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Mercury 4.5 (1 CYL.) (8068065 & Up) Parts & Diagrams
🔎 Mercury 4.5 (1 CYL.) Reference Library — Exploded parts diagrams (18 diagrams), specifications, common issues, and maintenance checklist.
The Mercury 4.5 (1 CYL.) is a 4-Stroke, 1-Cylinder 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 |
| Horsepower | 4 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 4.5 (1 CYL.):
- Water Pump / Overheating: If the tell-tale stream is weak or absent, the water pump impeller likely needs replacement. Inspect annually or every 100 hours. → Recommended: Water Pump Impeller Kit
- Engine Oil / Maintenance Light: 4-stroke engines require regular oil and filter changes. Use marine-grade oil rated for your engine. Change every 100 hours or annually. → Recommended: Oil Filter, Engine Oil
- Fuel Injector Issues (EFI models): Rough idle or misfires may indicate clogged fuel injectors. Use fuel stabilizer and clean injectors periodically. → Recommended: Fuel Injector, Fuel Filter
- Gear Case Oil Leak: Check lower unit seals if gear oil appears milky (water contamination). Replace seals and gaskets during lower unit service. → Recommended: Lower Unit Seal Kit, Drain Plug Gaskets
- Anode Corrosion: Inspect sacrificial anodes regularly, especially in saltwater. Replace when 50% depleted to protect against galvanic corrosion. → Recommended: Zinc/Aluminum Anode Kit
Parts Diagrams & OEM Part Numbers
Expand the sections below to view detailed exploded parts diagrams and find the exact OEM replacement components for your Mercury 4.5 (1 CYL.).
▶BOTTOM COWL ASSEMBLY (27 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| - | 27-78139A80 | GASKET SET |
| 1 | 187-7711A4 | BOTTOM COWL |
| 2 | 36187A1 | LEVER ASSEMBLY, CLAMPING - PORT |
| 3 | 36188A1 | LEVER ASSEMBLY, CLAMPING - STARBOARD |
| 4 | 53-55891 | FASTENER, CLAMPING LEVER |
| 5 | 84-60871A7 | STRAP ASSEMBLY, Ground |
| 6 | 24-63399 | SPRING, GROUNG STRAP |
| 7 | 23-26819 | BUSHING, NYLON - CLAMPING LEVER |
| 8 | 23-31293 | BUSHING, RUBBER - CLAMPING LEVER |
| 9 | 17-58997 | PIN, Roll (.164 x .750), CLAMPING LEVER |
| 10 | 10-79953Q04 | SCREW, (.375-16 x .250), BOTTOM COWL FLUSHING HOLE |
| 11 | 12-191833 | WASHER, BOTTOM COWL FLUSHING HOLE SCREW |
| 12 | 56712 | NOZZLE, TELL TALE |
| 13 | 10-35519 | SCREW, (#10-16 x .500), TELL TALE NOZZLE TO BOTTOM COWL |
| 14 | 32-8M0108355 | HOSE, TELL TALE (7-1/4") |
| 15 | 22-996642 | ELBOW, TELL TALE - HOSE TO CYLINDER BLOCK |
| 16 | 27-89937 | GASKET |
| 17 | 27-55847 | GASKET |
| 18 | 55936 | COVER, EXHAUST RELIEF |
| 19 | 10-69079 | SCREW, (#10-16 x .440) |
| 20 | 87-69508A31 | SWITCH ASSEMBLY, Stop Comment: PUSH BUTTON SWITCH |
| 21 | 87-99525A1 | COVER ASSEMBLY Comment: PUSH BUTTON SWITCH |
| 22 | 13-69845 | LOCKWASHER Comment: PUSH BUTTON SWITCH |
| 23 | 11-69844 | NUT, STOP SWITCH Comment: PUSH BUTTON SWITCH |
| 24 | 87-11083A9 | SWITCH ASSEMBLY, Stop Comment: TOGGLE SWITCH |
| 25 | 8M0032846 | RETANER Comment: TOGGLE SWITCH |
