Mercury 800 (4 CYL.), 80 (4 CYL.) (4831999 THRU 5582561) Parts & Diagrams

🔎 Mercury 800 (4 CYL.), 80 (4 CYL.) Reference Library — Exploded parts diagrams (20 diagrams), specifications, common issues, and maintenance checklist.

The Mercury 800 (4 CYL.), 80 (4 CYL.) is a 4-Stroke, Inline 4-Cylinder, EFI, SOHC outboard motor. Suited for bay boats, pontoons, and center-console fishing boats requiring reliable mid-range power.

Quick Reference Specifications

Specification	Value
Engine Type	4-Stroke, Inline 4-Cylinder, EFI, SOHC
Horsepower	80 HP
Displacement	2100 cc
Bore x Stroke	90 mm x 81 mm
Spark Plug (Type & Gap)	NGK IZFR6F-11
Engine Oil Capacity	5.2 L (5.5 quart)
Recommended Engine Oil	Mercury FourStroke Oil 10W-30
Gear Case Oil Capacity	710 mL (24 fl oz)
Idle Speed (in gear)	650–700 RPM (in gear)
Full Throttle RPM Range	5000-6000
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 800 (4 CYL.), 80 (4 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 800 (4 CYL.), 80 (4 CYL.).

▶BOTTOM COWL AND SHIFT LINKAGE (31 parts)

Ref	OEM Part #	Part Name
1	2158-7718	COWL, BOTTOM
2	74303	COVER, AIR INLET
3	10-62568	SCREW, COVER TO BOTTOM COWL (3/8')
3A	12-30164	WASHER, COVER SCREW
4	27-73646	GASKET, BOTTOM COWL
5	39616	BOOT, CONTROL CABLES - BOTTOM COWL
6	37637	BOOT, FUEL CONNECTOR - BOTTOM COWL
7	37445	SUPPORT, WIRING HARNESS - BOTTOM COWL
8	10-69029	SCREW, SUPPORT TO COWL (1 3/4")
9	11-36069	NUT, WIRING H ARNESS SUPPORT SCREW
10	32-8M0108355	HOSE Comment: TELL TALE - EXH. COVER TO BOTTOM COWL (14 3/4")
11	52889	NOZZLE, TELL TALE HOSE TO BOTTOM COWL
12	10-48408	SCREW Comment: TELL TALE NOZZLE TO BOTTOM COWL (1/2")
13	22-782792	ELBOW, TELL TALE HOSE TO CYLINDER BLOCK
14	60304A54	SHIFT SHAFT ASSEMBLY, UPPER (LONG SHAFT)
16	23-26856	BUSHIING, SHIFT SHAFT
17	73402	SHIFT LINK
18	12-35462	WASHER, LINK ROD (SHIFT LEVER END)
19	11-36069	NUT, LINK ROD
20	13-29720	WASHER, WAVE - LINK ROD
21	24-20099	SPRING, LINK ROD TO GUIDE BLOCK
22	37896	GUIDE BLOCK, LINK ROD
23	52732A6	BRACKET, ANCHOR - CONTROL CABLES
24	39519	CAP, BARREL RETAINER - ANCHOR
25	87609A1	LEVER, NYLON - SHIFT CABLE LOCKING
26	17-47175	PIN, LOCKING LEVER AND COVER FASTENING
27	39667	COVER, NYLON - SHIFT CABLE
28	87609A1	LINK, LOCKING LEVER TO COVER
29	10-35386	SCREW Comment: ANCHOR BRACKET TO CYLINDER BLOCK (1")
30	52100	WEAR PLATE, LINK ROD
31	8M0036768	LATCH Comment: CONTROL CABLE FASTENING - ANCHOR BRACKET

▶CARBURETOR ASSEMBLY (15 parts)

Ref	OEM Part #	Part Name
--	27-73645A87	GASKET SET
1	1379-6071A58	CARBURETOR ASSEMBLY, COMPLETE (BOTTOM)
2	1395-6207	JET, VENT BOWL (.072)
3	1395-83181	INLET NEEDLE AND SEAT
5	1395-6685	VENTURI
11	19273	FLOAT
12	1395-6488	FUEL BOWL
15	1395-6199	PLUG, MAIN JET
16	1395-6247	JET, MAIN (.090)
20	1395-4807	SHAFT, THROTTLE
21	1395-6196	VALVE, THROTTLE
23	1395-6204	SEAL, THROTTLE SHAFT
24	1395-6203	WASHER, THROTTLE SHAFT
26	1395-6198	VALVE ASSEMBLY, ENRICHMENT
29	27-733771	GASKET, CARBURETORO

▶CARBURETOR LINKAGE (29 parts)

Ref	OEM Part #	Part Name
-	27-73645A87	GASKET SET
1	54293A10	CHOKE SOLENOID ASSEMBLY
2	10-824941	SCREW Comment: CHOKE SOLENOID TO F RON BRACKET (3/4")
3	13-8M0204647	LOCKWASHER, CHOKE SOLENOID SCREW
4	54-52905	CLAMP, HARNESS - CHOKE SOLENOID SCREW
5	13-26996	LOCKWASHER, CHOKE SOLENOID TERMINAL
6	11-68219	NUT, CHOKE SOLENOID TERMINAL
7	89008A2	PLUNGER AND LINK ASSEMBLY
8	73400	CHOKE ROD
9	90242A1	CHOKE KNOB ASSEMBLY
10	10-77137	SCREW, WIRE TO CHOKE KNOB
11	25-20116	GROMMET, CHOKE KNOB
12	84-74263	WIRE, CHOKE KNOB TO CHOKE ROB (BLACK)
13	10-62568	SCREW, WIRE TO CHOKE ROD
14	1379-6071A57	CARBURETOR ASSEMBLY (TOP)
14A	1379-6071A58	CARBURETOR ASSEMBLY (BOTTOM)
15	22-19688	ELBOW, CARBURETOR
16	10-52743	SCREW, CARBURETOR TO CRANKCASE (3 3/4")
17	53720A2	COUPLING ASSEMBLY (LOWER CARBURETOR)
18	28-89694	INSERT, COUPLING
19	10-66104	SCREW, COUPLING TO CARBURETOR (3/4")
20	12-74726	WASHER, COUPLING SCREW
21	73847	ACTUATOR, THROTTLE (UPPER CARBURETOR)
22	10-60293	SCREW, ACTUATOR TO UPPER CARBURETOR (1/2")
23	73408	PLATE, CARBURETOR
24	27-73398	GASKET, CARBURETOR PLATE
25	27-76952	GASKET, CARBURETOR PLATE TO CARBURETOR
26	10-28635	SCREW, PLATE TO CAR BURETOR (5/8")
27	73647	SEAL, CARBURETOR PLATE

