Mercury 90 (4-STROKE) (0G960500 THRU 0T800999) Parts & Diagrams

🔎 Mercury 90 (4-STROKE) Reference Library — Exploded parts diagrams (34 diagrams), specifications, common issues, and maintenance checklist.

The Mercury 90 (4-STROKE) 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	90 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 ± 50 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 90 (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 90 (4-STROKE).

▶Accessories (1 parts)

Ref	OEM Part #	Part Name
-	816366A32	STEERING HANDLE KIT Comment: (2004 Model Year And Up)

▶Bottom Cowl (28 parts)

Ref	OEM Part #	Part Name
1	100-878587A1	BOTTOM COWL ASSEMBLY (Port)
2	100-8M0113913	BOTTOM COWL ASSEMBLY (Starboard)
3	8M0109217	SEAL, Cowl (41.00 Inches)
4	878547T	INSERT Comment: (Design II)
5	10-82130040	SCREW, (M6 x 40)
6	831209	RETAINER
7	858742	BOOT, Idle Exhaust
8	8M0039078	GROMMET
9	22-827948	FITTING
10	12-855576	WASHER
11	54-816311T	TIE STRAP, (8.00 Inches)
12	32-8M0108355	HOSE, (57.00 Inches Bulk) (Cut to 5 Inches)
13	32-8M0108355	HOSE, (57.00 Inches Bulk) (Cut to 11 Inches)
14	32-9912688	TUBING, (36.00 Inches Bulk) (Cut to 26 Inches)
15	22-817518	TEE
16	10-82130020	SCREW, (M6 x 20)
17	25-889724	GROMMET
18	87-8M0042301	SWITCH ASSEMBLY
19	10-824868	SCREW, (M6 x 75)
20	889740A02	FRONT HANDLE, Black
21	23-33589	BUSHING
22	25-48462	O-RING, (.614 x .070)
23	8219423	PAWL
24	12-69057	WASHER, (.281 x .734 x .063)
25	11-401366	NUT, (M6) Stainless Steel
26	13541	PLUG, Male
27	19-824928001	PLUG, Rubber Comment: (75 Bodensee)
28	859184T	COVER Comment: (Design I)

▶Carburetor (47 parts)

Ref	OEM Part #	Part Name
-	804346T02	REPAIR KIT, Carburetor (1 Per Carburetor)
1	3319-804708T1	CARBURETOR Comment: (1/3) (75)
2	3319-804708T2	CARBURETOR Comment: (2) (75)
3	3319-804168T7	CARBURETOR Comment: (4)(75 Bodensee)
4	10-83509M	SCREW, (M4 x 10)
5	804171	PLATE
6	25-804172	O-RING
7	35-804195	FILTER ELEMENT
8	10-804176	SCREW Comment: (1/2/3)
9	24-804177	SPRING Comment: (1/2/3)
10	24-804170	SPRING
11	25-804181	O-RING
12	10-804169	SCREW, Pilot
13	19-8M0080454	PLUG
14	804188	PRIMER, Starter Comment: (1/3)
15	10-804192	SCREW, (M4 x 10) Comment: (1/3)
16	804189	LEVER PLATE, Starter Comment: (1/3)
17	804187	HOUSING, Starter Comment: (1/3)
18	10-804190	SCREW, (M5 x 16) Comment: (1/3)
19	25-804191	O-RING Comment: (1/3)
20	25-80419130	O-RING Comment: (1/3)
21	25-80419120	O-RING Comment: (1/3)
22	25-80419110	O-RING Comment: (1/3)
23	24-804178	SPRING Comment: (1/2/3)
24	25-97070M	O-RING
25	17050M	NEEDLE VALVE SET
26	54-82781M	CLIP
27	17-92639M	PIN, Float
28	45,804871	JET, Pilot Comment: (75HP)
29	22-8M0080455	CAP
30	877865	MAIN NOZZLE Comment: (75 HP)
31	108,885125	JET, Main Comment: (75 Bodensee)
32	804184	FLOAT
33	17-804185	PIN, Float Arm
34	10-82500M	SCREW, (M4 x 8)
35	27-804183	GASKET
36	804182	FLOAT BOWL Comment: (1/3)
37	10-11796M	SCREW, (M4 x 14)
38	10-81293M	SCREW, Drain
39	25-94498M	O-RING
40	8041821	FLOAT BOWL Comment: (2/4)
41	10-804179	SCREW Comment: (4)
42	24-82080M	SPRING Comment: (4)
43	19233M	COLLAR Comment: (4)
44	23-804180	BUSHING Comment: (4)
45	804193	DIAPHRAGM Comment: (4)
46	10-804194	SCREW, (M6 x 14) Comment: (4)

▶Crankshaft, Pistons and Connecting Rods (13 parts)

Ref	OEM Part #	Part Name
-	27-804345A02	GASKET SET, Powerhead
1	2406-804098T	CRANKSHAFT
2	26-8040992	SEAL, Oil
3	26-8041002	SEAL, Oil
4	31-804101T20	BEARING Comment: (Red)
5	31-804102T30	BEARING Comment: (Red)
6	31-804103T20	BEARING Comment: (Red)
7	2715-880895T03	PISTON ASSEMBLY Comment: (.25MM Oversize)
8	10-804105	BOLT
9	31-804106T31	BEARING Comment: (Red)
10	39-880898T02	RING SET, Piston Comment: (.25MM Oversize)
11	28-804153	KEY
12	28-8261001	KEY

▶Cylinder Block and Crankcase (46 parts)

Ref	OEM Part #	Part Name
-	27-804345A02	GASKET SET, Powerhead
1	892-804071T3	CYLINDER BLOCK
2	17-82364M	PIN, Dowel
3	27-858732002	GASKET
4	10-8M0101617	BOLT, (M8 x 55)
5	10-804072	BOLT, (M10 x 135)
6	25-855690	GROMMET
7	19-825953	PLUG, (M14 x 12)
8	27-81990M	GASKET
9	10-804097	BOLT
10	35-8M0162830	FILTER, Oil
11	881600	CAP, Rubber
12	32-804078	HOSE
13	54-816311T	TIE STRAP, (8.00 Inches)
14	NSS	NOT SOLD SEPARATE, Anode Comment: Order Cover
15	25-804086	GROMMET
16	804085	COVER
17	10-827207	BOLT, (M8 x 25)
18	10-8524741	BOLT, (M6 x 20)
19	10-881428	BOLT, (M6 x 16)
20	804083001	COVER
21	27-804084	GASKET
22	24-804081	SPRING
23	804080001	VALVE, Pressure Control
24	25-804082	GROMMET
25	10-881427	BOLT, (M6 x 30)
26	804075T02	COVER, Outer Exhaust
27	27-804076003	GASKET
28	54-804089	CLIP
29	32-804088	HOSE
30	54-816311T	TIE STRAP, (8.00 Inches)
31	804073	LIFTING EYE
32	804149	PLATE, Valve
33	10-8257021	BOLT, (M6 x 20)
34	16-8587331	STUD
35	12-8M0214963	WASHER, (.406 x .750 x .105) Stainless Steel
36	11-40140	NUT, (M10)
37	10-81893435	SCREW, (M8 x 35)
38	25-804093	O-RING Comment: SN# 0T178499 & Below
39	804092	BRACKET Comment: SN# 0T178499 & Below
40	10-811188T	BOLT, (M6 x 16) Comment: SN# 0T178499 & Below
41	54-816311T	TIE STRAP, (8.00 Inches) Comment: SN# 0T178499 & Below
42	32-804094	BREATHER PIPE Comment: SN# 0T178499 & Below
43	54-804095	CLAMP Comment: SN# 0T178499 & Below
44	10-804602	BOLT, (M6 x 12) Comment: SN# 0T178499 & Below
45	54-804096	CLIP Comment: SN# 0T178499 & Below

