |
881137A1 |
CAP/DECAL ASSEMBLY |
| 17 |
10-40118107 |
SCREW, (M5 x 18) |
| 18 |
13-16923 |
LOCKWASHER, External |
| 19 |
16899T |
HOLDER, Neutral Lock |
| 20 |
16917 |
COVER |
| 21 |
10-40116110T |
SCREW, (M6 x 110) |
| 22 |
881145 |
KNOB, Throttle Friction |
| 23 |
12-16896 |
WASHER |
| 24 |
53-13194 |
RING, Retaining |
| 25 |
16895 |
ARM ASSEMBLY, Brake |
| 26 |
23-16875 |
BEARING, (1.750 Inside Diameter) (1.750 ID) |
| 27 |
12-16874 |
WASHER |
| 28 |
11-401385 |
NUT, (M5) Stainless Steel |
| 29 |
54-85899A1 |
CLIP ASSEMBLY |
| 30 |
NSS |
NOT SOLD SEPARATE, Gear Shift Assembly |
| 31 |
23-16868 |
BEARING, (.750 Inside Diameter) (.750 ID) |
| 32 |
12-16870 |
WASHER |
| 33 |
16873 |
ROLLER, Cam |
| 34 |
NSS |
NOT SOLD SEPARATE, Drive Gear |
| 35 |
NSS |
NOT SOLD SEPARATE, Plate/Stud Assembly |
| 36 |
12-8M0207778 |
WASHER |
| 37 |
10-4007154 |
SCREW, (M8 x 30) |
| 38 |
10-4005683 |
SCREW, (M4 x 6) |
| 39 |
16886 |
CLIP |
| 40 |
24-16888 |
SPRING |
| 41 |
16884 |
ROLLER |
| 42 |
16883 |
DRUM ASSEMBLY |
| 43 |
13-16922 |
WAVE WASHER |
| 44 |
NSS |
NOT SOLD SEPARATE, Cover-Bottom |
| 45 |
NSS |
NOT SOLD SEPARATE, Cover-Top |
| 46 |
23-16887 |
BEARING, (.810 Inside Diameter) (.810 ID) |
| 47 |
10-40118106 |
SCREW, (M5 x 12) |
| 48 |
16919A1 |
LEVER ASSEMBLY |
| 49 |
NSS |
NOT SOLD SEPARATE, Decal-Lift for Fast Idle |
| 50 |
12-35280 |
WASHER, (.255 x .620 x .030) Stainless Steel |
| 51 |
11-401196 |
NUT, (M6) |
| 52 |
17063T |
SPACER |
| 53 |
23-71942 |
BUSHING |
| 54 |
16879 |
ROLLER, Detent |
| 55 |
16880 |
CLIP, Detent |
| 56 |
24-16882 |
SPRING, Detent |
▶Remote Control Attaching Kit (41 parts)
| Ref |
OEM Part # |
Part Name |
| - |
8M0172938 |
ATTACHING KIT, Remote Control Comment: (With Grommet/ Reference #38) |
| 1 |
8M0062171 |
PLATE, Steering Hook |
| 2 |
10-4000354 |
SCREW, (M8 x 30) |
| 3 |
17023 |
BRACKET |
| 4 |
10-8230421 |
BOLT |
| 5 |
10-162233 |
SCREW |
| 6 |
12-17029 |
WASHER |
| 7 |
24-17028 |
SPRING |
| 8 |
17027 |
CAP |
| 9 |
17026 |
BRACKET |
| 10 |
804357 |
LEVER ASSEMBLY, Throttle |
| 11 |
13-16221 |
WAVE WASHER |
| 12 |
26-16219 |
SEAL |
| 13 |
23-16220 |
BUSHING |
| 14 |
10-162232 |
BOLT |
| 15 |
17-17031 |
PIN, Lock |
| 16 |
17-17033 |
PIN |
| 17 |
24-17032 |
SPRING |
| 18 |
17030 |
SLEEVE |
| 19 |
11-400212 |
NUT, (M6) Stainless Steel |
| 20 |
803584 |
ROD, Throttle Link |
| 21 |
23-16849 |
COLLAR |
| 22 |
803585 |
LEVER, Throttle Link |
| 23 |
11-804993A1 |
NUT KIT |
| 24 |
12-804992 |
WASHER |
| 25 |
11-804993 |
WASHER |
| 26 |
84-17035 |
HARNESS ASSEMBLY |
| 27 |
17-803588 |
PIN |
| 28 |
84-803587 |
CABLE, Throttle |
| 29 |