▶CLAMP BRACKET AND REVERSE LOCK (44 parts)

Ref	OEM Part #	Part Name
--	27-73645A87	GASKET SET
1	1440-8394A1	CLAMP BRACKET ASSEMBLY
2	10-78492A1	THUMB SCREW ASSEMBLY
2A	10-78495	SCREW, THUMB SCREW
2B	12-78493	WASHER, THUMB SCREW
3	75043	COVER, THUMB SCREW
4	8M0041936	TUBE, TILT - CLAMP BRACKET TO SWIVEL BRACKET
5	12-52864	WASHER, CLAMP BRACKET TILT TUBE
6	11-858869	NUT, TILT TUBE FASTENING
7	53078	CAP, PLASTIC - TILT TUBE
8	23-59624	SPACER, CLAMP BRACKET STUD
9	16-59625	STUD, CLAMP BRACKET
9A	12-36001	WASHER, CLAMP BRACKET STUD
10	13-8M0204647	LOCKWASHER, CLAMP BRACKET STUD
11	11-28770	NUT, CLAMP BRACKET STUD
12	17-8M0026068	TILT LOCK PIN ASSEMBLY
13	10-68299	BOLT, CLAMP BRACKET TO TRANSOM (3")
14	12-68300	WASHER, CLAMP BRACKET BOLT
15	11-82670912	NUT, CLAMP BRACKET BOLT
16	55-28416	PIN, UPPER SHOCK MOUNTING
17	76386	TILT LOCK ASSEMBLY, STARBOARD
18	76385T	TILT LOCK ASSEMBLY, PORT
19	79659	TUBE, TILT LOCK (LONG SHAFT)
20	23-47803	BUSHING, TILT LOCK TUBE (SHORT SHAFT)
21	13-69150	WASHER Comment: WAVE-TILT LOCK (STARBOAR SIDE ONLY) -LONG SHAFT
22	26-22734	OIL SEAL Comment: SWIVEL BRACKET (TILT LOCK) -LONG SHAFT
23	12-76388	WASHER Comment: TILT LOCK (STARBOARD SIDE ONLY) -LONG SHAFT
24	25-627021	"O" RING, TILT LOCK (LONG SHAFT)
25	18-47959	COTTER PIN, TILT LOCK
26	87431	REVERSE LOCK ASSEMBLY
27	24-78203A2	SPRING ASSEMBLY, REVERSE LOCK (LONG SHAFT)
28	56349	SHAFT, REVERSE LOCK PIVOT
29	18-45882	COTTER PIN, REVERSE LOCK TO SHAFT
30	55-28414	PIN, LOWER SHOCK MOUNTING (LONG SHAFT)
31	10-21937	SCREW, LOWER SHOCK PIN (2") (LONG SHAFT)
32	11-8M0207775	NUT, LOWER SHOCK PIN SCREW (LONG SHAFT)
33	55-58780A7	SHOCK ABSORBER
34	23-73203	SPACER Comment: UPPER SHOCK BUSHING TO CLAMP BRACKET
35	12-28196	WASHER, UPPER BUSHING RETAINER (INNER)
36	23-32171	BUSHING, RUBBER-SHOCK ABSORBER (UPPER)
37	23-28198	BUSHING, RUBBER-SHOCK ABSORBER (LOWER)
38	12-69374	WASHER Comment: UPPER/LOWER SHOCK MOUNTING PIN (LOWER)
39	10-69375	SCREW Comment: UPPER AND LOWER SHOCK MOUNTING PIN
40	23-69132	BUSHING PIVOT SHAFT

▶COWLING AND FRONT COVER (14 parts)

Ref	OEM Part #	Part Name
--	92-86166Q1	GLUE, ADHESIVE - SOUND BLANKET FASTENING
1	2182-7927A8	COWL FRONT COVER ASSEMBLY (WITHOUT DECALS)
2	73786	KNOB, COWL FRONT COVER FASTENING
3	12-30771	WASHER, COVER FASTENING KNOB (RUBBER)
4	12-75246	WASHER, COVER FASTENING KNOB (STEEL)
5	24-30772	SPRING, TENSION - COVER FASTENING KNOB
6	17-29077	ROLL PIN, TENSION SPRING TO KNOB
7	47341A11	ROPE, STARTER (FOR MANUAL STARTING ONLY)
8	71040	SEAL, SOUND ABSORBING
9	38674	BLANKET, SOUND ABSORBING
10	54143	SEAL, SOUND - UPPER
11	2119-3248A16	WRAP AROUND COWL ASSEMBLY Comment: (WITHOUT DECALS)
12	46785A1	COWL LATCH ASSEMBLY
13	30413	HOOK, COWL LATCH FASTENING

▶CRANKSHAFT, PISTON AND CONNECTING ROD (31 parts)

