– JLM Marine Boat Parts Limited

Mercury 25 (2 CYL.) (7166928 THRU 7207857) Parts & Diagrams

🔎 Mercury 25 (2 CYL.) Reference Library — Exploded parts diagrams (18 diagrams), specifications, common issues, and maintenance checklist.

The Mercury 25 (2 CYL.) is a 4-Stroke, Inline 3-Cylinder, EFI outboard motor. Commonly used on jon boats, pontoons, and mid-size utility craft.

Quick Reference Specifications

Specification	Value
Engine Type	4-Stroke, Inline 3-Cylinder, EFI
Horsepower	25 HP
Displacement	526 cc
Bore x Stroke	61 mm x 57 mm
Spark Plug (Type & Gap)	NGK BKR6E
Engine Oil Capacity	1.8 L (1.9 quart)
Recommended Engine Oil	SAE 25W-40 Synthetic Blend Mercury FC-W
Gear Case Oil Capacity	280-350 mL (9.5-12 fl oz)
Idle Speed (in gear)	700 ± 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 25 (2 CYL.):

Water Pump / Overheating: If the tell-tale stream is weak or absent, the water pump impeller likely needs replacement. Inspect annually or every 100 hours. → Recommended: Water Pump Impeller Kit
Engine Oil / Maintenance Light: 4-stroke engines require regular oil and filter changes. Use marine-grade oil rated for your engine. Change every 100 hours or annually. → Recommended: Oil Filter, Engine Oil
Fuel Injector Issues (EFI models): Rough idle or misfires may indicate clogged fuel injectors. Use fuel stabilizer and clean injectors periodically. → Recommended: Fuel Injector, Fuel Filter
Gear Case Oil Leak: Check lower unit seals if gear oil appears milky (water contamination). Replace seals and gaskets during lower unit service. → Recommended: Lower Unit Seal Kit, Drain Plug Gaskets
Anode Corrosion: Inspect sacrificial anodes regularly, especially in saltwater. Replace when 50% depleted to protect against galvanic corrosion. → Recommended: Zinc/Aluminum Anode Kit

Parts Diagrams & OEM Part Numbers

Expand the sections below to view detailed exploded parts diagrams and find the exact OEM replacement components for your Mercury 25 (2 CYL.).

▶CARBURETOR ASSEMBLY (41 parts)

Ref	OEM Part #	Part Name
-	27-85168A80	GASKET SET
1	1390-8677A5	CARBURETOR ASSEMBLY Comment: TILLOTSON #BC1C
2	1399-8138	VALVE, Enrichment
3	1399-1713	SCREW, IDLE
4	NSS	NOT SOLD SEPARATE, Spring-Idle Screw
5	NSS	NOT SOLD SEPARATE, Gasket-Metering Cover
6	1399-8145	COVER, METERING
7	1399-8146	SCREW, METERING COVER
8	1399-8152	SHUTTER, Throttle
9	NSS	NOT SOLD SEPARATE, Screw-Throtttle Shutter
10	1399-8151	SHAFT, Throttle
11	NSS	NOT SOLD SEPARATE, Spring-Return-Throttle Shaft
12	NSS	NOT SOLD SEPARATE, E-Ring-Throttle Shaft
13	NSS	NOT SOLD SEPARATE, Gasket-Fuel Bowl
14	1399-8655	FLOAT Comment: (BC1C)
15	NSS	NOT SOLD SEPARATE, Float Pin
16	1399-8143	NEEDLE AND SEAT, Inlet
17	1399-8656	BOWL, Fuel Comment: (BC1C)
18	1399-8141	SCREW, FUEL BOWL
19	16608070	JET, Main (.070)
20	NSS	NOT SOLD SEPARATE, Gasket-Main Jet
21	NSS	NOT SOLD SEPARATE, Gasket-Fuel Pump Diaphragm
22	NSS	NOT SOLD SEPARATE, Diaphragm-Fuel Pump
23	1399-8142	BODY, FUEL PUMP
24	NSS	NOT SOLD SEPARATE, Gasket-Fuel Pump Diaphragm
25	NSS	NOT SOLD SEPARATE, Diaphragm-Fuel Pump
26	1399-8147	BODY, STRAINER
27	1399-8148	SCREW, STRAINER BODY
28	NSS	NOT SOLD SEPARATE, Screen-Strainer
29	NSS	NOT SOLD SEPARATE, Gasket-Strainer Cover
30	99941	COVER, STRAINER
31	1399-8150	SCREW, STRAINER COVER
32	1395-5733	JET, Main (.092), BACK-DRAG Comment: BC1C
33	27-88004	GASKET, Carburetor
34	98183A1	KNOB ASSEMBLY, Choke
35	89762	ROD, Choke
36	54-89668	CLIP, CHOKE ROD
37	94301A1	PLATE ASSEMBLY, CHOKE KNOB Comment: ELECTRIC
38	92333	LINK, CHOKE DETENT
39	10-400018	SCREW, (M5 x 12), LINK AND PLATE TO CARBURETOR
40	96046	PLATE, CARBURETOR Comment: (ITALY ENGINES ONLY)