▶Cylinder Head (34 parts)

Ref	OEM Part #	Part Name
-	27-804345A02	GASKET SET, Powerhead
1	8M0057170	CYLINDER HEAD Comment: (Use PN 804127-1 Thermostat Cover and PN 855676-1 Thermostat to service this Cylinder Head)
2	17-804110	PIN, Guide
3	19-804111	PLUG
4	10-804112	BOLT, (M7 x 48)
5	17-804113	PIN, Dowel
6	10-804114	BOLT, (M7 x 37)
7	10-8248326	BOLT, (M6 x 25)
8	8041271	THERMOSTAT COVER Comment: (Use with 804109T4 Cylinder Head) SN# 0T178500 & Up
9	8556761	THERMOSTAT, 60Â°C (140Â°F) Comment: (Use with 804109T4 Cylinder Head) SN# 0T178500 & Up
10	10-881311	BOLT, (M10 x 145)
11	33-859495Q	SPARK PLUG, (NGK-LFR5A-11)
12	10-827207	BOLT, (M8 x 25)
13	10-8524741	BOLT, (M6 x 20)
14	804085	COVER
15	25-804086	GROMMET
16	NSS	NOT SOLD SEPARATE, Anode Comment: Order Cover
17	23-8M0070515	COLLAR
18	27-8041151	GASKET
19	10-83124714	BOLT
20	12-831246	WASHER, Sealing
21	10-881312	BOLT, (M8 x 55)
22	27-804123	GASKET
23	881313T1	COVER KIT Comment: SN# 0T409000 & Up
24	804119	COVER, Breather
25	10-804120	SCREW, (M4 x 8)
26	22-804122	NIPPLE Comment: SN# 0T178499 & Below
27	10-858530	BOLT, (M6 x 30)
28	859578A1	PLUG ASSEMBLY, Oil
29	NSS	NOT SOLD SEPARATE, O-Ring
30	25-855690	GROMMET
31	858752001	COVER
32	10-1993716	SCREW, (M6 x 16)
33	NSS	NOT SOLD SEPARATE, Decal-Bodensee

▶Driveshaft Housing (22 parts)

Ref	OEM Part #	Part Name
1	1507-858576T2	HOUSING ASSEMBLY, Driveshaft
2	16-9035015	STUD, (M10 x 227) Comment: (X-Long)
3	16-8M0034462	STUD, (M10 x 190) Comment: (X-Long)
4	12-8M0214963	WASHER, (.406 x .750 x .105) Stainless Steel
5	11-40140	NUT, (M10)
6	22-85822A13	PICK UP ASSEMBLY, Speedometer
7	22-433351	CONNECTOR, 90 Degree (.125-27) Nylon
8	22-85822T	CONNECTOR, Straight
9	44343T1	MOUNT
10	10-898835001	BOLT, (M12 x 154)
11	12-30119	WASHER, (.875 Inch Outside Diameter)
12	11-8M0204662	NUT, (M12)
13	88238A10	CABLE ASSEMBLY, Ground
14	10-41508	SCREW, (.250-20 x .500) Stainless Steel
15	858916T	CLAMP
16	10-4010725	SCREW, (M8 x 25)
17	8M0142713	CAP
18	23-859550	BUSHING
19	17-24873	PIN, Alignment
20	22-855622	FITTING
21	12092A3	SPACER KIT Comment: (X-Long)
22	17-43044	PIN, Dowel - Without Hole (.375 x .625) Comment: (X-Long)

▶Electrical Components (44 parts)

Ref	OEM Part #	Part Name
0	891824	COVER, Fuse - Black
1	804288T	COVER
2	37-881865	DECAL, Caution-Start in Gear
3	37-8272822	DECAL, Warning, High Voltage
4	804289	PULLER, Fuse
5	84-8042903	HARNESS ASSEMBLY Comment: SN# 0T599000 & Up
6	88-832969T20	FUSE, 20 Ampere
7	88-8M0057159	FUSE, 30 Ampere
8	54-816311T	TIE STRAP, (8.00 Inches)
9	804287T	BRACKET
10	10-811188T	BOLT, (M6 x 16)
11	804286T	BRACKET, Relay
12	10-811188T	BOLT, (M6 x 16)
13	8M0010250	BRACKET
14	825096T01	RELAY
15	12-827205	WASHER
16	11-827204	NUT, (M6)
17	85-826574	BOOT
18	804281T	RELAY
19	12-827205	WASHER
20	11-827204	NUT, (M6)
21	85-804284001	BOOT
22	804282T	RELAY
23	84-804285	CABLE
24	84-804283	CABLE
25	12-827205	WASHER
26	11-827204	NUT, (M6)
27	84-858740T4	HARNESS ASSEMBLY
28	92753	RETAINER
29	10-84058M	BOLT, (M6 x 20)
30	13-82212M	LOCKWASHER
31	12-82214M	WASHER
32	804292	PLATE
33	10-804602	BOLT, (M6 x 12)
34	84-88439A33	CABLE ASSEMBLY, Positive - Battery
35	84-88439A4	CABLE ASSEMBLY, Battery - Negative
36	11-401388	NUT, (M8) Stainless Steel
37	10-81893412	SCREW, (M8 x 12)
38	859249T1	CONNECTOR
39	84-858723T1	HARNESS ASSEMBLY, Adaptor/Trim
40	84-858914T1	HARNESS ASSEMBLY, Trim Motor Adaptor
41	11-401386	NUT, (M6) Stainless Steel
42	804293T	COVER Comment: (Use where Applicable)
43	10-804126	SCREW Comment: (Use where Applicable)

▶Exhaust Plate (33 parts)