Ref	OEM Part #	Part Name
--	27-73645A87	GASKET SET
1	440-9074A2	CRANKSHAFT ASSEMBLY
2	30-62567T	BEARING, BALL - UPPER
3	30-63742T	BEARING, BALL - LOWER
4	54196A6	CARRIER ASSEMBLY
5	65800	PACKING, CARRIER
6	540-5266T5	MAIN BEARING ASSEMBLY (VALVE TYPE)
7	17-20032	DOWEL PIN, MAIN BEARING
8	10-45775	SCREW, MAIN BEARING CLAMPING
9	11-45774	NUT, MAIN BEARING CLAMPING SCREW
10	34-56007A1	REED SET, MATCHED - MAIN BEARING
11	34-56008	REED STOP, MAIN BEARING REED VALVES
12	10-62204	SCREW, REED STOP MOUNTING
13	11-53153	NUT, REED STOP MOUNTING SCREW
14	535-5397A4	CENTER MAIN BEARING ASSEMBLY
15	17-20032	DOWEL PIN, CENTER MAIN BEARING
16	29-714221	BEARING, NEEDLE
17	26113T	RACE, OUTER (PAIR)
18	53-26933	RING, SNAP - OUTER RACE CLAMPING
19	10-22968	SCREW, CENTER MAIN BEARING CLAMPING
20	11-8M0207775	NUT, MAIN BEARING CLAMPING SCR EW
21	17-47246	DOWEL PIN, (STEPPED)
22	774-9137A12	PISTON AND PISTON PIN ASSEMBLY
23	53-857196	LOCK RING, PISTON PIN
24	39-78816A12	RING, PISTON
25	624-8101A3	CONNECTING ROD AND CAP ASSEMBLY
26	10-54803	SCREW, CAP TO CONNECTING ROD
27	11-49091	NUT, CONNECTING ROD SCREW
28	31-62596A1	BEARING ASSEMBLY, CRANKPIN
29	29-8M0214934	BEARING, NEEDLE - PISTON PIN
30	12-8M0032839	WASHER, NEEDLE LOCATING

▶CYLINDER BLOCK AND CRANKCASE ASSEMBLY (25 parts)

Ref	OEM Part #	Part Name
--	27-73645A87	GASKET SET
1	871-8338A3	CYLINDER BLOCK AND CRANKCASE ASSEMBLY
2	27-53650	GASKET, CRANKCASE TO CYLINDER BLOCK
3	56029T	COVER, STARTER MOTOR (UPPER)
4	10-35385	SCREW, COVER TO CRANKCASE (1 3/4")
5	13-8M0204647	LOCKWASHER, COVER SCREW
6	76867	COVER, STARTER MOTOR (LOWER)
7	10-73658	SCREW, COVER TO CRANKCASE (1/2")
8	16-64281	STUD Comment: CRANKCASE TO DRIVE SHAFT HOUSING (1 7/8")
9	17-43044	PIN, DOWEL - CRANKCASE TO CYLINDER BLOCK
10	17-63779	PIN, DOWEL - CYLINDER BLOCK TO MAIN BEARING
11	66517	RESTRICTOR, CRANKCASE BLEED
12	16-64282	STUD Comment: CYLINDER BLOCK TO EXHAUST EXTENSION PLATE (4")
13	10-74824	SCREW, CRANKCASE TO CYLINDER BLOCK (1 1/4")
14	10-73657	SCREW, CRANKCASE TO CYLINDER BLOCK (1 1/2")
15	10-20359	SCREW, CENTER MAIN BEARING LOCKING (1")
16	14-20091	TAB WASHER, BEARING LOCKING SCREW
17	21-42866	CHECK VALVE, BLEED HOSE - TOP
19	32-9938779	HOSE, CYLINDER BLEED (15 1/2")
20	21-428671	CHECK VALVE, BLEED HOSE - BOTTOM
21	22-996642	ELBOW Comment: BALANCE HOSE TO CYLINDER BLOCK - UPPER
22	32-8M0108355	HOSE ASSEMBLY, BALANCE (6 1/4")
23	22-130342	TEE, BALANCE HOSE TO CYLINDER BLOCK - LOWER
24	32-9938779	HOSE, BALANCE (5")
25	22-56759	FITTING, AIR INLET COVER

▶DRIVE SHAFT HOUSING ASSEMBLY (35 parts)

Ref	OEM Part #	Part Name
1	1573-5239A4	DRIVE SHAFT HOUSING ASSEMBLY (LONG SHAFT)
2	16-56295	STUD Comment: DRIVE SHAFT HOUSING TO GEAR HOUSING (2 11/16")
3	19-64649	PLUG, PLASTIC-TRIM TAB SCREW HOLE
5	10-57807	SCREW, TRIM COVER TO BOTTOM COWL (3/4")
6	25-92012	GROMMET, TRIM COVER SCREW
7	46933A2	GROUND STRAP ASSEMBLY, TRIM COVER SCREW
8	10-62568	SCREW, GROUNG STRAP ATTACHING
9	32-60897	TUBE, WATER INLET (LONG SHAFT)
10	78184T	TUBE, EXHAUST (LONG SHAFT)
11	65638	BOOT, EXHAUST TUBE
12	25887	GUIDE, PUSH ROD-REVERSE LOCKING
13	47558	ROD, PUSH-REVERSE LOCK (LONG SHAFT)
14	11-69254	NUT, JAM-PUSH ROD
15	47559	YOKE, PUSH ROD
16	24-78203A2	PIN, PUSH ROD TO REVERSE LOCK
17	18-25191	COTTER PIN, PUSH ROD PIN
18	75296	MOUNT, RUBBER-UPPER (LONG SHAFT)
19	12-47840	WASHER, RUBBE5R-UPPER MOUNT BOLT
20	12-31263	WASHER, UPPER MOUNT BOLT
21	11-8M0204653	NUT, UPPER MOUNT BOLT
22	75298	MOUNT, RUBBER-LOWER (LONG SHAFT)
23	10-75284	SCREW, UPPER MOUNT (5 1/2")
24	66336	MOUNT, RUBBER-LOWER (SHORT SHAFT)
25	11-25096	NUT, MOUNT SCREW
26	25067	BUMPER, RUBBER-MOUNTIN SCREW
27	11-8M0204653	NUT Comment: GEAR HOUSING AND DRIVE SHAFT HOUSING STUDS
28	12-45176	WASHER Comment: GEAR HOUSING TO DRIVE SHAFT HOUSING STUDS
29	11-29489	NUT Comment: GEAR HOUSING AND DRIVE SHAFT HOUSING STUDS
30	12-45176	WASHER Comment: GEAR HOUSING TO DRIVE SHAFT HOUSING STUDS
31	35608	CLAMP Comment: LOWER MOUNT TO DROVE SHAFT HOUSING
32	24-35522	SPRING, TENSION-LOWER MOUNT CLAMP
33	10-29256	SCREW Comment: LOWER MOUNT CLAMP TO DRIVE SHAFT HOUSING (7/8")
34	35474T	COVER, LOWER MOUNT CLAMP
35	11-35521	NUT, LOWER MOUNT CLAMP COVER
36	10-29722	SCREW, COVER TO LOWER CLAMP MOUNT (5/8")