▶CLAMP BRACKET ASSEMBLY (28 parts)

Ref	OEM Part #	Part Name
1	1497-8863A1	CLAMP BRACKET ASSEMBLY
2	10-92767A1	THUMB SCREW ASSEMBLY, (14 mm)
3	12-73719	WASHER, THUMB SCREW
4	10-768042	SCREW, WASHER ATTACHING
5	85155	HANDLE, CARRYING
6	17-99929A1	PIN ASSEMBLY, Tilt Comment: USED WITH REF. #7
7	90884	CLIP, Spring, TILT PIN
8	16-85099	STUD, CLAMP BRACKET
9	23-85100	SPACER, CLAMP BRACKET STUD
10	11-400213	NUT, (M8) Stainless Steel, CLAMP BRACKET STUD
11	85151	TILT TUBE
12	54-8M0085928	CLIP, SAFETY
13	11-93164	NUT, (.875), TILT TUBE
14	53078	CAP, TILT TUBE
15	10-69064	BOLT, (.312-18 x 2.750), CLAMP BRACKET TO TRANSOM
16	12-67981	WASHER, CLAMP BRACKET BOLT
17	11-82670910	NUT, (.312-18), CLAMP BRACKET BOLT
18	96965	LEVER, TILT STOP - PORT SIDE
19	10-41433	SCREW, (.250-28 x 1.00), LEVER TO SWIVEL BRACKET
20	11-826709109	NUT, (.250-28), TILT STOP LEVER SCREW
21	10-41524	SCREW, (.250-28 x 1.75), LEVER TO CLAMP BRACKET
22	24-44581	SPRING, TILT STOP LEVER SCREW
23	13-31030	WAVE WASHER, TILT STOP LEVER SCREW
24	90901	STRAP, TILT STOP - STARBOARD SIDE
25	10-41433	SCREW, (.250-28 x 1.00), LEVER TO SWIVEL BRACKET
26	11-826709109	NUT, (.250-28), TILT STOP LEVER SCREW
27	10-41524	SCREW, (.250-28 x 1.75), LEVER TO CLAMP BRACKET
28	13-31030	WAVE WASHER, TILT STOP LEVER SCREW

▶COWLS (25 parts)

Ref	OEM Part #	Part Name
1	2190-9163A22	TOP COWL ASSEMBLY
2	89584	HINGE, COWL LATCH
3	10-22028	SCREW, (#10-32 x .50), HINGE TO TOP COWL
4	10-32,11-27164	NUT AND LOCKWASHER, , HINGE PIN
5	91059	BLANKET, TOP COWL Comment: NOT USED ON LATER ENGINES
6	91061	BLANKET, TOP COWL Comment: NOT USED ON LATER ENGINES
7	91060	BLANKET, TOP COWL Comment: NOT USED ON LATER ENGINES
8	2176-8301A3	BOTTOM COWL ASSEMBLY, PORT
9	25-93770	GROMMET, FUEL ADAPTOR (2-1/16" LONG)
10	17-89010	PIN, Roll, BOTTOM COWL
11	42274	SEAL, BOTTOM COWL
12	89009	LATCH, BOTTOM COWL
13	10-8M0204707	SCREW, (M6 x 25), LATCH TO BOTTOM COWL
14	11-401366	NUT, (M6), LATCH SCREW
15	2176-8306A1	BOTTOM COWL ASSEMBLY, STARBOARD
16	25-93527002	GROMMET, BOTTOM COWL Comment: (1-1/8" X 2-1/8" OPENING)
17	25-89696	GROMMET, CHOKE KNOB
18	15865	PLATE, BOTTOM COWL
19	10-95700	SCREW, PLATE TO BOTTOM COWL (1/2")
20	43554A5	BRACKET, COWL LATCH
21	10-400018	SCREW, (M5 x 12), BRACKET TO BOTTOM COWL
22	17-25870	PIN, Roll, LINK
23	43554A5	LINK, COWL LATCH
24	43554A5	LATCH, COWL - REAR
25	12-8M0204649	WASHER, (.281 x .500 x .060) Stainless Steel, LATCH SCREW

▶CRANKSHAFT, PISTONS AND FLYWHEEL (22 parts)