Ref	OEM Part #	Part Name
1	858582T	ADAPTOR PLATE ASSEMBLY
2	17-23784	PIN, Dowel
3	22-291112	FITTING
4	21-817519A2	CHECK VALVE ASSEMBLY, Drain
5	25-12602002	GROMMET
6	27-8585831	GASKET
7	858572T01	SUMP, Oil
8	858584A1	TUBE ASSEMBLY, Exhaust
9	25-881295	O-RING
10	25-89417004	GROMMET
11	32-8M0026129	TUBE, Water Comment: (X-Long)
12	814080001	SEAL (Upper)
13	858571T	TUBE, Oil Pick Up
14	25-859082	O-RING
15	10-8M0204741	SCREW, (M6 x 20) Stainless Steel
16	10-8M0214957	SCREW, (M6 x 30)
17	8596021	DIPSTICK Comment: SN# 0T178500 & Up
18	23-48237	BUSHING
19	858577A3	SHIFT SHAFT
20	859177A3	SHIFT LINK
21	NSS	NOT SOLD SEPARATE, Bushing
22	NSS	NOT SOLD SEPARATE, Roller
23	11-401386	NUT, (M6) Stainless Steel
24	23-11289	SPACER Comment: (X-Long)
25	43585	COUPLING
26	18-859746	COTTER PIN
27	8M0039073	SEAL
28	8288181	PLUG, Drain
29	27-8M0204692	GASKET
30	10-82483213	SCREW, (M6 x 60)
31	10-4010750	SCREW, (M8 x 50)
32	22-479452	PLUG
33	22-384073	PLUG, Pipe (.500-14)

▶Flywheel (22 parts)

Ref	OEM Part #	Part Name
-	883548T02	POWERHEAD ASSEMBLY Comment: SN# 0T178499 & Below
1	881343T1	FLYWHEEL COVER
2	NSS	NOT SOLD SEPARATE, Decal-Warning-Spinning Flywheel
3	NSS	NOT SOLD SEPARATE, Decal-Servicing Referral
4	NSS	NOT SOLD SEPARATE, Decal-Engine Oil/Valve
5	37-804656A03	DECAL, EPA Label Information Comment: (2003)
6	NSS	NOT SOLD SEPARATE, Decal-Emergency
7	10-804348	BOLT, (M6 x 20)
8	825665	COLLAR
9	25-11416T	GROMMET
10	11-804265A1	NUT/WASHER KIT, Hex (36 mm) Comment: SN# 0T599000 & Up
11	12-804264	WASHER Comment: SN# 0T598999 & Below
12	280-804261T	FLYWHEEL
13	NSS	NOT SOLD SEPARATE, Decal-Warning Neutral
14	398-804262T	STATOR KIT
15	17-825010	PIN, Dowel
16	10-804124	BOLT
17	13-82212M	LOCKWASHER
18	12-82214M	WASHER
19	10-804267	SCREW
20	804266001	TIMING PLATE
21	804263	ROTOR

▶Fuel Pump(Serial Number 0T408999 & Below) (35 parts)

Ref	OEM Part #	Part Name
-	27-804345A02	GASKET SET, Powerhead
1	804249T1	PUMP, Fuel
2	10-809564	SCREW, (M5 x 35)
3	809565	COVER
4	8095611	DIAPHRAGM
5	10-804253	SCREW
6	21-41888M	CHECK VALVE
7	804250	DIAPHRAGM
8	17-804254	PIN
9	24-809562	SPRING
10	11-82388M	NUT, (M5)
11	24-804252	SPRING
12	804251	PLUNGER
13	10-804256	BOLT, (M6 x 30)
14	25-8M0050719	O-RING
15	12-84292M	WASHER
16	804257	LEVER, Fuel Change
17	17-82738M	PIN
18	804258	SHAFT
19	17-804113	PIN, Dowel
20	804260	BRACKET
21	10-804112	BOLT, (M7 x 48)
22	35-877565T1	FILTER, Fuel
23	8775381	PROTECTIVE SLEEVE
24	54-816311T	TIE STRAP, (8.00 Inches)
25	32-8M0108349	TUBING, (.312) (70.00 Inches Bulk) (Cut to 36 Inches)
26	22-822769	CONNECTOR
27	NSS	NOT SOLD SEPARATE, Cap
28	32-8M0108355	HOSE, (57.00 Inches Bulk) (Cut to 2 Inches)
29	22-818993	CONNECTOR, Tee
30	32-8M0108355	HOSE, (57.00 Inches Bulk) (Cut to 4.75 Inches)
31	32-8M0108349	TUBING, (.312) (70.00 Inches Bulk) (Cut to 13.5 Inches)
32	32-828547633	CONDUIT, (.620 Inside Diameter x 3.00 Feet Bulk) (Cut to 13 Inches)
33	32-828547T	CONDUIT, (1.00 Inside Diameter x 3.00 Feet Bulk) (Cut to 3.75 Inches)
34	32-828547T	CONDUIT, (1.00 Inside Diameter x 3.00 Feet Bulk) (Cut to 1.25 Inches)

▶Fuel Pump(Serial Number 0T409000 & Up) (39 parts)

Ref	OEM Part #	Part Name
-	27-804345A02	GASKET SET, Powerhead
1	880890T1	PUMP, Fuel
2	NSS	NOT SOLD SEPARATE, Body
3	24-881544	SPRING
4	881545	PLUNGER
5	24-881546	SPRING
6	881547	DIAPHRAGM
7	17-881548	PIN
8	NSS	NOT SOLD SEPARATE, Body
9	NSS	NOT SOLD SEPARATE, Diaphragm
10	NSS	NOT SOLD SEPARATE, Body
11	10-881550	SCREW
12	11-881333	NUT
13	25-8M0050719	O-RING
14	56762	CLAMP
15	10-804256	BOLT, (M6 x 30)
16	32-881543002	HOSE
17	881542	BRACKET
18	10-826957M	BOLT
19	11-82382M	NUT
20	35-881538T02	FILTER ASSEMBLY
21	35-8M0168897	ELEMENT
22	25-826966T	O-RING
23	881541	FLOAT
24	881539	CUP
25	56762	CLAMP
26	804260	BRACKET
27	10-804112	BOLT, (M7 x 48)
28	17-804113	PIN, Dowel
29	12-84292M	WASHER
30	804257	LEVER, Fuel Change
31	881334	SHAFT
32	17-82738M	PIN
33	32-8M0108349	TUBING, (.312) (70.00 Inches Bulk) (Cut to 55 Inches)
34	54-816311T	TIE STRAP, (8.00 Inches)
35	22-822769	CONNECTOR
36	NSS	NOT SOLD SEPARATE, Cap
37	32-828547T1	CONDUIT, (.500 Inside Diameter x 3.00 Feet Bulk)
38	12-82214M	WASHER

▶Fuel/Vent Lines(Serial Number 0T408999 & Below) (31 parts)