12-16335 |
WASHER |
| 30 |
18-16189 |
COTTER PIN |
| 31 |
803590 |
BRACKET |
| 32 |
803589 |
LINK, Throttle |
| 33 |
10-16223 |
BOLT, (M6 x 14) |
| 34 |
16333 |
ROD, Snap |
| 35 |
12-16192 |
WASHER |
| 36 |
13-400256 |
LOCKWASHER, (M6) |
| 37 |
11-400213 |
NUT, (M8) Stainless Steel |
| 38 |
25-885154 |
GROMMET |
| 39 |
10-855544 |
SCREW |
| 40 |
84-17162 |
HARNESS ASSEMBLY (5.9M) |
▶Sailpower/Sailmate Components (16 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
16074T |
ALTERNATOR |
| 2 |
10-16059 |
SCREW |
| 3 |
54-16060 |
CLAMP |
| 4 |
10-16821 |
SCREW |
| 5 |
16076A1 |
RECTIFIER KIT Comment: (Use with 25MM Screw) |
| 6 |
89-16077 |
FUSE |
| 7 |
10-16078 |
SCREW Comment: (20MM) |
| 8 |
13-16079 |
LOCKWASHER |
| 9 |
12-8M0108373 |
WASHER, Stainless Steel |
| 10 |
54-813275 |
CLAMP |
| 11 |
11-16081 |
NUT, Stainless Steel |
| 12 |
84-16822 |
HARNESS, Extension |
| 13 |
25-16823 |
GROMMET |
| 14 |
84-16082 |
CABLE, Battery |
| 15 |
87-823037A04 |
SWITCH ASSEMBLY, Emergency Stop Comment: SN# 0R036272 & Up |
| 16 |
823054 |
LANYARD |
▶Service/Support Material (1 parts)
| Ref |
OEM Part # |
Part Name |
| - |
37-804651A05 |
DECAL, EPA Label Information Comment: (2005) |
▶Shift Components (12 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
803594 |
LEVER, Shift |
| 2 |
30-812937 |
STOPPER |
| 3 |
24-813028 |
SPRING |
| 4 |
25-16181 |
O-RING |
| 5 |
17-16188 |
PIN |
| 6 |
18-16189 |
COTTER PIN |
| 7 |
10-16185 |
BOLT |
| 8 |
16184 |
LEVER |
| 9 |
16187 |
SHIFT ROD Comment: (Long) |
| 10 |
12-16826 |
WASHER, Stainless Steel |
| 11 |
16190 |
JOINT, Set |
| 12 |
10-8248324 |
BOLT |
▶Special Tools (11 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
91-8M0161873 |
HOLDER TOOL |
| 2 |
91-58222A1 |
DIAL INDICATOR TOOL |
| 3 |
91-63998A1 |
GAP TOOL, Single Chamber |
| 4 |
91-83155 |
ADAPTER KIT, Dial Indicator |
| 5 |
91-83164M |
FLYWHEEL PULLER |
| 6 |
91-890451 |
ADAPTOR TOOL, Direct Voltage |
| 7 |
91-99379 |
TIMING LIGHT |
| 8 |
91-99750A1 |
MULTI METER |
| 9 |
91-854009A3 |
TACH MULTI METER, DMT 2000 Digital |
| 10 |
91-8M0059838 |
HOLDER/PULLER TOOL, Flywheel |
| 11 |
91-37299Q2 |
GREASE GUN |
▶Steering Handle (36 parts)
| Ref |
OEM Part # |
Part Name |
| - |
8M0106934 |
HANDLE KIT, Steering |
| 1 |
803565T |
HANDLE, Steering |
| 2 |
17-16085 |
PIN |
| 3 |
16093 |
SHAFT, Throttle |
| 4 |
16338 |
BRACKET |
| 5 |
10-16827 |
SCREW |
| 6 |
10-16087 |
SCREW, Adjusting |
| 7 |
12-16826 |
WASHER, Stainless Steel |
| 8 |
813026 |
FRICTION PIECE |
| 9 |
11-400212 |
NUT, (M6) Stainless Steel |
| 10 |
10-16094 |
SCREW |
| 11 |
16086 |
GRIP |
| 12 |
803569 |