▶END CAPS, MANIFOLD AND EXHAUST COVER (35 parts)

Ref	OEM Part #	Part Name
--	27-73645A87	GASKET SET
1	871-8338A3	CYLINDER BLOCK AND CRANKCASE ASSEMBLY
2	1161-5940A2	END CAP ASSEMBLY, UPPER
3	26-41953	OIL SEAL
4	25-47254	"O" RING
5	15-73644A1	SHIM ASSEMBLY Comment: END CAP TO CRANKCASE (.006-8-10)
6	10-812618	SCREW, END CAP MOUNTING (1")
7	43352	POINTER, TIMING
8	10-65746	SCREW, TIMING POINTER ATTACHING (3/4")
9	12-20533	WASHER, TIMING POINTER SCREW
10	1148-5410T1	END CAP ASSEMBLY, LOWER
11	26-41953	OIL SEAL
12	25-32546	"O" RING
13	15-20085A1	SHIM, END CAP TO CRANKCASE (.002-3-5-10)
14	10-30225	SCREW, END CAP MOUNTING (1")
15	27-73665	GASKET, WATER JACKET COVER
16	76198	COVER, WATER JACKET - CYLINDER BLOCK
17	10-53167T	SCREW Comment: WATER JACKET COVER TO CYLINDER BLOCK (7/8')
18	12-8M0042642	WASHER Comment: WATER JACKET COVER FASTENING SCREW
19	27-854981	GASKET, CYLINDER BLOCK TO BAFFLE PLATE
20	73436	PLATE, BAFFLE - EXHAUST MANIFOLD
21	27-854961	GASKET Comment: BAFFLE PLATE TO EXHAUST MANIFOLD COVER
22	78277A1	COVER, EXHAUST MANIFOLD
23	10-53576	SCREW, MANIFOLD COVER MOUNTING (1 1/8")
24	1021-7699	COVER, CYLINDER BLOCK
25	27-85493	GASKET, CYLNDER BLOCK COVER
26	10-8M0214943	SCREW, CYLINDER BLOCK COVER MOUNTING (1")
27	87872	COVER, TRANSFER PORT - BOTTOM
28	27-73645	GASKET, TRANSFER PORT COVER
29	10-49668	SCREW, TRANSFER PORT COVER MOUNTING (3/4")
30	37440	BRACKET, MOUNT SUPPORT - CYLINDER BLOCK
31	10-35386	SCREW, BRACKET TO CYLINDER BLOCK (1")
32	46933A3	GROUND STRAP ASSEMBLY Comment: EXHAUST COVER SCREW
33	10-62568	SCREW, GROUND STRAP ATTACHING (3/8")
34	22-68307	PLUG, PIPE - CYLINDER BLOCK COVER

▶EXHAUST EXTENSION PLATE (23 parts)

Ref	OEM Part #	Part Name
--	27-73645A87	GASKET SET
1	43289A2	PLATE ASSEMBLY, EXHAUST EXTENSION
2	23-27132	BUSHING, NYLONG - EXHAUSST EXTENSION PLATE
3	17-23784	DOWEL PIN, EXHAUST EXTENSION PLATE
4	37918	SEAL, EXHAUST EXTENSION PLATE
5	99358	STRIP, RETAINING - EXHAUST EXTENSION PLATE
6	10-37571	SCREW Comment: SEAL AND RETAINING STRIP TO EXH. PLATE (1/2")
7	27-692381	GASKET Comment: POWERHEAD TO EXHAUST EXTENSION PLATE
8	10-66023	SCREW, ADAPTOR PLATE TO HOUSING PLATE (2")
9	10-66023	SCREW Comment: HOUSING PLATE TO DRIVE SHAFT HOUSING (2")
10	11-69254	NUT Comment: CRANKCASE STUDS TO EXHAUST EXTENSION PLATE
11	12-20553	WASHER Comment: CRANKCASE STUDS TO EXHAUST EXTENSION PLATE
12	27-661021	GASKET, PLATE TO DRIVE SHAFT H SG. PLATE
13	26-60898	SEAL, DRIVE SHAFT HOUSING PLATE
14	43290A4	PLATE ASSEMBLY, DRIVE SHAFT HOUSING
15	26-38970	SEAL, RUBBER Comment: WATER INLET TUBE (DRIVE SHAFT HSG. PLATE)
16	17-23784	DOWEL PIN, DRIVE SHAFT HOUSING PLATE
17	27-69860	GASKET Comment: DRIVE SHAFT HOUSING PLATE TO EXHAUST TUBE
18	99698	EXHAUST TUBE
19	10-65414	SCREW Comment: EXHAUST TUBE TO DRIVE SHAFT HOUSING PLATE (3/4")
20	13-26992	LOCKWASHER, EXHAUST TUBE SCREW
21	12-20553	WASHER, POWERHEAD STUDS
22	11-82671013	NUT, POWERHEAD STUDS