| 26 | 15920Q54 | LANYARD ASSEMBLY Comment: TOGGLE SWITCH |
▶CARBURETOR ASSEMBLY(TILLOTSON) (40 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| - | 1395-92621 | REPAIR PARTS KIT |
| 1 | 1341-8740A1 | CARBURETOR ASSEMBLY, COMPLETE |
| 2 | 1395-8673 | FLOAT ASSEMBLY |
| 3 | NSS | NOT SOLD SEPARATE, Pin-Float Lever Pinion |
| 4 | NSS | NOT SOLD SEPARATE, Float Lever-Lower |
| 5 | NSS | NOT SOLD SEPARATE, Float Lever-Upper |
| 6 | 1395-92581 | NEEDLE/SEAT KIT, Inlet, SEAT AND GASKET |
| 7 | NSS | NOT SOLD SEPARATE, Gasket-Inlet Seat |
| 8 | NSS | NOT SOLD SEPARATE, Gasket-Float Bowl Cover |
| 9 | 1399-1133 | COVER, FLOAT BOWL |
| 10 | 10-52195 | SCREW, FLOAT BOWL (SHORT) |
| 11 | 10-52196 | SCREW, FLOAT BOWL COVER (LONG) |
| 12 | 8,13-26995 | LOCKWASHER, Stainless Steel, FLOAT BOWL COVER SCREW |
| 13 | NSS | NOT SOLD SEPARATE, Gasket-Strainer cover (Large) |
| 14 | 1399-3938 | SCREEN, FILTER |
| 15 | NSS | NOT SOLD SEPARATE, Gasket, Strainer cover (Small) |
| 16 | 1399-1135 | COVER, STRAINER (90 DEGREES) |
| 17 | NSS | NOT SOLD SEPARATE, Gasket, Strainer cover Screw |
| 18 | 10-25822 | SCREW, STRAINER COVER |
| 19 | 1395-6027 | SCREW, THROTTLE STOP LEVER |
| 20 | 8146791 | LEVER, THROTTLE STOP |
| 21 | 1399-1716 | SHAFT |
| 22 | NSS | NOT SOLD SEPARATE, Idle Tube |
| 23 | NSS | NOT SOLD SEPARATE, Gasket, Idle tube |
| 24 | NSS | NOT SOLD SEPARATE, Screw-throttle Shutter |
| 25 | 1399-3739 | SHUTTER |
| 26 | NSS | NOT SOLD SEPARATE, Welch Plug, Body Channel |
| 27 | NSS | NOT SOLD SEPARATE, Spring, throttle shaft return |
| 28 | 10-28845 | SCREW, PLUG-BODY CHANNEL |
| 29 | NSS | NOT SOLD SEPARATE, Main Nozzle |
| 30 | 10-23178 | SCREW, PLUG-MAIN NOZZLE |
| 31 | 1399-1896 | JET, MAIN FUEL (.041) |
| 32 | NSS | NOT SOLD SEPARATE, Gasket-Main Fuel Jet |
| 33 | NSS | NOT SOLD SEPARATE, Gasket, Jet Channel Plug Screw |
| 34 | 10-28405 | SCREW, PLUG-MAIN FUEL JET CHANNEL |
| 35 | 1399-3740 | SCREW, IDLE ADJUSTMENT |
| 36 | NSS | NOT SOLD SEPARATE, Spring, Idle Adjustment Screw |
| 37 | 27-63309 | GASKET, CARBURETOR TO REED BLOCK |
| 38 | 12-20583 | WASHER, CARBURETOR MOUNTING STUD |
| 39 | 11-24652 | NUT, (.250-28), CARBURETOR MOUNTING STUD |
▶CARBURETOR ASSEMBLY(WALBRO) (37 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| - | 1395-9019 | REPAIR PARTS KIT |
| 1 | 1341-8740A1 | CARBURETOR, COMPLETE |
| 2 | 1395-8673 | FLOAT ASSEMBLY |
| 3 | NSS | NOT SOLD SEPARATE, Pin, float lever pinion |
| 4 | NSS | NOT SOLD SEPARATE, Lever, float (Lower) |
| 5 | NSS | NOT SOLD SEPARATE, Lever, float (Upper) |
| 6 | 1395-83181 | NEEDLE, Inlet, SEAT AND GASKET |
| 7 | NSS | NOT SOLD SEPARATE, Gasket, inlet seat |
| 8 | NSS | NOT SOLD SEPARATE, Gasket, float bowl cover |
| 9 | 1399-1133 | COVER, FLOAT BOWL |
| 10 | 10-52195 | SCREW, FLOAT BOWL COVER (SHORT) |
| 11 | 10-52196 | SCREW, FLOAT BOWL COVER (LARGE) |
| 13 | NSS | NOT SOLD SEPARATE, Gasket, strainer cover (Large) |
| 14 | 1399-3938 | SCREEN, FILTER |
| 15 | NSS | NOT SOLD SEPARATE, Screen, filter |
| 16 | 1399-1135 | COVER, STRAINER (90 DEGREE) |