Ref	OEM Part #	Part Name
1	804230	ROD, Choke
2	54-816311T	TIE STRAP, (8.00 Inches)
3	32-804236	HOSE
4	84-804197	HARNESS ASSEMBLY
5	21-804198	CHECK VALVE
6	32-804229	HOSE
7	22-804231	CONNECTOR
8	32-804229	HOSE
9	54-98974M	CLIP
10	32-804237	HOSE
11	32-804236	HOSE
12	32-804236	HOSE
13	54-804239	CLAMP
14	54-8556961	CLAMP
15	10-804602	BOLT, (M6 x 12)
16	22-97083M	TEE FITTING
17	32-804236	HOSE
18	32-804236	HOSE
19	22-804238	CONNECTOR
20	32-804236	HOSE
21	54-814967M	CLIP
22	32-804229	HOSE
23	32-804229	HOSE
24	32-804229	HOSE
25	32-804229	HOSE
26	32-804229	HOSE
27	32-9912688	TUBING, (36.00 Inches Bulk) (Cut to 1.75 Inches)
28	22-875268	TEE FITTING
29	54-816311T	TIE STRAP, (8.00 Inches)
30	32-8M0108349	TUBING, (.312) (70.00 Inches Bulk) (Cut to 22 Inches)
31	32-8752481	TUBE, Carburetor Vent

▶Fuel/Vent Lines(Serial Number 0T409000 & Up) (29 parts)

Ref	OEM Part #	Part Name
1	804230	ROD, Choke
2	54-816311T	TIE STRAP, (8.00 Inches)
3	32-804236	HOSE
4	84-804197	HARNESS ASSEMBLY
5	21-804198	CHECK VALVE
6	32-804229	HOSE
7	22-804231	CONNECTOR
8	32-804229	HOSE
9	54-8M0099240	CLIP
10	32-804237	HOSE
11	32-804236	HOSE
12	32-804236	HOSE
13	54-804239	CLAMP
14	54-8556961	CLAMP
15	10-804602	BOLT, (M6 x 12)
16	22-97083M	TEE FITTING
17	32-804236	HOSE
18	32-885197	HOSE
19	32-885198	PIPE
20	32-804229	HOSE
21	32-804229	HOSE
22	32-804229	HOSE
23	32-804229	HOSE
24	32-804229	HOSE
25	32-9912688	TUBING, (36.00 Inches Bulk) (Cut to 1.75 Inches)
26	22-875268	TEE FITTING
27	54-816311T	TIE STRAP, (8.00 Inches)
28	32-8M0108349	TUBING, (.312) (70.00 Inches Bulk) (Cut to 22 Inches)
29	32-8752481	TUBE, Carburetor Vent

▶Gear Hsg Drive 2.07:1-S/N-0T598999 & Below (43 parts)

Ref	OEM Part #	Part Name
-	47-8M0100526	REPAIR KIT, Water Pump Impeller
1	1667-9011G59	GEAR HOUSING ASSEMBLY, Basic
2	17-8M0084244	PIN, Dowel - With Hole (.375 x .625) (Front)
3	43046	TUBE, Oiler
4	10-79953Q04	SCREW KIT, (.375-16 x .250) Drain
5	12-191833	WASHER
6	17-43044	PIN, Dowel - Without Hole (.375 x .625) (Rear)
7	31640T07	TRIM TAB
8	10-825427	SCREW, (.437-14 x 1.250) Stainless Steel
9	12-451761	WASHER, (.453 x .812 x .105) Black Oxide
10	43040T1	CARRIER ASSEMBLY
11	NSS	NOT SOLD SEPARATE, Needle Bearing
12	97-826134Q	ANODE
13	11-401386	NUT, (M6) Stainless Steel
14	10-4000333	SCREW, (M6 x 40)
15	NSS	NOT SOLD SEPARATE, Pinion Gear (Part of 43-881260A5) Comment: SN# 0T575480 THRU 0T598999
16	11-35921	NUT, (.625-18)
17	850307	CAM, Shift Control
18	31-883047A1	BEARING ASSEMBLY, Tapered Roller Comment: (Use With Pinion stamped 43-881259) SN# 0T575480 THRU 0T598999
19	15-44492A1	SHIM SET
20	45-878575T1	DRIVESHAFT ASSEMBLY Comment: (X-Long)
21	42461A1	SLEEVE/RING KIT
22	NSS	NOT SOLD SEPARATE, Seal Ring
23	43055A4	COVER ASSEMBLY, Water Pump
24	27-430331	GASKET
25	27-8M0214931	GASKET
26	26-43036	SEAL, Oil (Lower)
27	26-43035	SEAL, Oil (Upper)
28	27-8172771	GASKET
29	817275A2	HOUSING KIT, Upper Water Pump
30	8M0204709	FACEPLATE
31	10-82684430	SCREW, (M6 x 30)
32	430232	SEAL
33	28-8M0204723	KEY
34	47-43026T2	IMPELLER
35	10-82684425	SCREW, (M6 x 25)
36	853908A1	SHIFT SHAFT ASSEMBLY Comment: (X-Long)
37	53-29641	E RING
38	23-43052A4	BUSHING ASSEMBLY
39	25-8M0204681	O-RING, (1.424 x .103)
40	26-8M0204708	SEAL, Oil
41	10-82684425	SCREW, (M6 x 25)
42	26-861415	FACE SEAL

▶Gear Hsg Prop 2.07:1-S/N-0T598999 & Below (30 parts)

Ref	OEM Part #	Part Name
-	43-881260A5	GEAR ASSEMBLY, Forward (With Forward Bearing
1	1667-9011G59	GEAR HOUSING ASSEMBLY, Basic
2	31-30894A1	BEARING SET, Cup And Cone
3	NSS	NOT SOLD SEPARATE, Cup
4	43-881260A5	GEAR ASSEMBLY, Pinion/Forward (29 Teeth) Comment: SN# 0T545480 THRU 0T598999
5	31-30895T	BEARING, Needle
6	53-856823	RING, Retaining
7	850315A1	FOLLOWER KIT, Cam
8	30-44530	BALL
9	NSS	NOT SOLD SEPARATE, Slide
10	24-850327	SPRING
11	17-8M0100263	PIN, Cross
12	24-30893	SPRING
13	52-850048T	CLUTCH
14	44-8M0140445	PROPELLER SHAFT
15	43-850036T	GEAR, Reverse - 29 Teeth
16	8M0168901	CARRIER ASSEMBLY, Bearing
17	25-8M0214974	O-RING, (3.609 x .139)
18	31-30956T	BEARING, Needle
19	26-8M0205728	SEAL, Oil (Inner)
20	26-8M0205729	SEAL, Oil (Outer)
21	31-12578T	BEARING, Roller
22	12-12577	THRUST WASHER
23	31-12576	BEARING, Thrust
24	16-8M0034456	STUD, (M8 x 48)
25	12-855941	WASHER, (.323 x .590 x .112) Stainless Steel
26	11-401378	NUT, (M8)
27	15-44491A1	SHIM SET
28	8227731	INSERT, Threaded
29	NSS	NOT SOLD SEPARATE, Decal-Pinion Identification