▶FLYWHEEL, STATOR AND IGNITION COIL (50 parts)

Ref	OEM Part #	Part Name
1	11-52901	NUT, FLYWHEEL
2	12-33001	WASHER, FLYWHEEL NUT
3	19-45907	PLUG, FLYWHEEL PULLER THREADS
4	248-8722A6	FLYWHEEL ASSEMBLY Comment: UNITED STATES 5141097 AND UP AUSTRALIA 8056520 AND UP BELGIUM 9207928 AND UP CANADA 7122588 ANDUP
5	10-68997	SCREW, PLATE/HUB TO FLEXIBLE PLATE (3/4")
6	10-32417	SCREW, FLEXIBLE PLATE TO FLYWHEEL (5/8")
7	90332	PLATE, SWITCH BOX
8	25-57009001	GROMMET, SWITCH BOX PLATE
9	10-824941	SCREW Comment: SWITCH BOX PLATE TO CYLINDER BLOCK (3/4")
10	12-56720	WASHER, SWITCH BOX PLATE SCREW
11	54-47483	"J" CLIP, SWITCH BOX WIRES AND FUEL LINE
12	332-5772A7	SWITCH BOX ASSEMBLY
13	10-20619	SCREW, SWITCH BOX TO PLATE (1 3/8")
14	84-65999A5	WIRE ASSEMBLY
16	11-45076	NUT, SWITCH BOX TERMINAL
17	58124A19	MERCURY SWITCH ASSEMBLY
18	10-37571	SCREW, MERCURY SWITCH TO PLATE (1/2")
19	86-66986	TERMINAL BLOCK
20	10-38055	SCREW, TERMINAL BLOCK TO PLATE (5/8")
21	10-37655	SCREW, WIRE TO TERMINAL BLOCK (1/2")
22	54-23567	CLIP, WIRES AND HARNESS
23	10-48408	SCREW, CLIP TO PLATE (3/8")
24	8M0084613	"D" WAHER, CLIP SCREW
28	54-47483	"J" CLAMP, TRIGGER PLATE HARNESS
29	73395	PLATE, MOUNTING - IGNITION COIL
30	10-28668	SCREW, MOUNTING PLATE TO CRANKCASE (7/8")
31	339-832757A4	IGNITION COIL ASSEMBLY Comment: UNITED STATES 5141097 AND UP AUSTRALIA 8056520 AND UP BELGIUM 9207928 AND UP CANADA 7122588 ANDUP
33	11-45076	NUT, IGNITION COIL TERMINAL
34	87554	COVER, IGNITION COIL
35	10-88856	SCREW, COVER TO MOUNTING PLATE (2")
36	12-30164	WASHER, COVER SCREW
37	77672	STRAP, PRIMARY HARNESS
37A	10-48408	SCREW, STRAP ATTACHING
38	398-5454A26	STATOR ASSEMBLY
39	10-75840	SCREW, STATOR TO UPPER END CAP (7/8")
40	96453A2	TRIGGER PLATE ASSEMBLY
41	84-77617	HARNESS, PRIMARY (CYLINDERS 1 AND 2)
42	84-77618	HARNESS, PRIMARY (CYLINDERS 3 AND 4)
43	54-45806	CLAMP, HARNESS ATTACHING
44	10-48408	SCREW, CLAMP TO CRANKCASE (1/2")
45	8M0084613	"D" WASHER, HARNESS CLAMP SCREW
46	84-813715A1	WIRE ASSEMBLY, SPARK PLUG
47	332-2854T01	BOOT, IGNITION COIL END
48	33-896329833	SPARK PLUG (AC#V40FFK) Comment: FOR CANADA AND BELGIUM, USE C-33-68098 (CHAMPION #QL-76V)
49	78278	RETAINER, WIRE
50	10-48408	SCREW, WIRE RETAINER
51	12-21273	WASHER, WIRE RETAINER SCREW
52	63319	RETAINER, SPARK PLUG WIRE
53	10-46378	SCREW, RETAINER TO CYLINDER BLOCK COVER (1")
54	11-20013	NUT, RETAINER SCREW

▶FUEL PUMP AND FUEL LINES (26 parts)

Ref	OEM Part #	Part Name
--	27-73645A87	GASKET SET
1	73434A5	FUEL PUMP ASSEMBLY
2	21-8M0084276	CHECK VALVE ASSEMBLY
3	55278A5	DIAPHRAGM ASSEMBLY
6	23004	RETAINER, CHECK VALVE
7	10-43725	SCREW, CHECK VALVE TO FUEL PUMP (1/4")
8	35-73532	FUEL FILTER
9	25-35480	"O" RING, COVER TO FUEL PUMP
10	35-14805A2	COVER, FUEL PUMP
11	10-37370	SCREW, COVER TO FUEL PUMP (5/8")
12	27-25848	GASKET, COVER SCREW
13	10-69067	SCREW Comment: FUEL PUMP TO UPPER TRANSFER COVER (1 3/8")
14	22-64705	FITTING, FUEL PUMP (OUTLET)
15	32-8M0108355	FUEL LINE, TEE TO FUEL PUMP (11")
16	22-73318	TEE, FUEL LINE
17	32-8M0108355	FUEL LINE Comment: CARBURETOR TO TEE TO CARBURETOR (3")
18	54-68424	CLAMP, FUEL LINE ATTACHING
19	32-8M0108355	FUEL LINE, ADAPTOR TO FUEL PUMP (15")
20	22-63187	FITTING, FUEL LINE TO ADAPTOR
21	22833	ADAPTOR, CHECK UNIT (FUEL LINE)
22	23069	STEM, CHECK UNIT ADAPTOR
23	25-16524	"O" RING, ADAPTOR STEM
24	24-23067T	SPRING, ADAPTOR STSEM
25	30188	CUP WASHER, ADAPTOR
26	10-69029	SCREW, ADAPTOR TO BOTTOM COWL (1 3/4")
27	11-36069	NUT, ADAPTOR SCREW