| 17 | NSS | NOT SOLD SEPARATE, Gasket, strainer cover screw |
| 18 | 10-25822 | SCREW, STRAINER COVER |
| 19 | 1395-6027 | SCREW, THROTTLE STOP LEVER |
| 20 | 8146791 | LEVER, THROTTLE STOP |
| 21 | 1399-1716 | SHAFT |
| 22 | NSS | NOT SOLD SEPARATE, Idle Tube |
| 23 | NSS | NOT SOLD SEPARATE, Gasket, idle tube |
| 24 | NSS | NOT SOLD SEPARATE, Screw, throttle shutter |
| 25 | 1399-3739 | SHUTTER |
| 26 | NSS | NOT SOLD SEPARATE, Welch Plug, body channel |
| 27 | NSS | NOT SOLD SEPARATE, Spring, throttle shaft return |
| 28 | NSS | NOT SOLD SEPARATE, Screw, plug - body channel |
| 30 | NSS | NOT SOLD SEPARATE, Screw, plug - main nozzle |
| 31 | 1399-1896 | JET, MAIN FUEL (.041) |
| 33 | NSS | NOT SOLD SEPARATE, Gasket, jet channel plug screw |
| 34 | NSS | NOT SOLD SEPARATE, Screw, plug - main fuel jet channel |
| 35 | 1399-3740 | SCREW, IDLE ADJUSTMENT |
| 36 | NSS | NOT SOLD SEPARATE, Spring, idle adjustment screw |
| 37 | 27-63309 | GASKET, CARBURETOR TO REED BLOCK |
| 38 | 12-20583 | WASHER, CARBURETOR MOUNTING STUD |
| 39 | 11-24652 | NUT, (.250-28), CARBURETOR MOUNTING STUD |
▶CARBURETOR CHOKE LINKAGE (9 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| 1 | 59000 | LEVER, Throttle |
| 2 | 10-20597 | SCREW, (#8-32 x .380) |
| 3 | 79092 | SHUTTER AND SCREEN, CHOKE - CARBURETOR |
| 4 | 24-53193 | SPRING, CHOKE SHUTTER TO LEVER |
| 5 | 24-55299A1 | SPRING ASSEMBLY, CARBURETOR |
| 6 | 10-55298 | SCREW, (#10-32 x .580), SPRING TO CARBURETOR |
| 7 | 53187 | LEVER |
| 8 | 24-53190 | SPRING, TENSION - CHOKE KNOB |
| 9 | 53189 | KNOB |
▶CLAMP BRACKET ASSEMBLY (18 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| 1 | 1468-5570A3 | CLAMP BRACKET ASSEMBLY (PORT) |
| 2 | 1467-5571A3 | CLAMP BRACKET ASSEMBLY (STARBOARD) |
| 3 | 10-77190A3 | THUMB SCREW ASSEMBLY |
| 4 | 10-768042 | SCREW, THUMB SCREW |
| 5 | 12-73719 | WASHER, THUMB SCREW |
| 6 | 12-71421 | WASHER, Nylon, TILT TUBE - CLAMP TO SWIVEL BRACKET |
| 7 | 96962 | TILT TUBE, CLAMP TO SWIVEL BRACKET |
| 8 | 19-39333 | PLUG, TILT TUBE |
| 9 | 11-93164 | NUT, (.875), TILT TUBE FASTENING |
| 10 | 71420 | HANDLE, CARRYING |
| 11 | 16-71417 | STUD, CLAMP BRACKET |
| 12 | 13-26992 | LOCKWASHER, (.250) Stainless Steel, CLAMP BRACKET STUD |
| 13 | 11-29598 | NUT, (.250-28) Stainless Steel, CLAMP BRACKET STUD |
| 14 | 17-71418A2 | PIN ASSEMBLY, Tilt Lock |
| 15 | 24-62143 | SPRING, TILT LOCK PIN |
| 16 | 10-67982 | BOLT, CLAMP BRACKET TO BOAT |
| 17 | 12-67983 | WASHER, CLAMP BRACKET SCREW |
| 18 | 11-8267098 | NUT, (.250-20), CLAMP BRACKET SCREW |
▶CRANKSHAFT, PISTON AND CONNECTING ROD (14 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| - | 27-78139A80 | GASKET SET |
| 1 | 427-7334A2 | CRANKSHAFT ASSEMBLY |
| 2 | 79952A1 | CARRIER ASSEMBLY |
| 3 | 25-62704 | O-RING, (.362 x .103) |
| 4 | 28-20094 | KEY, Woodruff, CRANKSHAFT |
| 5 | 608-7395A2 | CONNECTING ROD ASSEMBLY |
| 6 | 10-87374 | SCREW, (.250-28 x 1.030), CONNECTING ROD |
| 7 | 29-26815 | BEARING, Needle, CRANKPIN |
| 8 | 11-20061 | NUT, CONNECTING ROD SCREW |
| 9 | 12-65967 | WASHER, NEEDLE BEARING RETAINING |