Ref	OEM Part #	Part Name
-	879732T89	POWERHEAD ASSEMBLY
1	258-859232T15	FLYWHEEL ASSEMBLY
2	10-97359A1	SCREW ASSEMBLY, FLYWHEEL TO CRANKSHAFT
3	12-86496	WASHER, FLYWHEEL SCREW
4	43-99301	RING GEAR, FLYWHEEL Comment: ELECTRIC SN# USA-6055408/BEL-9340566/CAN-7186768 & Up
5	10-88190313	SCREW, (M5 x 13), RING GEAR TO FLYWHEEL Comment: ELECTRIC
6	464-8978T2	CRANKSHAFT ASSEMBLY
7	85981	SEAL, Crankshaft
8	26-85107	SEAL, Oil, CRANKSHAFT -LOWER
9	31-85113T	BEARING, Roller, CRANKSHAFT - LOWER
10	31-85114T	BEARING, Roller - Upper, CRANKSHAFT
11	26-859741	SEAL, Oil, CRANKSHAFT - UPPER
12	86992A5	BEARING ASSEMBLY, CENTER MAIN
13	28-20094	KEY, Woodruff, FLYWHEEL DRIVE
14	767-9104A3	PISTON ASSEMBLY
15	40-828119	LOCK RING, PISTON PIN
16	39-8M0083677	RING SET, Piston
17	630-8835A4	CONNECTING ROD ASSEMBLY Comment: SN# USA-6241937/BEL-9369471/CAN-7201893 & Up
18	29-98295	BEARING, Needle, PISTON END Comment: SN# USA-6241937/BEL-9369471/CAN-7201893 & Up
19	12-8M0012294	WASHER, LOCATING - NEEDLE BEARING Comment: SN# USA-6241937/BEL-9369471/CAN-7201893 & Up
20	31-879877A1	BEARING ASSEMBLY, Roller Comment: SN# USA-6241937/BEL-9369471/CAN-7201893 & Up
21	10-4008225	SCREW, (M6 x 25), CONNECTING ROD Comment: SN# USA-6241937/BEL-9369471/CAN-7201893 & Up

▶CYLINDER BLOCK AND COVER (47 parts)

Ref	OEM Part #	Part Name
-	27-85168A80	GASKET SET
1	872-9533T38	CYLINDER BLOCK ASSEMBLY Comment: SN# USA-6055408/BEL-9340566/CAN-7186768 & Up
2	17-85171	PIN, Dowel, CYLINDER BLOCK
3	22-15133	ELBOW, BLEED HOSE (45 Degree)
4	32-892024122	HOSE, BLEED (12-1/4")
5	16-429173	STUD, CARBURETOR
6	10-40001209	SCREW, (M10 x 60)
7	27-892158	GASKET, EXHAUST MANIFOLD
8	92329	MANIFOLD, Exhaust
9	27-414991	GASKET, EXHAUST COVER
10	92330T	COVER, EXHAUST
11	10-4000333	SCREW, (M6 x 40)
12	144071	COVER, TRANSFER PORT
13	25-822370	O-RING, TRANSFER PORT COVER
14	10-40057107	SCREW, (M5 x 16)
15	1028-8283A1	COVER ASEMBLY, CYLINDER BLOCK Comment: USE WITH 30MM SCREWS
16	10-8M0204707	SCREW, (M6 x 25), COVER ATTACHING
17	27-86389	GASKET, CYLINDER BLOCK COVER
18	22-996642	ELBOW, TELL TALE HOSE
19	32-8M0108355	HOSE, TELL TALE (8")
20	22-94848	FITTING, TELL TALE HOSE - BOTTOM COWL
21	14406	COVER, TRANSFER PORT
22	25-86391	O-RING, TRANSFER PORT COVER
23	10-40057107	SCREW, (M5 x 16)
24	92350	COVER, TRANSFER PORT
25	25-8M0214925	O-RING, TRANSFER PORT COVER
26	10-40057107	SCREW, (M5 x 16), COVER TO CYLINDER BLOCK (16MM)
27	14112T	REED BLOCK
28	85977002	SEAL, Rubber, REED BLOCK - RUBBER
29	27-414172	GASKET, REED BLOCK
30	34-816806	REED
31	34-897931	STOP, Reed
32	10-4005785	SCREW, (M4 x 10)
33	27-414181	GASKET, ADAPTOR PLATE
34	90785	PLATE, ADAPTOR - CARBURETOR
35	10-40019108	SCREW, (M5 x 20), PLATE TO REED BLOCK
36	11-400213	NUT, (M8) Stainless Steel, CARBURETOR STUD
37	22-56759	FITTING, Barbed, ADAPTOR PLATE - BLEED HOSE
38	93879	IDLE WIRE
39	24-97176	SPRING, CHOKE
40	42545	LEVER, CHOKE/FAST IDLE
41	10-91073	SCREW, LEVER Comment: BC1B/BC1C CARBURETOR
42	48039	CAP, ADJUSTING SCREW Comment: BC1A CARBURETOR
43	43220A1	PLATE ASSEMBLY, DRIVER Comment: BC1B/BC1C CARBURETOR
44	23-26856	BUSHING, CHOKE/FAST IDLE LEVER
45	12-28463	WASHER, CHOKE/FAST IDLE LEVER
46	18-93500	COTTER PIN, CHOKE/FAST IDLE LEVER