▶GEAR HOUSING ASSEMBLY, COMPLETE (PAGE 1) (49 parts)

Ref	OEM Part #	Part Name
-	1655-7333A25	GEAR HOUSING ASS'Y, COMPLETE (LONG SHAFT) Comment: THE ENCLOSED GEAR HOUSINGS INCLUDE ALL PARTS FROM REFERENCE #1 THRU #75 AS LISTED ON C10 AND C12 UNITED STATES 5141097 AND UP AUSTRALIA 8056520 AND UP BELGIUM 9207928 AND UP CANADA 7122588 ANDUP
--	26-55682A1	SEAL REPAIR KIT
1	1655-7333T23	GEAR HOUSING ASSEMBLY Comment: UNITED STATES 5141097 AND UP AUSTRALIA 8056520 AND UP BELGIUM 9207928 AND UP CANADA 7122588 ANDUP
1A	22-85822A10	CONNECTOR ASSEMBLY, SPEEDOMETER Comment: UNITED STATES 5141097 AND UP AUSTRALIA 8056520 AND UP BELGIUM 9207928 AND UP CANADA 7122588 ANDUP
2	17-8M0084726	DOWEL PIN, GEAR HOUSING LOCATING
3	16-57921	STUD Comment: GEAR HOUSING TO DRIVE SHAFT HOUSING (4")
4	16-8M0133358	STUD Comment: GEAR HOUSING TO DRIVE SHAFT HOUSING (2 1/16")
5	16-8M0034463	STUD Comment: WATER PUMP BASE AND BODY TO GEAER HOUSING (3 3/8")
6	16-306671	STUD Comment: WATER PUMP BASE AND BODY TO GEAR HOUSING (3 1/8")
7	31-32898T	BEARING, ROLLER-DRIVE SHAFT
8	45-42646	DRIVE SHAFT (LONG SHAFT
9	43-75316T	GEAR, PINION-DRIVE SHAFT
10	11-35921	NUT, PINION GEAR TO DRIVE SHAFT
11	15-57007A1	SHIM, ROLLER BEARING TO WATER PUMP BASE
12	31-69220T	ROLLER BEARING, DRIVE SHAFT
14	27-8M0214962	GASKET, WATER PUMP BASE TO GEAR HOUSING
15	25-8M0214923	"O" RING, WATER PUMP BASE
16	46-96146A5	WATER PUMP BASE ASSEMBLY
17	26-94038	OIL SEAL, WATER PUMP BASE
18	26-16977	OIL SEAL, WATER PUMP BASE
19	17-35973	DOWEL PIN Comment: WATER PUMP BASE TO WATER PUMP BODY
20	27-8M0090319	GASKET Comment: LOWER-WATER PUMP BASE TO FACE PLATE
21	37-56036A2	PLATE Comment: FACE-WATER PUMP BASE TO WATER PUMP BODY
22	27-858524	GASKET Comment: UPPER-FACE PLATE TO WATER PUMP BODY
23	46-96148T1	WATER PUMP BODY ASSEMBLY
24	48752T	INSERT, WATER PUMP BODY
26	26-38970	SEAL, RUBBER-WATER INLET TUBE
27	47-89984T4	IMPELLER, WATER PUMP
28	28-8M0214992	KEY, IMPELLER DRIVE
29	10-30720	SCREW Comment: WATER PUMP BODY TO GEAR HOUSING (2 1/4")
30	13-26992	LOCKWASHER, WATER PUMP BODY SCREW
31	12-8M0204649	WASHER Comment: WATER PUMP BODY FASTENING SCREW AND STUD
32	11-35888	NUT, WATER PUMP FASTENING SCREW
33	12-36001	WASHER, WATER PUMP BODY FASTENING STUD
34	11-82670911	NUT, WATER PUMP BODY FASTENING STUD
35	25-8M0214918	RING Comment: RUBBER-CENTRIFUGAL SLINGER (DRIVE SHAFT)
36	23-29804T	SLEEVE, GUIDE-WATER INLET TUBE
37	37641001	SEAL, EXHAUST TUBE
38	38051	PLATE, SUPPORT-EXHAUSST TUBE SEAL
39	76062A1	SHAFT ASSEMBLY, SHIFT
40	53-29641	"E" RING, RETAINING-SHIFT SHAFT
41	25-25439	"O" RING, SHIFT SHAFT BUSHING
42	23-77631A2	BUSHING ASSEMBLY, SHIFT SHAFT
43	26-8M0204708	OIL SEAL, SHIFT SHAFT HOUSING
44	12-77674	WASHER, RUBBER-SHIFT SHAFT BUSHING
45	78036	SPACER, LOWER-REVERSE LOCKING
46	43308T1	CAM, REVERSE LOCKING
47	22-8M0058389	SCREW, DRAIN (MAGNETIC)
48	12-191833	WASHSER Comment: GREASE FILLER AND VENT HOLE SCREW

▶GEAR HOUSING ASSEMBLY, COMPLETE (PAGE 2) (32 parts)