| 10 | 29-31505 | BEARING, Needle, PISTON PIN |
| 11 | 719-7391T3 | PISTON ASSEMBLY |
| 12 | 40-21666 | LOCK RING, PISTON PIN |
| 13 | 39-21665A12 | RING SET, Piston |
▶CYLINDER BLOCK AND CRANKCASE ASSEMBLY (41 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| - | 87096A79 | POWERHEAD ASSEMBLY |
| 1 | 843-8694A3 | CYLINDER BLOCK |
| 2 | 16-66021 | STUD |
| 3 | 17-8M0084726 | PIN, Dowel (.187 x .530), CRANKCASE TO CYLINDER BLOCK |
| 4 | 22-89275 | FITTING, BLEED DRAIN |
| 5 | 32-9912688 | TUBING, (36.00 Inches Bulk), BLEED DRAIN |
| 6 | 54-68424 | CLAMP, BLEED HOSE ATTACHING |
| 7 | 22-887801 | ELBOW, Tell-Tale Tubing, BLEED DRAIN |
| 8 | 10-73280 | SCREW, CRANKCASE TO CYLINDER BLOCK (1-1/2") |
| 9 | 10-76621 | SCREW, CRANKCASE TO CYLINDER BLOCK (1") |
| 10 | 70726 | REED BLOCK |
| 11 | 34-35836 | REED, INLET VALVE |
| 12 | 34-22215 | RETAINER, REED |
| 13 | 10-28430 | SCREW, (#6-32 x .25) |
| 14 | 27-357391 | GASKET, REED BLOCK TO CRANKCASE |
| 15 | 30-72961 | BEARING, Ball, CRANKCASE (LOWER) |
| 16 | 26-56397 | SEAL, Oil, CRANKCASE (LOWER) |
| 17 | 15-31412A1 | SHIM |
| 18 | 1132-6352A1 | HOUSING ASSEMBLY, Bearing, UPPER |
| 19 | 30-72961 | BEARING, Ball, UPPER BEARING HOUSING |
| 20 | 31-31410 | BEARING, Roller, UPPER BEARING HOUSING |
| 21 | 26-66301 | SEAL, Oil, UPPER BEARING HOUSING |
| 22 | 25-20863 | O-RING, UPPER BEARING HOUSING |
| 23 | 54-34598 | CLAMP, HOLD DOWN |
| 24 | 10-36205 | SCREW, (#10-24 x .563) |
| 25 | 24-34731 | SPRING, HOLD DOWN RING CLAMP |
| 26 | 10-39002 | SCREW (1/2") |
| 27 | 35658 | COVER, TRANSFER COVER |
| 28 | 27-35657 | GASKET, TRANSFER PORT COVER |
| 29 | 10-20720 | SCREW, (.190-24 x .62) |
| 30 | 1016-7070A1 | COVER ASSEMBLY, CYLINDER BLOCK |
| 31 | 66019 | MOUNT, RUBBER - COVER TO TOP COWL |
| 32 | 13-20202 | LOCKWASHER, RUBBER MOUNT |
| 33 | 11-22053 | NUT, (.312-24), RUBBER MOUNT TO COVER |
| 34 | 27-416151 | GASKET, COVER TO CYLINDER BLOCK |
| 35 | 10-8M0214943 | SCREW, (.250-20 x 1.00) |
| 36 | 27-416141 | GASKET, CYLINDER BLOCK TO BAFFLE PLATE |
| 37 | 46234 | PLATE, BAFFLE - EXHAUST MANIFOLD |
| 38 | 27-416141 | GASKET |
| 39 | 46171 | COVER, EXHAUST MANIFOLD |
| 40 | 10-49668 | SCREW, (.250-20 x .750) |
▶DRIVESHAFT HOUSING ASSEMBLY (21 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| - | 27-78139A80 | GASKET SET |
| 1 | 1542-8452A1 | HOUSING ASSEMBLY, Driveshaft Comment: (LONG SHAFT) |
| 2 | 16-66373 | STUD, DRIVE SHAFT HOUSING TO GEAR HOUSING |
| 3 | 11-82670911 | NUT, (.312-24) Stainless Steel, DRIVE SHAFT HOUSING STUD |
| 4 | 11-8M0204726 | NUT, (.375-24), GEAR HOUSING STUD |
| 5 | 1539-8450A1 | SADDLE |
| 6 | 64076 | BUMPER, THRUST - SADDLE |
| 7 | 79896A1 | MOUNT, LOWER Comment: (LONG SHAFT) |
| 8 | 79896A1 | MOUNT, UPPER Comment: (LONG SHAFT) |
| 9 | 53-26406 | RING, UPPER AND LOWER MOUNT |
| 10 | 79907 | COVER, UPPER AND LOWER MOUNT |
| 11 | 27-59079 | GASKET |
| 12 | 11-24652 | NUT, (.250-28) |
| 13 | 32-32077 | TUBE, WATER OUTLET Comment: (LONG SHAFT) |
| 14 | 26-36556 | SEAL, (.500 Inch Outside Diameter), RUBBER - WATER OUTLET TUBE |