SHAFT, Rubber |
| 13 |
23-8035671 |
BUSHING |
| 14 |
37-8M0097201 |
DECAL |
| 15 |
16-815028 |
STUD BOLT |
| 16 |
12-804508 |
WASHER |
| 17 |
23-803566 |
SPACER |
| 18 |
23-803567 |
BUSHING |
| 19 |
17-16085 |
PIN |
| 20 |
8035681 |
STOPPER |
| 21 |
13-400256 |
LOCKWASHER, (M6) |
| 22 |
11-400212 |
NUT, (M6) Stainless Steel |
| 23 |
10-16827 |
SCREW Comment: (Use where Applicable) |
| 24 |
54-953951 |
CLAMP Comment: (Use where Applicable) |
| 25 |
84-803570001 |
WIRE, Throttle Comment: SN# 0R036272 & Up |
| 26 |
23-8035731 |
COLLAR Comment: (Use where Applicable) |
| 27 |
803575 |
BRACKET Comment: (Use where Applicable) |
| 28 |
10-82304221 |
BOLT Comment: (M6 X 40) |
| 29 |
803571 |
DRUM, Throttle |
| 30 |
803574 |
ROD, Throttle |
| 31 |
803572 |
OPENER, Throttle |
| 32 |
23-803573 |
COLLAR |
| 33 |
12-953921 |
WASHER, Stainless Steel |
| 34 |
10-82304220 |
BOLT, (M6 x 35) |
| 35 |
853740018 |
PROTECTIVE SLEEVE |
▶Tank Assembly, Fuel (Plastic - 3.2 Gallon) (6 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
1260-859061A1 |
TANK ASSEMBLY, Fuel |
| 2 |
823535 |
GAUGE/CAP ASSEMBLY |
| 3 |
27-8169771 |
GASKET, Fuel Cap |
| 4 |
22-8M0175544 |
CONNECTOR KIT, Fuel |
| 5 |
25-823533 |
O-RING |
| 6 |
35-823534 |
SCREEN |
▶Throttle Shift Cables (2 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
8M0178530 |
REMOTE CONTROL Comment: (See Breakdown On Remote Control) |
| 2 |
896143A40 |
CABLE ASSEMBLY, Throttle/Shift Comment: (40 Feet) |
100-Hour / Annual Service Checklist
Regular maintenance keeps your Mercury 5 (4-STROKE) running reliably season after season. Most of these tasks can be performed with basic tools and the factory service manual.
- Replace water pump impeller and inspect wear plate
- Change engine oil and oil filter (check drain plug washer)
- Replace spark plugs and check ignition timing
- Drain and refill lower unit gear oil; inspect for water contamination
- Inspect fuel lines, primer bulb, and fuel filter for deterioration
- Check and replace sacrificial anodes (zinc or aluminum)
- Inspect propeller for damage; check shaft seal and cotter pin
- Check valve clearance (refer to service manual for specifications)
- Lubricate all grease points (steering, tilt tube, shift linkage)
- Inspect control cables and throttle/shift linkage for smooth operation
-
Pro Tip: Always flush the engine with fresh water after saltwater use — even a quick 10-minute flush significantly extends component life.
-
Pro Tip: Use fuel stabilizer in the tank before winter storage, and fog the cylinders to prevent internal corrosion during extended periods of non-use.