▶Gear Hsg(Drive-2.33:1)(S/N-0T599000 & Up) (43 parts)

Ref	OEM Part #	Part Name
-	47-8M0100526	REPAIR KIT, Water Pump Impeller
1	1667-9011G59	GEAR HOUSING ASSEMBLY, Basic
2	17-8M0084244	PIN, Dowel - With Hole (.375 x .625) (Front)
3	43046	TUBE, Oiler
4	10-79953Q04	SCREW KIT, (.375-16 x .250) Drain
5	12-191833	WASHER
6	17-43044	PIN, Dowel - Without Hole (.375 x .625) (Rear)
7	31640T07	TRIM TAB
8	10-825427	SCREW, (.437-14 x 1.250) Stainless Steel
9	12-451761	WASHER, (.453 x .812 x .105) Black Oxide
10	43040T1	CARRIER ASSEMBLY
11	NSS	NOT SOLD SEPARATE, Needle Bearing
12	97-826134Q	ANODE
13	11-401386	NUT, (M6) Stainless Steel
14	10-4000333	SCREW, (M6 x 40)
15	NSS	NOT SOLD SEPARATE, Pinion Gear (12 Teeth) Comment: (Part of 43-882813A3)
16	11-35921	NUT, (.625-18)
17	850307	CAM, Shift Control
18	31-883047A1	BEARING ASSEMBLY, Tapered Roller
19	15-44492A1	SHIM SET
20	45-878575T1	DRIVESHAFT ASSEMBLY Comment: (X-Long)
21	42461A1	SLEEVE/RING KIT
22	NSS	NOT SOLD SEPARATE, Seal Ring
23	43055A4	COVER ASSEMBLY, Water Pump
24	27-430331	GASKET
25	27-8M0214931	GASKET
26	26-43036	SEAL, Oil (Lower)
27	26-43035	SEAL, Oil (Upper)
28	27-8172771	GASKET
29	817275A2	HOUSING KIT, Upper Water Pump
30	8M0204709	FACEPLATE
31	10-82684430	SCREW, (M6 x 30)
32	430232	SEAL
33	28-8M0204723	KEY
34	47-43026T2	IMPELLER
35	10-82684425	SCREW, (M6 x 25)
36	853908A1	SHIFT SHAFT ASSEMBLY Comment: (X-Long)
37	53-29641	E RING
38	23-43052A4	BUSHING ASSEMBLY
39	25-8M0204681	O-RING, (1.424 x .103)
40	26-8M0204708	SEAL, Oil
41	10-82684425	SCREW, (M6 x 25)
42	26-861415	FACE SEAL

▶Gear Hsg(Prop-2.33:1)(S/N-0T599000 & Up) (30 parts)

Ref	OEM Part #	Part Name
-	52-803489T1	REPAIR KIT, Clutch/Cam
1	1667-9011G59	GEAR HOUSING ASSEMBLY, Basic
2	31-30894A1	BEARING SET, Cup And Cone
3	NSS	NOT SOLD SEPARATE, Cup
4	43-882813A3	GEAR KIT, Forward And Pinion 28 Teeth
5	31-30895T	BEARING, Needle
6	53-856823	RING, Retaining
7	850315A1	FOLLOWER KIT, Cam
8	30-44530	BALL
9	NSS	NOT SOLD SEPARATE, Slide
10	24-850327	SPRING
11	52-850048T	CLUTCH
12	17-8M0100263	PIN, Cross
13	24-30893	SPRING
14	44-8M0140445	PROPELLER SHAFT
15	43-882814T	GEAR, Reverse - 28 Teeth
16	8M0168901	CARRIER ASSEMBLY, Bearing
17	25-8M0214974	O-RING, (3.609 x .139)
18	31-30956T	BEARING, Needle
19	26-8M0205728	SEAL, Oil (Inner)
20	26-8M0205729	SEAL, Oil (Outer)
21	31-12578T	BEARING, Roller
22	12-12577	THRUST WASHER
23	31-12576	BEARING, Thrust
24	16-8M0034456	STUD, (M8 x 48)
25	12-855941	WASHER, (.323 x .590 x .112) Stainless Steel
26	11-401378	NUT, (M8)
27	15-44491A1	SHIM SET
28	8227731	INSERT, Threaded
29	NSS	NOT SOLD SEPARATE, Decal-Pinion Identification

▶Ignition Components (20 parts)

Ref	OEM Part #	Part Name
NS	NSS	NOT SOLD SEPARATE, CLAMP
1	804278T11	RECTIFIER/REGULATOR Comment: (Design I) SN# 0T408999 & Below
2	804279	COVER
3	10-853536	BOLT, (M6 x 25)
4	10-804604	BOLT, (M6 x 20)
5	804269T2	CDI UNIT Comment: SN# 0T599000 & Up
6	10-804270	BOLT, (M6 x 28)
7	25-881304	GROMMET
8	23-804344003	BUSHING
9	339-804271T	COIL, Ignition
10	10-804603	BOLT, (M6 x 30)
11	54-83577M	CLAMP
12	10-804602	BOLT, (M6 x 12)
13	10-804604	BOLT, (M6 x 20)
14	84-804272A1	CABLE SET, Hi Tension
15	54-804276	CLAMP
16	54-804277	CLAMP
17	804278A12	RECTIFIER/REGULATOR Comment: (Design II)
18	84-8042903	HARNESS ASSEMBLY
19	804278T12	REGULATOR, Voltage

▶Intake (24 parts)

Ref	OEM Part #	Part Name
-	27-804345A02	GASKET SET, Powerhead
1	804164T	SILENCER, Intake
2	10-804167	BOLT, M8 x 60
3	10-804165	BOLT, (M6 x 16)
4	804154	PLATE
5	25-84054M	O-RING
6	25-804166	O-RING
7	10-804155	BOLT, (M6 x 115)
8	804157	INSULATOR
9	26-804156	SEAL
10	804158T	MANIFOLD
11	17-804160	PIN
12	27-804161	GASKET
13	10-804159	BOLT, (M8 x 35)
14	10-84088M	SCREW, (M6 x 10)
15	27-827610	GASKET
16	32-804162	BREATHER PIPE
17	54-816311T	TIE STRAP, (8.00 Inches)
18	54-804163	CLAMP
19	10-804602	BOLT, (M6 x 12)
20	54-804089	CLIP
21	892849	INDUCTION SILENCER
22	881268	BRACKET
23	10-8M0204741	SCREW, (M6 x 20) Stainless Steel