| 15 | 23-13127 | SPACER, NYLON - OUTLET TUBE SEAL |
| 16 | 71057 | LINK ROD, REVERSE LOCK |
| 17 | 10-65414 | SCREW |
| 18 | 65216 | CAM, REVERSE LOCK |
| 19 | 72007 | RETAINER, REVERSE LOCK CAM |
| 20 | 93145 | BLOCK, DRIVESHAFT Comment: (LONG SHAFT) |
▶FLYWHEEL AND IGNITION COMPONENTS (44 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| 1 | 236-4475A1 | FLYWHEEL ASSEMBLY |
| 2 | 12-36245 | WASHER, FLYWHEEL NUT |
| 3 | 11-20696 | NUT, FLYWHEEL |
| 4 | 13-35629 | WASHER, WAVE-CAM TENSION |
| 5 | 336-4465 | CAM |
| 6 | 336-4524A1 | COVER ASSEMBLY |
| 7 | 10-60491 | SCREW, (#8-32 x .620), COVER TO MODULE |
| 8 | 336-4516A2 | IGNITION MODULE ASSEMBLY |
| 9 | 10-59800 | SCREW, MODULE TO STATOR (9/16") |
| 10 | 10-36046 | SCREW, MODULE-COIL LEAD (1/4") |
| 11 | 10,13-26996 | LOCKWASHER, Stainless Steel, MODUEL TERMINALS |
| 12 | 10-32,11-45076 | NUT, Brass, MODULE TERMINALS |
| 13 | 336-4469A1 | COIL ASSEMBLY Comment: LOW SPEED |
| 14 | 54-59538 | CLIP, COIL RETAINING |
| 15 | 54-59539 | CLIP, COIL RETAINING |
| 16 | 336-4463 | CONDENSER ASSEMBLY |
| 17 | 10-62269 | SCREW, (#10-32 x .437), CONDENSER ATTACHING |
| 18 | 336-4476A6 | STATOR ASSEMBLY |
| 19 | 336-4458 | PLATE, STATOR HOLD DOWN |
| 20 | 10-35400 | SCREW, HOLD DOWN PLATE TO STATOR (7/16") |
| 21 | 15-33910015 | SHIM, STATOR PLATE TO UPPER END CAP |
| 22 | 336-3989 | WICK, CAM WIPER |
| 23 | 336-4318A2 | MAKER ASSEMBLY, STATOR HOUSING |
| 24 | 10-56266 | SCREW, MAKER TO STATOR HOUSING (3/8") |
| 25 | 56520 | CAM |
| 26 | 10-69054 | SCREW, (.250-20 x .620), THROTTLE CAM TO CONTACT HOUSING |
| 27 | 12-37998 | WASHER, THROTTLE CAM ATTACHING SCREW |
| 28 | 56757A5 | WIRE ASSEMBLY, Jumper (BLACK-4-1/4") |
| 29 | 56318A11 | LEAD ASSEMBLY (GREEN-12-1/4") |
| 30 | 38938 | BOOT, LEAD ASSEMBLY |
| 31 | 56316A4 | CABLE ASSEMBLY, STATOR HOUSING (WHITE-103/4") |
| 32 | 38938 | BOOT, CABLE |
| 33 | 336-4460 | INSULATOR, CABLE TO CONTACT HOUSING |
| 34 | 11-56325 | NUT, CABLE INSULATOR |
| 35 | 336-4528T2 | COIL ASSEMBLY, Ignition |
| 36 | 10,13-26996 | LOCKWASHER, Stainless Steel, IGNITION COIL TERMINAL |
| 37 | 10-32,11-45076 | NUT, Brass, IGNITION COIL TERMINAL |
| 38 | 66355 | COVER |
| 39 | 10-61530 | SCREW |
| 40 | 10-32,11-27164 | NUT AND LOCKWASHER, , COIL COVER SCREW |
| 41 | 84-813715A1 | LEAD ASSEMBLY, HIGH TENSION |
| 42 | 332-2854T01 | BOOT, IGNITION COIL |
| 43 | 85-63709A1 | BOOT/TERMINAL KIT, SPARK PLUG |
| 44 | 33-14103Q | SPARK PLUG Comment: CANADA AND BELGIUM |
▶FUEL PUMP AND FUEL LINES (16 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| - | 27-78139A80 | GASKET SET |
| 1 | 89977A1 | PUMP ASSEMBLY, Fuel |
| 2 | 32-8M0108355 | LINE, (57.00 Inches Bulk) |
| 3 | 54-68424 | CLAMP, FUEL LINE |
| 4 | 22-19688 | FITTING, FUEL LINE TO CARBURETOR |
| 5 | 22-98750 | FITTING, FUEL LINE TO ADAPTOR |
| 6 | 32-9912878 | TUBING, FUEL PUMP TO CYLINDER BLOCK |
| 7 | 22-33373001 | ELBOW, HOSE TO CYLINDER BLOCK (90 DEGREE) |
| 8 | 54-68424 | CLAMP, FUEL PUMP HOSE TO ELBOWS |
| 9 | 30188 | WASHER, ADAPTOR |