▶DRIVESHAFT HOUSING ASSEMBLY (16 parts)

Ref	OEM Part #	Part Name
-	27-85168A80	GASKET SET
1	99702A7	ADAPTOR PLATE ASSEMBLY
2	96248A1	HOUSING ASSEMBLY, WATER TUBE Comment: NOT USED WITH REF. #3
3	25-36390	O-RING, WATER TUBE HOUSING
4	85164	SEAL, WATER TUBE Comment: USED WITH REF. #3
5	26-25329	SEAL, WATER TUBE Comment: NOT USED WITH REF. #3
6	23-889715	SPACER, WATER TUBE Comment: NOT USED WITH REF. #3
7	10-400035	SCREW, (M5 x 16), HOUSING TO ADAPTOR PLATE
8	27-41670006	GASKET, ADAPTOR PLATE
9	158662	SEAL, Adaptor Plate
10	1591-8749A1	HOUSING ASSEMBLY Comment: LONG SHAFT SN# USA-6055408/BEL-9340566/CAN-7186768 & Up
11	27-433374	GASKET, DRIVESHAFT HOUSING Comment: SN# USA-6055408/BEL-9340566/CAN-7186768 & Up
12	10-400035	SCREW, (M5 x 16)
13	10-1993870	SCREW (60MM)
14	12-4002317	WASHER, DRIVESHAFT HOUSING SCREW
15	32-86292	TUBE, Water Comment: LONG SHAFT

▶ELECTRIC COMPONENTS(ELECTRIC) (32 parts)

Ref	OEM Part #	Part Name
1	8M0058226	RECTIFIER ASSEMBLY
2	10-48409	SCREW, (#10-16 x .625) Stainless Steel, RECTIFIER TO CYLINDER BLOCK
3	10-32,11-45076	NUT, Brass, RECTIFIER TERMINALS
4	89-8M0185149	SOLENOID, Starter
5	10-4000327	SCREW, (M6 x 14)
6	8-32,11-26419	NUT, Brass, STARTER SOLENOID TERMINAL (10-32)
7	11-64015	NUT, (.250-20), STARTER SOLENOID TERMINAL (1/4-20)
8	84-88809A5	WIRE ASSEMBLY, YELLOW
9	84-88439A28	CABLE ASSEMBLY, Battery, BLACK
10	84-92436A5	HARNESS ASSEMBLY, ENGINE
11	88-95085	FUSE
12	92439	BRACKET, WIRING HARNESS
13	10-4000327	SCREW, (M6 x 14), BRACKET
14	11-400212	NUT, (M6) Stainless Steel, BRACKET SCREW
15	54-815504310	CLAMP, WIRING HARNESS
16	54-8M0024808	J CLIP, WIRING HARNESS
17	86704A10	STATOR ASSEMBLY, AUXILIARY
18	10-4000123	SCREW, (M5 x 30), STATOR ATTACHING
19	94301A1	PLATE ASSEMBLY, CHOKE KNOB
20	10-95088	SCREW, PLATE TO SOLENOID
21	95020	LEVER, CHOKE
22	53-95019	RING, Retaining, CHOKE LEVER TO PLATE
23	89-94973A3	SOLENOID ASSEMBLY
24	18-210711	COTTER PIN, CHOKE LEVER TO SOLENOID
25	50-8M0033984	STARTER MOTOR ASSEMBLY
26	96561	DRIVE KIT
27	96562	DRIVE
28	96563T	END CAP
29	96565	ARMATURE
30	96564T	END CAP, COMMUTATOR W/SPRINGS AND BRUSHES
31	10-96566	THRU BOLT
32	10-4000358	SCREW, (M8 x 50), STARTER MOTOR ATTACHING

▶ELECTRICAL COMPONENTS(BELGIUM ENGINES) (8 parts)

Ref	OEM Part #	Part Name
1	95845T	REGULATOR, Voltage
2	10-74841	SCREW
3	10-32,11-45076	NUT, Brass, VOLTAGE REGULATOR TERMINAL
4	84-74725A2	HARNESS ASSEMBLY, VOLTAGE REGULATOR (BLACK/RED)
5	71663	PLUG, HARNESS
6	84-65017A2	HARNESS ASSEMBLY, LIGHTING (EXTERNAL)
7	86704A10	STATOR ASSEMBLY
8	10-4000123	SCREW, (M5 x 30), STATOR ATTACHING

▶FUEL FILTER ASSEMBLY (15 parts)