Ref	OEM Part #	Part Name
-	1655-7333A25	GEAR HOUSING ASS'Y, COMP. (LONG SHAFT) Comment: THE ENCLOSED GEAR HOUSINGS INCLUDE ALL PARTS FROM REFERENCE #1 THRU #75 AS LISTED ON C10 AND C12 UNITED STATES 5141097 AND UP AUSTRALIA 8056520 AND UP BELGIUM 9207928 AND UP CANADA 7122588 ANDUP
--	27-73645A87	GASKET SET
1	1655-7333T23	GEAR HOUSING ASS'Y Comment: UNITED STATES 5141097 AND UP AUSTRALIA 8056520 AND UP BELGIUM 9207928 AND UP CANADA 7122588 ANDUP
51	760394	CAM, SHIFT
52	30625	FOLLOWER, CAM
53	30624	SLIDE, CROSS PIN
54	24-30622	SPRING, COMPRESSION-CAM FOLLOWER
55	15-30923A1	SHIM Comment: BEARING OUTER RACE TO GEAR HSG. (.002-3-5-10)
56	31-30894A1	TAPERED ROLLER BEARING ASSEMBLY
57	31-30895T	BEARING, ROLLER-FORWARD GEAR
58	43-75314T2	FORWARD GEAR ASSEMBLY
59	52-822539T	RATCHET, SLIDING CLUTCH
60	17-8M0100263	PIN, CROSS-RATCHET TO PROPELLER SHAFT
61	24-30893	SPRING, RETAINING-CROSS PIN
62	44-93003	SHAFT, PROPELLER
63	43-77562T	REVERSE GEAR ASSEMBLY
65	12-76358	WASHER Comment: THRUST-BEARING CARRIER TO GEAR HOUSING
67	25-29976	"O" RING, BEARING CARRIER
68	41529T2	BEARING CARRIER ASSEMBLY
69	31-30956T	BEARING, ROLLER-BEARING CARRIER
70	26-8M0204670	OIL SEAL, BEARING CARRIER
71	28-30281	KEY,LOCATING-BEARING CARRIER
72	14-52700	TAB WASHER, GEAR HOUSING COVER
73	52699	COVER, GEAR HOUSING
74	97-31640Q4	TROM TAB, GEAR HOUSING
75	10-66024	SCREW, TRIM TAB TO GEAR HOUSING (1 3/4")
76	12-45176	WASHER Comment: GEAR HOUSING TO DRIVE SHAFT HOUSING STUDS
77	11-8M0204653	NUT Comment: GEAR HOUSING TO DRIVE SHAFT HOUSING STUDS
78	10-65210	SCREW Comment: GEAR HOUSING TO DRIVE SHAFT HOUSING (1")
79	13191Q01	THRUST HUB
82	14-816629Q	TAB WASHER, PROPELLER NUT
83	11-52707Q1	NUT, PROPELLER

▶MISCELLANEOUS PARTS/ACCESSORIES (1 parts)

Ref	OEM Part #	Part Name
-	37-93152A81	DECAL SET - SERIAL GROUP #2

▶PROPELLERS (RIGHT HAND ROTATION) (1 parts)

Ref	OEM Part #	Part Name
-	48-77350A45	PROPELLER ASSEMBLY (ALUMINUM)(PITCH 23") Comment: 3 BLADES

▶STARTER MOTOR AND WIRING HARNESS (24 parts)

Ref	OEM Part #	Part Name
1	50-893891T	STARTER MOTOR
2	23-8M0034918	COLLAR, RUBBER - STARTER MOTOR
3	23-56774	SPACER, COLLAR TO BRACKET
4	8M0043376	STOP, RUBBER - STARTER MOTOR
5	84-93389A1	WIRE ASS'Y Comment: STARTER MOTOR/STARTER SOLENOID (YELLOW)
6	13-26992	LOCKWASHER, STARTER MOTOR TERMINAL
7	11-64015	NUT, STARTER MOTOR TERMINAL
8	10-69035	SCREW Comment: WIRING HARNESS TO STARTER MOTOR (5/8")
9	8M0058226	RECTIFIER ASSEMBLY
10	10-37656	SCREW, RECTIFIER TO PLATE (5/8")
13	11-45076	NUT, RECTIFIER TERMINAL
14	89-853654A1	STARTER SOLENOID
15	10,13-26996	LOCKWASHER, SOLENOID TERMINAL
16	10,11-68219	NUT, SOLENOID TERMINAL
17	13-8M0204647	LOCKWASHER, WOLENOID TERMINAL (5/16")
18	11-8M0204668	NUT, SOLENOID TERMINAL (5/16")
19	46265	BOOT, TERMINAL - STARTER SOLENOID
20	10-38601	SCREW, SOLENOID TO BOTTOM COWL (5/8")
21	13-26992	WASHER, SOLENOID SCREW
22	84-73369A1	WIRING HARNESS (INTERNAL)
23	24-28975	SPRING, GARTER - INTERNAL WIRING HARNESS
24	54-76368	CLAMP, WIRING HARNESS
25	10-690201	SCREW Comment: WIRING HARNESS CLAMP TO BOTTOM COWL (7/8")
26	12-30164	WASHER, WIRING HARNESS CLAMP SCREW

▶SWIVEL BRACKET ASSEMBLY (17 parts)

Ref	OEM Part #	Part Name
1	1482-6386A4	SWIVEL BRACKET ASS'Y (LONG SHAFT)
2	23-69341	BUSHING, SWIVEL BRACKET
3	12-69342	WASHER, SWIVEL PIN - UPPER
4	26-37448	OIL SEAL, SWIVEL BRACKET
5	10-47828	SCREW, DRIVE - SWIEL BRACKET
6	22-8M0169589	FITTING, GREASE
7	17-25598	PIN, REVERSE LOCK SPRING ATTACHING
8	12-37429	WASHER, SWIVEL PIN - LOWER
9	28205T	STRAP STOP Comment: DRIVE SHAFT HOUSING TO SWIVEL BRACKET
10	10-28200	SCREW Comment: STRAP STOP TO HOUSING (3 7/8")-LONG SHAFT
11	11-25269	NUT, STRAP STOP FASTENING SCREW
12	17-73593A2	SWIVEL PIN ASS'Y (LONG SHAFT)
13	73984T	YOKE, BOTTOM
15	53-73591	SNAP RING, YOKE ATTACHING
16	28203	BUMPER, STEERING ARM
17	10-49554	BOLT, STEERING ARM TO UPPER MOUNT (5 7/8")
18	11-8M0204653	NUT, STEERING ARM BOLT FASTENING