| 10 | 24-23067T | SPRING, ADAPTOR STEM |
| 11 | 25-16524 | O-RING, ADAPTOR STEM |
| 12 | 23069 | STEM, CHECK UNIT ADAPTOR |
| 13 | 22833 | ADAPTOR, CHECK UNIT |
| 14 | 10-37923 | SCREW, (.250-28 x 1.250) |
| 15 | 11-24652 | NUT, (.250-28), ADAPTOR SCREW |
▶GEAR HOUSING(DRIVESHAFT) (34 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| - | 26-77066A1 | SEAL KIT, Water Pump |
| 1 | 1630-7360A11 | GEAR HOUSING ASSEMBLY |
| 2 | 16-58138 | STUD, GEAR HOUSING (3-1/2") |
| 3 | 16-58136 | STUD, WATER PUMP HOUSING (2-3/4") |
| 4 | 31-22756 | BEARING, Roller, DRIVE SHAFT |
| 5 | 17-20032 | PIN, Dowel, LOCATING |
| 6 | 26-33613 | SEAL, RUBBER - WATER INTAKE TUBE |
| 7 | 23-86215 | BEARING, NYLON - INTAKE TUBE SEAL |
| 8 | 35-33425 | SCREEN, WATER INTAKE |
| 9 | 10-25612 | SCREW, WATER INTAKE SCREEN |
| 10 | 43-98696 | GEAR, Pinion |
| 11 | 14-30377 | TAB WASHER, PINION GEAR SCREW |
| 12 | 10-30376 | SCREW, (#12-28 x .750), PINION GEAR TO DRIVE SHAFT |
| 13 | 45-95874A1 | DRIVESHAFT Comment: (LONG SHAFT)(USE WITH 47-89980 IMPELLER) |
| 14 | 15-30527A1 | SHIM ASSEMBLY, BALL BEARING (.002-3-5-10) |
| 15 | 30-70944 | BEARING, Ball, DRIVE SHAFT |
| 16 | 53-30523 | RING, Retaining, BALL BEARING |
| 17 | 15-30527A1 | SHIM ASSEMBLY, BALL BEARING (.002-3-5-10) |
| 18 | 46-92970A1 | HOUSING ASSEMBLY, Water Pump Comment: (USE WITH 47-89980 IMPELLER) |
| 19 | 25-29439 | O-RING |
| 20 | 26-897153 | SEAL, Oil Comment: (USE WITH 47-89980 IMPELLER) |
| 21 | 70977T | INSERT |
| 22 | 26-33613 | SEAL, WATER INTAKE TUBE |
| 23 | 32-34293 | TUBE, WATER INTAKE |
| 24 | 28-8M0032835 | KEY, IMPELLER DRIVE |
| 25 | 47-89980 | IMPELLER Comment: (MOLDED 47-89980 - .438 I.D.) |
| 26 | 46895 | FACE PLATE, WATER PUMP |
| 27 | 93224A1 | COVER ASSEMBLY, Water Pump |
| 28 | 26-36558 | SEAL, WATER PUMP COVER |
| 30 | 26-30913 | SEAL, Oil, WATER PUMP COVER |
| 31 | 12-20533 | WASHER |
| 32 | 11-8267119 | NUT, (.250-28), WATER PUMP HOUSING STUD |
| 33 | 25-30526 | RING, RUBBER - CENTRIFUGAL SLINGER |
| 34 | 23-31792T | SLEEVE, GUIDE - INLET TUBE |
▶GEAR HOUSING(PROPELLER SHAFT) (36 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| - | 27-78139A80 | GASKET SET |
| 1 | 1630-7360A11 | GEAR HOUSING ASSEMBLY |
| 36 | 10-79953Q04 | SCREW, (.375-16 x .250), GREASE FILLER HOLE |
| 37 | 12-191833 | WASHER, GREASE FILLER HOLE SCREW |
| 38 | 10-28653 | SCREW, (#10-32 x 0.25), GREASE VENT HOLE |
| 39 | 19643 | WASHER, GREASE VENT HOLE SCREW |
| 40 | 71658A1 | SHIFT SHAFT ASSEMBLY, SHIFT Comment: (LONG SHAFT) |
| 41 | 53-22899 | RING, Retaining, SHIFT SHAFT |
| 42 | 23-30676A1 | BUSHING ASSEMBLY, SHIFT SHAFT |
| 43 | 25-26802 | O-RING, (.424 x .103), SHIFT SHAFT BUSHING |
| 44 | 26-30696 | SEAL, Oil, SHIFT SHAFT BUSHING |
| 45 | 10-39149 | SCREW, (#10-24 x .500) |
| 46 | 44434 | CAM |
| 47 | 15-30522A1 | SHIM ASSEMBLY (.002-3-5-10) |
| 48 | 30-21889 | BEARING, Ball, FORWARD GEAR |
| 49 | 43-48577A3 | GEAR ASSEMBLY, Forward |
| 50 | 31-22458 | BEARING, Roller, FORWARD GEAR |
| 51 | 52-63314 | RATCHET, SLIDING CLUTCH |