▶Intake/Exhsust Valves (24 parts)

Ref	OEM Part #	Part Name
-	27-804345A02	GASKET SET, Powerhead
1	804128T	VALVE, Intake
2	804129T	VALVE, Exhaust
3	804130	SEAT
4	26-804136	SEAL
5	26-804137	SEAL
6	24-804131	SPRING, Valve
7	804132	RETAINER
8	28-804135	COTTER VALVE
9	804138T	LIFTER, Valve
10	15-80460880	SHIM Comment: (2.975)
11	2407-804139T	CAMSHAFT
12	17-804141	PIN, Dowel
13	2407-8M0057172	CAMSHAFT
14	26-804144001	SEAL, Oil
15	43-804142T	GEAR, Driven
16	10-804143001	BOLT, (M10 x 35)
17	57-804145	V BELT
18	804146	TENSIONER
19	24-804147	SPRING
20	32-804148	HOSE
21	10-804150	BOLT, (M10 x 45)
22	11-881314003	NUT, (M40)
23	43-804151T	GEAR, Drive

▶Key Chart, Ignition Switch (1 parts)

Ref	OEM Part #	Part Name
-	8949112	KEY, Ignition (2F)

▶Oil Pump (20 parts)

Ref	OEM Part #	Part Name
1	25-62705001	O-RING
2	17-41275M	PIN, Dowel
3	881900T03	MOUNT
4	10-898487	BOLT, (M12 x 175)
5	12-32834	WASHER, Neoprene
6	12-8M0204648	WASHER, (1.5 x 3.05 x 0.13) Stainless Steel
7	11-896963	NUT, (M12)
8	10-4010750	SCREW, (M8 x 50)
9	858579T3	PUMP, Oil
10	10-8M0052670	BOLT, (M6 x 45)
11	26-804349	SEAL
12	858793T10	BRACKET, Shift Linkage
13	10-42975	DRIVE SCREW
14	10-82130020	SCREW, (M6 x 20)
15	8591761	RETAINER
16	98889	LATCH
17	87-8M0052927	SWITCH
18	10-88075020	SCREW, (M3 x 20)
19	84-878178A1	HARNESS ASSEMBLY, Shift Interrupt
20	8M0043168	SEAL

▶Power Trim Components (22 parts)

Ref	OEM Part #	Part Name
-	25-893914A02	O-RING KIT (Complete Trim)
1	8M0171821	SHOCK ROD KIT
2	25-8M0171819	O-RING KIT, Rebuild
3	8M0171822	PISTON ASSEMBLY, Memory
4	893916A01	CYLINDER ASSEMBLY
5	893905A02	VALVE KIT, Trim Limit
6	893906A02	PUMP ASSEMBLY
7	893907A02	MOTOR KIT
8	22-8134351	PLUG
9	893929A01	MANUAL RELEASE ASSEMBLY
10	893909A02	MANIFOLD KIT
11	10-809876A1	SCREW KIT (Motor)
12	88238A18	CABLE ASSEMBLY
13	809877A1	DRIVESHAFT/SEAL KIT
14	35-893912A02	FILTER KIT
15	893913A02	POPPET KIT
16	17-821539	PIN, Trilobe
17	17-818898	PIN, Anchor
18	99625002	SHAFT
19	54-22740	CLIP
20	10-878609	SCREW, (#10-16 x .600)
21	8M0084613	C WASHER

▶Sensors (24 parts)

Ref	OEM Part #	Part Name
-	27-804345A02	GASKET SET, Powerhead
1	8042941	PLATE
2	10-811188T	BOLT, (M6 x 16)
3	804295T	THERMOSENSOR
4	804296	RETAINER
5	27-8042971	GASKET Comment: SN# 0T178500 & Up
6	10-811188T	BOLT, (M6 x 16)
7	87-8043071	SWITCH, Oil Pressure Comment: SN# 0T178500 & Up
8	54-804300	CLAMP
9	54-804300	CLAMP
10	54-816311T	TIE STRAP, (8.00 Inches)
11	10-827160M	SCREW, (M5 x 10)
12	804298T	SENSOR, Throttle
13	804301	LEVER
14	10-804306	SCREW, (M5 x 25)
15	12-804305	WASHER
16	804302	BRACKET
17	25-804304	GROMMET
18	23-804303	COLLAR
19	54-816311T	TIE STRAP, (8.00 Inches)
20	84-859295T1	HARNESS ASSEMBLY
21	54-83577M	CLAMP
22	10-84088M	SCREW, (M6 x 10)
23	56762	CLAMP

▶Service/Support Material (1 parts)

Ref	OEM Part #	Part Name
-	37-804656A03	DECAL, EPA Label Information Comment: (2003)

▶Starter Motor (27 parts)

Ref	OEM Part #	Part Name
-	50-8M0065220	STARTER MOTOR ASSEMBLY
1	804320	STOP SET, Pinion
2	804319	PINION
3	804331T	COVER
4	10-804336	BOLT, (M6 x 52)
5	804332	LEVER KIT
6	804333T	RELAY, Starter
7	804334	COVER
8	804321T1	GEAR KIT
9	804322	CLUTCH
10	12-804330	WASHER KIT
11	804324	BRACKET
12	804326	RING GEAR
13	27-804327	GASKET
14	31-804325	BEARING
15	804323	SHAFT, Pinion
16	43-804329001	IDLER GEAR
17	804328	BRACKET
18	804314T	STATOR
19	804313T	ARMATURE
20	804315T1	HOLDER KIT, Brush
21	804316	BRUSH SET
22	24-804317	SPRING
23	804318T	BRACKET
24	10-804337	SCREW, (M4 x 16)
25	10-804335	THRU BOLT, (M6 x 120)
26	10-804605	BOLT, (M8 x 45)

▶Steering Handle Kit (39 parts)