▶THROTTLE LEVER AND SPARK ADVANCE LEVER (32 parts)

Ref	OEM Part #	Part Name
1	73416	LEVER, THROTTLE
2	73404	LATCH, THROTTLE LEVER (THROTTLE CABLE)
3	10-59702	SCREW, LATCH TO THROTTLE LEVER (7/8")
4	24-20099	SPRING, LATCH SCREW
5	11-36069	NUT, LATCH SCREW
6	10-69029	SCREW, ADJUSTING - THROTTLE LEVER (1 3/4")
7	11-29598	NUT, JAM - ADJUSTING SCREW
8	52023	CAP, NYLON - ADJUSTING SCREW
9	73414	ARM, SPARK ADVANCE
10	10-73656	SCREW, ADJUSTING - SPARK ADVANCE ARM (1 3/8")
11	11-68219	NUT, JAM - ADJUSTING SCREW
12	48039	CAP, NYLON - ADJUSTING SCREW
13	10-67916	SCREW, ADJUSTING - SPARK ADVANCE ARM (2")
14	11-29598	NUT, JAM - ADJUSTING SCREW
15	52023	CAP, NYLON - ADJUSTING SCREW
16	10-818165	SCREW Comment: LEVER AND ARM TO CYLNDER BLOCK (1 3/4")
17	23-55164	BUSHING, LEVER AND ARM SCREW
18	23-55171	BUSHING, FLANGE - LEVER AND ARM SCREW
19	24-73375	SPRING, RETURN - LEVER AND ARM SCREW
20	12-46765	WASHER, LEVER AND ARM SCREW
21	8M0221994	BARREL, NYLON - LEVER AND ARMS
22	73374	LINK ROD, THROTTLE
23	73432	CAM, THROTTLE
24	77001	HOUSING, THROTTLE CAM
25	10-60605	SCREW, HOUSING TO CRANKCASE (3/4")
26	77010	LINK ROD, SPARK ADVANCE
27	76158A1	SWIVEL ASSEMBLY, LINK ROD TO ARM
28	23-26856	BUSHING, NYLON - LINK ROD SWIVEL
29	13-29402	WAVE WASHER, LINK ROD SWIVEL
30	12-73288	WASHER, LINK ROD SWIVEL
31	11-20110	NUT, LINK ROD SWIVEL
32	77158	SPACER, THROTTLE CAM HOUSING

▶TOP COWL AND SUPPORT BRACKETS (38 parts)

Ref	OEM Part #	Part Name
-	27-73645A87	GASKET SET
1	2114-7934T	COWL, TOP (WITHOUT DECALS)
2	52733A9	RETAINER ASSEMBLY, TOP COWL
3	35496	PAD, BUMPER-TOP COWL RETAINER
4	10-74824	SCREW, RETAINER TO TOP COWL (1 1/4")
5	13-39107	LOCKWASHER, RETAINER FASTENING SCREW
6	76370	SHIELD, TOP COWL - REAR
7	10-37370	SCREW, SHIELD TO TOP COWL (5/8")
8	13-37371	LOCKWASHER, SHIELD SCREW
9	52739	HINGE, COWL LATCH - TOP COWL
10	94918F1	LEVER, COWL LATCH HINGE
11	17-58998	PIN, COWL LATCH LEVER TO HINGE
12	55455	HOOK, TOP COWL LATCH - REAR
13	13-26992	LOCKWASHER, REAR HOOK MOUNTING SCREW
14	10-22956	SCREW, REAR HOOK TO TOP COWL (7/8")
15	73401T	FRAME, SUPPORT - TOP COWL
16	37640	MOUNT, RUBBER - SUPPORT FRAME
17	13-8M0204647	LOCKWASHER, RUBBER MOUNT
18	11-28770	NUT, RUBBER MOUNT
19	10-37562	SCREW, SUPPORT FRAME TO FRONT FRAME (1")
20	13-8M0204647	LOCKWASHER, SUPPORT FRAME SCREW
21	90435	MOUNT, RUBBER - TOP COWL FRAME
22	11-35888	NUT, RUBBER MOUNT (UPPER)
23	11-8M0207775	NUT, RUBBER MOUNT (LOWER)
24	52468	BRACKET, TOP COWL SUPPORT - REAR
25	31014	MOUNT, RUBBER - REAR SUPPORT BRACKET)
26	13-26992	LOCKWASHER Comment: RUBBER MOUNT TO REAR SUPPORT BRACKET
27	11-29598	NUT Comment: RUBBER MOUNT TO REAR SUPPORT BRACKET
28	10-37562	SCREW, REAR BRACKET TO FRAME (1")
29	13-8M0204647	LOCKWASHER, REAR BRACKET SCREW
30	10-37562	SCREW Comment: REAR SUPPORT BRACKET TO BOTTOM COWL (1")
31	13-8M0204647	LOCKWASHER Comment: REAR SUPPORT BRACKET SCREW
32	73396	FRAME, FRONT SUPPORT
33	10-37562	SCREW, SILENCER COVER
34	13-8M0204647	LOCKWASHER, FRAME SCREW
35	76226A1	COVER ASSMEBLY, SILENCER
36	27-76168A2	GASKET, SILENCER COVER
37	10-28638	SCREW, COVER TO FRONT SUPPORT FRAME (3/4")

100-Hour / Annual Service Checklist

Regular maintenance keeps your Mercury 800 (4 CYL.), 80 (4 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 800 (4 CYL.), 80 (4 CYL.) (4831999 THRU 5582561) Parts & Diagrams

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