| 52 | 17-30535 | PIN, Cross, RATCHET TO PROPELLER SHAFT |
| 53 | 53-32449 | RING, Retaining, CROSS PIN |
| 54 | 31334 | FOLLOWER |
| 55 | 24-76298 | SPRING, COMPRESSION - CAM FOLLOWER |
| 56 | 44-75667A2 | PROELLER SHAFT ASSEMBLY |
| 57 | 43-63316 | GEAR, Reverse |
| 58 | 71479 | SLEEVE, THRUST - REVERSE GEAR |
| 59 | 15-30532A1 | SHIM ASSEMBLY (.002-3-5-10) |
| 60 | 30-21889 | BEARING, Ball, REVERSE GEAR |
| 61 | 25-30529 | O-RING, (1.925 x .103), BEARING CARRIER |
| 62 | 72673T1 | CARRIER ASSEMBLY, Bearing |
| 63 | 31-22458 | BEARING, Roller, BEARING CARRIER |
| 64 | 26-66022 | SEAL, Oil, BEARING CARRIER |
| 65 | 86236 | COVER, GEAR HOUSING |
| 66 | 86665A1 | COLLAR, PROPELLER |
| 67 | 48-63494A10 | PROPELLER ASSEMBLY Comment: (2 BLADE ALUMINUM - 6" PITCH) |
| 68 | 11-64075A1 | SPACER, SPLINED - PROPELLER NUT |
| 69 | 11-64075A1 | NUT |
▶MISCELLANEOUS PARTS/ACCESSORIES (1 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| - | 37-86667A86 | DECAL SET Comment: (SAILPOWER) |
▶SHIFT CONTROL LINKAGE (16 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| 1 | 93730T | HANDLE, SHIFT CONTROL |
| 2 | 66378 | SHAFT, CONTROL HANDLE |
| 3 | 23-66375 | BUSHING, NYLON - SHIFT CONTROL HANDLE |
| 4 | 66414 | CAM, SHIFT SHAFT |
| 5 | 43-66377 | SECTOR GEAR, SHIFT CONTROL HANDLE |
| 6 | 12-8M0204649 | WASHER, (.281 x .500 x .060) Stainless Steel |
| 7 | 11-826709109 | NUT |
| 8 | 17-25905 | PIN, DETENT CAM TO SHIFT SHAFT |
| 9 | 12-8M0204649 | WASHER, (.281 x .500 x .060) Stainless Steel |
| 10 | 11-8267089 | NUT, (.250-28) |
| 11 | 24-39627 | SPRING, DETENT - CRANKCASE |
| 12 | 39601 | PLATE, DETENT SPRING |
| 13 | 10-25764 | SCREW, (.190-32 x .50) |
| 14 | 71660 | SHIFT SHAFT, UPPER |
| 15 | 23-30677 | BUSHING, NYLON - SHIFT CONTROL SHAFT |
| 16 | 43-86686A1 | SECTOR GEAR, SHIFT SHAFT |
▶STEERING HANDLE ASSEMBLY (20 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| - | 60850A6 | HANDLE ASSEMBLY, Steering, COMPLETE |
| 1 | 60854 | GRIP, HANDLE - THROTTLE |
| 2 | 62251 | CAP, HANDLE THROTTLE |
| 3 | 66393 | SHAFT |
| 4 | 66394A1 | HANDLE ASSEMBLY, THROTTLE SHAFT |
| 5 | 17-46152 | PIN, THROTTLE HANDLE |
| 6 | 12-62252 | WASHER, THROTTLE HANDLE TO STEERING ARM |
| 7 | 60850 | ARM, STEERING HANDLE |
| 8 | 43-60852 | GEAR, THROTTLE SHAFT |
| 9 | 17-27088 | PIN, BALL GEAR TO THROTTLE SHAFT |
| 10 | 48003 | PIVOT, STEEIRNG HANDLE TO BRACKET |
| 11 | 15-48002015 | SHIM, HANDLE PIVOT TO BRACKET (.015) |
| 12 | 10-96138 | SCREW, (.250-28 x .620), HANDLE TO ARM BRACKET |
| 13 | 60857A2 | UNIVERSAL JOINT ASSEMBLY |
| 14 | 43-60852 | GEAR, UNIVERSAL JOINT |
| 15 | 17-27088 | PIN, BALL GEAR TO UNIVERSAL JOINT |
| 16 | 96130A1 | BRACKET, STEERING ARM |
| 17 | 10-62233 | SCREW, (#10-16 x .625), DETENT SPRING TO BRACKET |
| 18 | 24-72847 | SPRING, DETENT - STEERING HANDLE |
| 19 | 12-30164 | WASHER, (.192 x .375 x .0312) Stainless Steel, DETENT SPRING SCREW |
▶SWIVEL BRACKET ASSEMBLY (29 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| 1 | 1471-7324A1 | SWIVEL BRACKET ASSEMBLY |
| 2 | 22-8M0169589 | FITTING, Grease, SWIVEL BRACKET |