Ref	OEM Part #	Part Name
-	816366A32	STEERING HANDLE KIT Comment: (2004 Model Year and Up)
NS	22-8M0169589	FITTING, Grease
1	12020A3	HANDLE ASSEMBLY, Steering Arm
2	23-42992T02	BUSHING
3	48414	HOUSING
4	48519	PLATE
5	27-48518	GASKET
6	10-878609	SCREW, (#10-16 x .600)
7	10-878608	SCREW, (#10-16 x .500)
8	54-889729	CLAMP
9	10-40007112	SCREW, (M5 x 40)
10	10-32,11-816874	WING NUT,
11	87-823609A15	SWITCH KIT, Stop - Throttle Handle
12	87-8M0104612	SWITCH ASSEMBLY, Stop
13	NSS	NOT SOLD SEPARATE, Insulator
14	12018A4	TUBE ASSEMBLY, Throttle
15	NSS	NOT SOLD SEPARATE, Drive Wheel
16	NSS	NOT SOLD SEPARATE, Roll Pin
17	10-62568	SCREW, (#10-16 x .375)
18	8M0221732	GRIP
19	54-648552	CLIP
20	11-40140	NUT, (M10)
21	8885241	CONDUIT, (9.03 Inches) Comment: (Black Vinyl Coverd)
22	895665	GUIDE TUBE
23	89578	BARREL, Throttle Actuator
24	10-32,10-824081	SET SCREW,
25	12019003	CABLE ASSEMBLY
26	8M0204660	GUIDE, Cable
27	20007	ANCHOR, Cable End
28	8-32,10-8M0204644	SET SCREW,
29	10-823567105	SCREW, (M10 x 105) Hex Flange - Stainless Steel
30	48416	CAP
31	12-4002319	WASHER
32	12-12024	WASHER, (.402 x .787 x .039 Bellevi)
33	23-146011	SPACER
34	54-816311T	TIE STRAP, (8.00 Inches)
35	NSS	NOT SOLD SEPARATE, Decal-Throttle
36	881240	GROMMET, Hose Cable Comment: (Use W/ Stainless Steel Mesh Covered Conduit - Ref. #21)
37	25-889724	GROMMET, Hose Cable Comment: (Use W/ Black Vinyl Coverd Conduit - Ref. #21)

▶Steering Handle Kit Components (50 parts)

Ref	OEM Part #	Part Name
-	816366T10	HANDLE Comment: (2004 Model Year and Up)
1	816366T10	HANDLE, Bracket Comment: (2004 Model Year and Up)
2	10-881261	SCREW, (.313-24 x 3.50)
3	14-42981	TAB WASHER
4	822263	SPACER
5	84-12649A4	HARNESS ASSEMBLY
6	87-88107A5	SWITCH KIT, Key Comment: (For Replacement Key - Order 89491--1 Thru 89491-12)(See Key Chart - Ignition Switch Section)
7	11-879755	NUT, Special - Black Nylon Comment: (Black Nylon)
8	13541	PLUG, Male
9	121051	GROMMET
10	19-889730	PLUG
11	8M0032846	RETAINER, Brass
12	8158041	COVER
13	10-878608	SCREW, (#10-16 x .500)
14	87-11083A4	SWITCH ASSEMBLY, Stop
15	15920Q54	LANYARD ASSEMBLY
16	84-11149A3	CABLE ASSEMBLY
17	889528T01	HORN ASSEMBLY Comment: (Use W/ Black Vinyl Coverd Conduit)
18	87-18286A19	SWITCH KIT, Trim (25.00 Feet) Comment: (Use W/ Black Vinyl Coverd Conduit)
19	87-8M0052927	SWITCH
20	10-12110	SCREW, (#6-32 x .750)
21	54-648551	CLAMP
22	10-878608	SCREW, (#10-16 x .500)
23	10-849838	SCREW, (.375-24 x 1.250)
24	11-8M0204726	NUT, (.375-24) Stainless Steel
25	48419T01	ROD END Comment: (2004 Model Year and Up)
26	495637	ROD, Shift
27	23-26856	BUSHING
28	12-35950	WASHER, (.273 x .437 x .031) Stainless Steel
29	18-25191	COTTER PIN, Cotter
30	8163677	LEVER, Shift, Shift
31	16-8M0034452	STUD, (.375-24 x 1.125)
32	98530	KNOB
33	12016A2	DETENT/SPRING KIT
34	23-8159831	BUSHING
35	12-823970	WASHER
36	12-824610	WASHER, Plastic
37	12-814803	WASHER
38	14-8158051	TAB WASHER
39	10-4000357	SCREW, (M8 x 45)
40	56-52148A08	CO PILOT ASSEMBLY Comment: (Use W/ Black Vinyl Coverd Conduit)
41	52148002	PILOT ROD, (15.00 Inches) Comment: (Use W/ Black Vinyl Coverd Conduit)(15 IN.)
42	11-52155A1	NUT ASSEMBLY
43	10-36137	SCREW, (.250-28 x 1.00)
44	821621	KNOB, Prong
45	873491	ROD, Link
46	23-26841	BUSHING Comment: (Use W/ Black Vinyl Coverd Conduit)(Flanged)
47	12-8M0042642	WASHER, (.323 x .563 x .063) Stainless Steel
48	11-826709111	NUT, (.312-24) Stainless Steel
49	11-64015	NUT, (.250-20)

▶Swivel Bracket and Steering Arm (18 parts)

Ref	OEM Part #	Part Name
1	1400-8M0220957	SWIVEL BRACKET
2	26-87735	SEAL, Oil (Lower)
3	23-818764	BUSHING
4	25-8M0214926	O-RING
5	23-816039	SPACER
6	22-8M0169589	FITTING, Grease
7	23-821207	BUSHING
8	10-64014	SCREW, (.250-28 x .500)
9	99661A35	SWIVEL PIN ASSEMBLY
10	92876A12	LINK ROD ASSEMBLY
11	10-849838	SCREW, (.375-24 x 1.250)
12	11-8M0204726	NUT, (.375-24) Stainless Steel
13	12-37828	WASHER, (.390 x .625 x .062) Stainless Steel
14	42961A06	YOKE ASSEMBLY, Bottom
15	53-67684	RING, Retaining
16	12-816432	THRUST WASHER
17	NSS	NOT SOLD SEPARATE, Decal-Serial Overlaminate
18	11288001	BUMPER, Bottom Yoke Comment: (X-Long)

▶Throttle Lever and Linkage (22 parts)

Ref	OEM Part #	Part Name
1	10-804602	BOLT, (M6 x 12)
2	12-81794M	WASHER
3	13-83457M	WAVE WASHER
4	12-82221M	PLATE
5	23-81949M	BUSHING
6	804340	BRACKET
7	10-8248326	SCREW, (M6 x 25 MM)
8	804338	LEVER, Throttle Control
9	17-82149M	PIN, (18.5 mm)
10	23-804344	COLLAR
11	24-804343	SPRING
12	8043421	CAM
13	12-84974M	WASHER
14	13-81868M	WAVE WASHER
15	12-94524M	WASHER
16	10-826958M	BOLT, (M6 x 35)
17	8587951	BRACKET, Throttle Lever
18	10-85593912	SCREW, (M6 x 12)
19	8587961	LINK, Throttle
20	12-71055	WASHER
21	12-35459	WASHER
22	18-859746	COTTER PIN

▶Tools, Special (60 parts)