Ref	OEM Part #	Part Name
1	35-889527A07	FILTER ASSEMBLY, Fuel
2	35-87946Q04	FILTER ASSEMBLY
3	25-897536	SEAL, FUEL FILTER
4	858731	BALL, FUEL FILTER
5	32-8M0108355	LINE, Fuel, FILTER TO CARBURETOR (5-1/4")
6	32-8M0108355	LINE, Fuel, FILTER TO ADAPTOR (8-1/2")
7	54-68424	CLAMP, FUEL LINE
8	22-98750	FITTING, FUEL LINE
9	30188	WASHER, ADAPTOR
10	24-23067T	SPRING, ADAPTOR STEM
11	25-16524	O-RING, ADAPTOR STEM
12	23069	STEM, ADAPTOR
13	22833	ADAPTOR, CHECK UNIT
14	10-4000332	SCREW, (M6 x 35), ADAPTOR TO BOTTOM COWL
15	11-400212	NUT, (M6) Stainless Steel, ADAPTOR SCREW

▶GEAR HOUSING(DRIVESHAFT) (40 parts)

Ref	OEM Part #	Part Name
-	26-85090A1	SEAL KIT, Water Pump
1	1653-8157A6	GEAR HOUSING ASSEMBLY, BASIC
2	35-98487	SCREEN, WATER INLET Comment: PORT
3	10-40031112	SCREW, (M5 x 40), SCREEN TO GEAR HOUSING
4	11-400263	NUT, (M5), SCREEN SCREW
5	31-85559	BEARING, Roller, LOWER (SEE NOTE)
6	23-85092	SLEEVE, UPPER ROLLING BEARING
7	31-85558	BEARING, Roller, UPPER
8	26-897154	SEAL, Oil, GEAR HOUSING
9	45-98085	DRIVESHAFT Comment: LONG SHAFT
10	98861A1	WASHER, THRUST - DRIVESHAFT - SEE NOTE Comment: (.234 THICK)
11	31-85560	BEARING, Thrust, DRIVESHAFT (SEE NOTE)
12	43-85132	GEAR, Pinion
13	22-8M0058389	SCREW, Magnetic, DRAIN
14	12-191833	WASHER, DRAIN AND FILLER SCREW
15	10-79953Q04	SCREW, (.375-16 x .250), GREASE FILLER
16	85562A1	CAM ASSEMBLY, SHIFT
17	17-85096	PIN, Drive, SHIFT CAM
18	17-85593	PIN, (.078 x .437), SHIFT SHAFT
19	12-8M0204649	WASHER, (.281 x .500 x .060) Stainless Steel, SHIFT SHAFT
20	24-93007	SPRING, SHIFT SHAFT
21	12-85091	WASHER, SHIFT SHAFT
22	25-85594	O-RING, (.239 x .174), SHIFT SHAFT
23	25-35276	O-RING, SHIFT SHAFT RETAINER
24	93878	RETAINER, SHIFT SHAFT
25	85552001	BOOT, SHIFT SHAFT
26	86293	SHIFT SHAFT Comment: LONG SHAFT
27	12-8M0204649	WASHER, (.281 x .500 x .060) Stainless Steel, SHIFT SHAFT - UPPER
28	27-993261	GASKET, WATER PUMP
29	85083	FACE PLATE
30	12-8M0204722	WASHER, IMPELLER
31	28-8M0214993	KEY, IMPELLER DRIVE
32	47-8M0204712	IMPELLER
33	25-69202	O-RING, WATER PUMP
34	46-99157T2	REPAIR KIT, Water Pump
35	10-400035	SCREW, (M5 x 16), WATER PUMP TO GEAR HOUSING
36	12-89302	WASHER, (.203 x .406 x .040), WATER PUMP SCREW
37	23-8M0214959	BUSHING, WATER PUMP SCREW
38	26-85090001	SEAL, WATER TUBE
39	25-86203	O-RING, DRIVE SHAFT - RUBBER

▶GEAR HOUSING(PROPELLER SHAFT) (26 parts)

Ref	OEM Part #	Part Name
-	26-85090A1	SEAL KIT, Water Pump
1	1653-8157A6	GEAR HOUSING ASSEMBLY, BASIC
40	94286T1	TRIM TAB
41	10-4000352	SCREW, (M8 x 20), TRIM TAB
42	14-85169	TAB WASHER, TRIM TAB SCREW
43	31-85555A1	BEARING ASSEMBLY, Roller, TAPERED
44	43-85135A2	GEAR ASSEMBLY, Forward
45	23-85557	BUSHING, FORWARD GEAR
46	85094	FOLLOWER, Cam
47	24-38114	SPRING, RETAINING - CROSS PIN
48	52-85133	CLUTCH, SLIDING
49	17-8M0020999	PIN, CLUTCH TO PROPELLER SHAFT
50	24-88680	SPRING, COMPRESSION - PROPELLER SHAFT
51	44-8166231	PROPELLER SHAFT
52	43-99542A1	GEAR, Reverse
53	99906T1	CARRIER ASSEMBLY, Bearing
54	31-21739	BEARING, Roller
55	26-98283	SEAL, Oil, BEARING CARRIER
56	25-85549	O-RING, BEARING CARRIER
57	87293	PLATE, GEAR HOUSING
58	10-90883	SCREW, COVER TO GEAR HOUSING (16MM)
59	858498	THRUST HUB ASSEMBLY, PROPELLER
60	48-19640A40	PROPELLER ASSEMBLY
61	11-88228	PROP NUT
62	10-4000353	SCREW, (M8 x 25), GEAR HOUSING
63	12-4002317	WASHER, GEAR HOUSING SCREW

▶IGNITION COMPONENTS (23 parts)

Ref	OEM Part #	Part Name
1	84-88891A1	HARNESS ASSEMBLY, PRIMARY
2	86617A20	STATOR ASSEMBLY
3	10-400015	SCREW, (M5 x 10), STATOR ATTACHING Comment: MANUAL
4	54-24836	CLIP, STATOR LEADS
5	10-40019108	SCREW, (M5 x 20), CLIP TO SWITCH BOX
6	12-89302	WASHER, CLIP SCREW
7	98450A10	TRIGGER ASSEMBLY Comment: SN# USA-6055408/BEL-9340565/CAN-7186768 & Up
8	54-24836	CLIP, TRIGGER LEADS
9	10-77137	SCREW, (.190-16 x .620), CLIP TO CRANKCASE
10	8M0084613	C WASHER, CLIP SCREW
11	339-832757A4	COIL ASSEMBLY, Ignition
12	10-4000189	SCREW, (M6 x 45), COIL TO CYLINDER BLOCK
13	88173	TAB WASHER, COIL SCREW
14	23-88171	BUSHING, COIL SCREW
15	10-32,11-45076	NUT, Brass, COIL TERMINAL
16	84-813715A1	WIRE ASSEMBLY, HIGH TENSION
17	85-92308	BOOT, COIL
18	85-63709A1	BOOT/TERMINAL KIT, SPARK PLUG
19	33-896329828	SPARK PLUG, CHAMPION #QL-77J4 Comment: CANADA AND BELGIUM
20	339-7452A3	SWITCHBOX ASSEMBLY
21	10,13-69432	LOCKWASHER, External , GROUND
22	10-40019108	SCREW, (M5 x 20), SWITCH BOX TO CYLINDER BLOCK
23	10-32,11-45076	NUT, Brass, SWITCH BOX TERMINALS

▶MISCELLANEOUS PARTS/ACCESSORIES (1 parts)

Ref	OEM Part #	Part Name
-	37-90535A80	DECAL SET

▶STARTER ASSEMBLY, MANUAL (24 parts)

Ref	OEM Part #	Part Name
1	86689A5	HOUSING, STARTER
2	86971	COVER, STARTER HOUSING
3	858925	LEVER, LOCK (UPPER)
4	24-12734	SPRING, UPPER LOCK LEVER
5	93876T02	LEVER, LOCK (LOWER)
6	10-61802	SCREW, LOWER LOCK LEVER
7	17-38489	PIN, Roll, LOCK LEVER
8	10-4000183	SCREW, (M6 x 35), STARTER HOUSING ATTACHING
9	833161T	PAD, FELT
10	24-86857T01	SPRING, STARTER
11	50-825269T01	SHEAVE, STARTER
12	24-86851T02	SPRING, CAM
13	868501	CAM
14	53-86849T01	RING, Retaining, CAM
15	50-12066Q10	ROPE, STARTER
16	85174A1	HANDLE ASSEMBLY, STARTER ROPE
17	24-868523	SPRING, CAM
18	86853T01	CAM
19	10-826253	SCREW, CAM TO STARTER SHEAVE
20	426264	SUPPORT, STARTER HANDLE
21	10-40019111	SCREW, SUPPORT TO STARTER HOUSING (35MM)
22	12-4002313	WASHER, SUPPORT SCREW
23	23-309772	SPACER, SUPPORT SCREW
24	11-401385	NUT, (M5), SUPPORT SCREW

▶STEERING HANDLE ASSEMBLY(MANUAL) (18 parts)