Ref	OEM Part #	Part Name
1	91-802653Q02	WRENCH, Oil Filter
2	91-8M0161873	HOLDER TOOL, Flywheel
3	91-83164M	FLYWHEEL PULLER
4	FT2997	COMPRESSOR TOOL, Piston Ring
5	44357Q2	FLUSHING ATTACHMENT
6	90265A5	PUMP ASSEMBLY, Crankcase Oil
7	NSS	NOT SOLD SEPARATE Comment: (Snap-On MT26J) (Snap-On MT26J300)
8	22-86306A01	ADAPTOR
9	22-89772	CONNECTOR, (.125-27)
10	91-79250A2	GAUGE KIT
11	91-36392	GAUGE TOOL, Carburetor
12	91-37241	PULLER PLATE, Universal
13	91-99379	TIMING LIGHT
14	NSS	NOT SOLD SEPARATE, Valve Seat Cutter Kit (Obtain Locally)
15	91-890451	ADAPTOR TOOL, Direct Voltage
16	91-34569A1	PULLER ASSEMBLY, Slide Hammer
17	91-850439T1	TESTER
18	91-854009A3	TACH MULTI METER, DMT 2000 Digital
19	91-804771	HARNESS ASSEMBLY, Pick Up Test
20	91-804772	HARNESS ASSEMBLY, Charge Coil Test
21	91-804773	HARNESS ASSEMBLY, Throttle Position Test
22	91-875216	HOLDER TOOL, Brush
23	91-875215A1	INSTALLER TOOL, Driveshaft Bushing
24	91-804774001	REMOVER/INSTALLER TOOL, Valve Guide
25	91-804775	REAMER TOOL, Valve Guide
26	91-809494A1	COMPRESSOR TOOL, Valve Spring
27	91-24697	EXPANDER TOOL, Piston Ring
28	91-804770A1	HOLDER TOOL, Crankshaft
30	91-74951	SPANNER WRENCH
31	NSS	NOT SOLD SEPARATE, Lock-Ring Pliers (Snap-On SRP-4)
32	NSS	NOT SOLD SEPARATE, Expanding Rod (Snap-On CG 41-11)
33	NSS	NOT SOLD SEPARATE, Collet (Snap-On CG 41-12)
34	91-63209	HEAT LAMP
35	91-12349A05	LOCATION TOOL, Pinion
36	91-13945	INSTALLATION TOOL, Bearing
37	91-13949	DRIVER TOOL, Oil Seal
38	91-14308T02	TOOL KIT, Bearing Race
39	91-14309T02	INSTALLATION TOOL, Bearing
40	91-14310T1	WEAR SLEEVE INSTALLATION TOOL
41	91-14311A04	PRE LOAD TOOL, Bearing
42	91-15755T	MANDREL
43	91-196601	INDICATOR TOOL, Backlash
44	91-31106T	MANDREL, Bearing Driver Cup
45	91-31108T	DRIVER, Oil Seal
46	91-36569T	DRIVE HEAD TOOL
47	91-804776A1	HOLDING TOOL, Driveshaft
48	91-31229	SHAFT
49	91-34569A1	PULLER ASSEMBLY, Slide Hammer
50	91-37323	DRIVER ROD TOOL, Needle Bearings
51	91-37241	PULLER PLATE, Universal
52	91-37350T	MANDREL
53	91-46086A1	PULLER JAW ASSEMBLY
54	91-58222A1	DIAL INDICATOR TOOL
55	91-8M0053505	INDICATOR TOOL, Backlash
56	91-85716	PULLER BOLT TOOL, Bearing Carrier
57	91-83155	ADAPTER KIT, Dial Indicator
58	91-83165T	PULLER ASSEMBLY
59	91-856875A1	INSTALLATION TOOL, Bearing
60	91-877321A1	INSTALLATION TOOL, Bearing
62	91-880177	SCRENCH TOOL, (10 mm)

▶Top Cowl (26 parts)

Ref	OEM Part #	Part Name
1	4021-827328T10	TOP COWL ASSEMBLY Comment: (SILVER)
2	821256T2	INLET, Air - Silver Comment: (SILVER)
3	10-82130016	SCREW, (M6 x 16)
4	859356A02	SOUND BLANKET KIT
5	NSS	NOT SOLD SEPARATE, Sound Blanket-Port
6	NSS	NOT SOLD SEPARATE, Sound Blanket-Starboard
7	NSS	NOT SOLD SEPARATE, Sound Blanket-Back
8	19-823865	CAP PLUG
9	831207A16	HANDLE
10	23-812707	BUSHING
11	23-831214	SPACER
12	13-12134	WASHER, Wave
13	8M0001081	CAM, Latch Shaft
14	12-8M0214930	WASHER
15	10-1993716	SCREW, (M6 x 16)
16	8M0036792	BRACKET, Front
17	815477	BUMPER, Latch
18	12-8M0204649	WASHER, (.281 x .500 x .060) Stainless Steel
19	11-401366	NUT, (M6) Stainless Steel
20	53-8237951	RING, Retaining
21	8M0207770	ROLLER
22	8155381	PIN, Roll
23	12-8M0204649	WASHER, (.281 x .500 x .060) Stainless Steel
24	11-401366	NUT, (M6) Stainless Steel
25	47341A11	ROPE AND HANDLE KIT, Manual Starting
26	50-12066Q10	ROPE

▶Transom Bracket (26 parts)

Ref	OEM Part #	Part Name
1	3426-828334T02	BRACKET, Transom (Starboard)
2	3425-828333T07	BRACKET ASSEMBLY, Transom (Port)
3	22-8M0169588	FITTING, Grease (Port)
4	826125A1	TILT TUBE Comment: (Saltwater)
5	11-826135	NUT, (1.00-14) Nylon Insert Comment: (Saltwater)
6	25-45711	O-RING, (.612 x .103)
7	13-88750	WASHER
8	11-826164	NUT, (.875-14) Comment: (Saltwater)
9	10-8M0149747	SCREW, (.500-20 x 4.500)
10	12-8M0204665	WASHER, (.530 x .870 x .105) Stainless Steel
11	12-8M0204648	WASHER, (1.5 x 3.05 x 0.13) Stainless Steel
12	11-82671117	NUT, (.500-20)
13	24-830899	SPRING, Tension
14	8M0109798	LEVER ASSEMBLY, Tilt Lock
15	23-65830	NYLINER
16	24-830900	SPRING, Compression
17	99633	KNOB
18	17-99615	PIN, Groove
19	17-893709	PIN
20	8M0086406	BRACKET, Anchor
21	10-858771	SCREW, (M10 x 30)
22	12-4002319	WASHER
23	11-40114	NUT, (M10 x 1.5)
24	97-818298Q1	ANODE KIT
25	10-8M0204707	SCREW, (M6 x 25)
26	12-8M0204649	WASHER, (.281 x .500 x .060) Stainless Steel

100-Hour / Annual Service Checklist

Regular maintenance keeps your Mercury 90 (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.

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Mercury 90 (4-STROKE) (0G960500 THRU 0T800999) Parts & Diagrams

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