Ref	OEM Part #	Part Name
-	94185A16	HANDLE ASSEMBLY, Steering
1	8M0221732	GRIP, RUBBER
2	84-89591A5	HARNESS ASSEMBLY, STOP SWITCH
3	11099A1	BOOT ASSEMBLY, STOP SWITCH
4	87-823609A10	HANDLE ASSEMBLY, THROTTLE
5	37-13239	DECAL, THROTTLE HANDLE
6	10-62568	SCREW, (#10-16 x .375), THROTTLE HANDLE
7	99333A2	TUBE ASSEMBLY, STEERING
8	975501	TUBE ASSEMBLY Comment: SN# USA-6055408/BEL-9340566/CAN-7186768 & Up
9	44397A6	BRACKEY ASSEMBLY
10	10-4005688	SCREW, (M4 x 20), BRACKET CLAMPING
11	12-57860	WASHER, NYLON - BRACKET
12	11-859133	NUT, BRACKET
13	23-85973	BUSHING, BRACKET
14	43242	CABLE, THROTTLE
15	11-400212	NUT, (M6) Stainless Steel, THROTTLE CABLE
16	43447A3	BRACKET ASSEMBLY, STEERING
17	10-4000384	SCREW, (M10 x 80), BRACKET TO SWIVEL TUBE

▶SWIVEL BRACKET ASSEMBLY (27 parts)

Ref	OEM Part #	Part Name
-	27-85168A80	GASKET SET
1	97544A5	SWIVEL TUBE ASSEMBLY
2	10-125161	SCREW, UPPER MOUNT (133MM)
3	14894	MOUNT, UPPER
4	12-85172	WASHER, RUBBER - UPPER MOUNT SCREW
5	12-85106	WASHER, UPPER MOUNT SCREW
6	11-400213	NUT, (M8) Stainless Steel, UPPER MOUNT SCREW
7	85157	ROD, REVERSE HOOK
8	85173	PLATE, PILOT CONTROL
9	12-85104	WASHER
10	3415-822237A1	SWIVEL BRACKET ASSEMBLY
11	22-8M0169589	FITTING, Grease
12	23-95949	BUSHING, SWIVEL BRACKET
13	10-91807	SCREW, PILOT CONTROL
14	24-96203	SPRING, PILOT CONTROL SCREW
15	25-86993	O-RING, SWIVEL TUBE
16	23-85154	BUSHING, SWIVEL TUBE (LOWER)
17	98830A2	HOOK ASSEMBLY, REVERSE LOCK
18	24-96018	SPRING, REVERSE HOOK - PORT
19	24-97427	SPRING, REVERSE HOOK - STARBOARD
20	85122001	MOUNT, LOWER
21	85123001	BUMPER, Front
22	95068A1	COVER, LOWER MOUNT Comment: SN# USA-6055408/BEL-9340566/CAN-7186768 & Up
23	10-1994360	SCREW, LOWER MOUNT COVER (60MM) Comment: SN# USA-6055408/BEL-9340566/CAN-7186768 & Up
24	10-19943100	SCREW, LOWER MOUNT COVER (100MM) Comment: SN# USA-6055408/BEL-9340566/CAN-7186768 & Up
25	11-400213	NUT, (M8) Stainless Steel, LOWER MOUNT COVER SCREW
26	85547	COVER, LOWER MOUNT (PLASTIC) Comment: SN# USA-6055407/AUS-8074217/BEL-9340565/CAN-7186767 & Below

▶THROTTLE AND SHIFT LINKAGE(ELECTRIC) (47 parts)

Ref	OEM Part #	Part Name
1	96096	CAM, Throttle Comment: BC1B/BC1C CARBURETOR
2	10-400035	SCREW, (M5 x 16)
3	12-87791	WASHER, THROTTLE CAM SCREW
4	13-69150	WAVE WASHER, THROTTLE CAM SCREW
5	17764A2	BUSHING, THROTTLE CAM SCREW
6	92425	DASHPOT
7	93001	BRACKET, DASHPOT
8	11-22053	NUT, (.312-24), DASHPOT TERMINAL
9	98463A2	ROD ASSEMBLY, Throttle
10	10-32,11-68219	NUT, Stainless Steel, THROTTLE ROD
11	8M0084742	SOCKET, THROTTLE ROD
12	92730	LEVER, CONTROL
13	817429	TIMING ROD
14	44299	PLATFOM, CONTROL
15	24-89540	SPRING, SPARK ADVANCE
16	95034	LEVER, ACTUATING
17	53-46250	RING, Retaining
18	10-40019108	SCREW, (M5 x 20), CONTROL PLATFORM
19	10-40037126	SCREW, CONTROL PLATFORM (13MM)
20	10-40007128	SCREW, (M6 x 20), SHIFT LEVER TO PLATFORM
21	12-95093	WASHER, SHIFT LEVER TO PLATFORM
22	95035	LEVER, SHIFT
23	23-95091	SLEEVE, SHIFT LEVER TO PLATFORM
24	12-35280	WASHER, (.255 x .620 x .030) Stainless Steel, SHIFT LEVER SCREW
25	11-401386	NUT, (M6), SHIFT LEVER SCREW
26	17-95029	PIN, SHIFT LEVER
27	12-71055	WASHER, SHIFT LEVER PIN
28	18-210711	COTTER PIN, SHIFT LEVER PIN
29	17-95784	PIN, ACTUATING LEVER
30	12-71055	WASHER, ACTUATING LEVER PIN
31	18-210711	COTTER PIN, ACTUATING LEVER PIN
32	95025	SHIFT LINK
33	23-96202	BUSHING, NYLON - SHIFT LINK
34	12-89302	WASHER, (.203 x .406 x .040), SHIFT LINK
35	18-210711	COTTER PIN, SHIFT LINK
36	95027A6	SHIFT SHAFT ASSEMBLY, HORIZONTAL
37	95023	LEVER, SHIFT SHAFT
38	53-95019	RING, Retaining, LEVER TO SHIFT SHAFT
39	23-60762	BUSHING, SHIFT SHAFT
40	17724A1	LEVER, SHIFT SHAFT
41	11-401385	NUT, (M5), SHIFT SHAFT
42	95033	BRACKET, REMOTE CONTROL
43	10-4000327	SCREW, (M6 x 14), REMOTE CONTROL BRACKET
44	18-210711	COTTER PIN, REMOTE CONTROL CABLES
45	96186A2	BRACKET ASSEMBLY, ATTACHING
46	96201	STRAP, Key
47	10-1993325	SCREW, (M10 x 25), BRACKET

▶THROTTLE AND SHIFT LINKAGE(MANUAL) (39 parts)

Ref	OEM Part #	Part Name
1	96096	CAM, Throttle Comment: (USE WITH BC1B/BC1C CARBURETORS)
2	10-400035	SCREW, (M5 x 16), THROTTLE CAM TO CRANKCASE
3	12-87791	WASHER, THROTTLE CAM SCREW
4	13-69150	WAVE WASHER, THROTTLE CAM SCREW
5	17764A2	BUSHING, THROTTLE CAM SCREW
6	92425	DASHPOT
7	93001	BRACKET, DASHPOT
8	11-22053	NUT, (.312-24), DASHPOT TERMINAL
9	98463A2	ROD ASSEMBLY, Throttle
10	10-32,11-68219	NUT, Stainless Steel, LOCK - THROTTLE ROD
11	8M0084742	SOCKET, THROTTLE ROD
12	92730	LEVER, CONTROL
13	817429	TIMING ROD
14	10-32,11-68219	NUT, Stainless Steel, LOCK - TIMING ROD
15	8M0084742	SOCKET, TIMING ROD
16	12863A1	PLATFORM, CONTROL
17	24-89540	SPRING, SPARK ADVANCE
18	92362A1	LEVER, ACTUATING
19	53-46250	RING, Retaining
20	92362A1	LINK, THROTTLE/ADVANCE
21	53-86731	RETANINING RING, THROTTLE/ADVANCE LINK
22	94152	GEAR
23	92362A1	LEVER, PRIMARY
24	53-46250	RING, Retaining, PRIMARY LEVER AND GEAR
25	24-8M0215005	SPRING, DETENT BALL
26	30-93008	BALL, DETENT
27	94085A1	GEAR, SHIFT
28	12-49339	WASHER, (.8125), SHIFT GEAR
29	53-46250	RING, Retaining, SHIFT GEAR
30	193852	SHIFT ROD
31	94084	LEVER, SHIFT ROD
32	10-4001589	LEVER, Shift Rod
33	23-60762	BUSHING, SHIFT SHAFT
34	87794	SHIFT SHAFT, HORIZONTAL
35	93744	LEVER, SHIFT SHAFT
36	93928	LEVER, ROD END
37	10-4001588	SCREW, (M4 x 20), ROD END LEVER
38	94186	BRACKET, THROTTLE CABLE
39	10-4000171	SCREW, (M6 x 16), BRACKET TO CYLINDER BLOCK

100-Hour / Annual Service Checklist

Regular maintenance keeps your Mercury 25 (2 CYL.) running reliably season after season. Most of these tasks can be performed with basic tools and the factory service manual.

Replace water pump impeller and inspect wear plate
Change engine oil and oil filter (check drain plug washer)
Replace spark plugs and check ignition timing
Drain and refill lower unit gear oil; inspect for water contamination
Inspect fuel lines, primer bulb, and fuel filter for deterioration
Check and replace sacrificial anodes (zinc or aluminum)
Inspect propeller for damage; check shaft seal and cotter pin
Check valve clearance (refer to service manual for specifications)
Lubricate all grease points (steering, tilt tube, shift linkage)
Inspect control cables and throttle/shift linkage for smooth operation

Pro Tip: Always flush the engine with fresh water after saltwater use — even a quick 10-minute flush significantly extends component life.
Pro Tip: Use fuel stabilizer in the tank before winter storage, and fog the cylinders to prevent internal corrosion during extended periods of non-use.

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