| 3 | 23-64028 | BUSHING, SWIVEL BRACKET |
| 4 | 77334 | PLATE, CO-PILOT |
| 5 | 10-78038 | SCREW, (.250-20 x 1.75), CO-PILOT DISC TO SADDLE |
| 6 | 72845A1 | PLATE ASSEMBLY, CLAMP - CO-PILOT |
| 7 | 20203 | DISC, FRICTION |
| 8 | 10-36154 | SCREW, (.250-28 x 1.380), CLAMP PLATE ADJUSTING |
| 9 | 12-35462 | WASHER, (.2656 x .625 x .0625) Stainless Steel |
| 10 | 17-25319 | PIN, (.125 x 0.75 Inches), SPRING GUIDE |
| 11 | 87984A1 | LEVER ASSEMBLY, TILT STOP |
| 12 | 10-41433 | SCREW, (.250-28 x 1.00), TILT STOP LEVER |
| 13 | 13-31030 | WAVE WASHER, LEVER ANCHOR SCREW |
| 14 | 11-35888 | NUT, (.250-28) Stainless Steel, TILT STOP LEVER SCREW |
| 15 | 72794 | STOP, REVERSE LOCK |
| 16 | 10-71056 | SCREW, (.250-28 x .560), REVERSE STOP TO SWIVEL BRACKET |
| 17 | 13-26992 | LOCKWASHER, (.250) Stainless Steel, REVERSE STOP SCREW |
| 18 | 12-71055 | WASHER, REVERSE STOP SCREW |
| 19 | 63554 | GUIDE, SPRING |
| 20 | 79744 | LEVER, CONTROL - TROLL BRACKET |
| 21 | 13-63631 | WAVE WASHER, TROLL BRACKET LEVER |
| 22 | 71419 | ROD, REVERSE LOCK TO SWITCH BRACKET |
| 23 | 23-26841 | BUSHING, NYLON - REVERSE LOCK LEVER ROD |
| 24 | 18-45882 | COTTER PIN, REVERSE LOCK LEVER TO ROD |
| 25 | 63628T | LEVER, REVERSE LOCK |
| 26 | 61007 | RETAINER, ROD - REVERSE LOCK |
| 27 | 63559T | BRACKET, TROLL |
| 28 | 24-63630 | SPRING, EXTENSION - TROLL BRACKET |
| 29 | 66559 | TUBE, SWIVEL BRACKET TO SADDLE |
▶THROTTLE CONTROL LINKAGE (15 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| 1 | 43-60856 | GEAR, THROTTLE CONTROL |
| 2 | 60885T | HOUSING, HORIZONTAL GEAR |
| 3 | 10-96138 | SCREW, (1/4-28 x 5/8) |
| 4 | 15-64653A1 | SHIM ASSEMBLY, PINION GEAR TO BOTTOM COWL |
| 5 | 42666A3 | GEAR AND SHAFT ASSEMBLY |
| 6 | 62099T | BRACKET, THROTTLE CONTROL LEVER |
| 7 | 10-23015 | SCREW, (.190-32 x 1.00), ADJUSTING - THROTTLE |
| 8 | 10-32,11-68219 | NUT, Stainless Steel |
| 9 | 17-69745 | PIN, Roll, LEVER TO VERTICAL SHAFT |
| 10 | 60920 | LINK, THROTTLE LEVER TO STATOR PLATE |
| 11 | 10-34696 | SCREW, (#8-32 x .750) |
| 12 | 12-34392 | WASHER |
| 13 | 13-29720 | WAVE WASHER |
| 14 | 11-28656 | NUT |
| 15 | 10-56027 | SCREW |
▶TOP COWL AND STARTER ASSEMBLY (33 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| 1 | 191-7668A2 | TOP COWL ASSEMBLY |
| 2 | 39538 | STRIP, SOUND SEAL-REAR |
| 3 | 39537 | STRIP, SOUND SEAL-FORWARD |
| 4 | 66018 | MOUNT, RUBBER-TOP COWL |
| 5 | 89096 | TRIM COVER, TOP COWL |
| 6 | 10-64652 | SCREW, TRIM COVER TO TOP COWL |
| 7 | 14-20165 | TAB WASHER, SHEAVE SHAFT NUT |
| 8 | 11-20166 | NUT, SHEAVE SHAFT (LEFT HAND THREAD) |
| 9 | 64601 | COVER, VENT-TOP COWL |
| 10 | 10-35519 | SCREW, (#10-16 x .500), VENT SCREEN TO TOP COWL |
| 11 | 39258 | BRACKET, TOP COWL FASTENING Comment: (STARBOARD) |
| 12 | 10-39514 | SCREW, BRACKET TO TOP COWL (1-1/8") |
| 13 | 12-39143 | WASHER, (.253 x .625 x .0937), BRACKET SCREW |
| 14 | 20155 | RETAINER, STARTER SPRING |
| 15 | 24-29340T02 | SPRING, STARTER REWIND |
| 16 | 23-28912 | BUSHING, SPRING GUIDE |
| 17 | 50-93696A2 | SHEAVE ASSEMBLY, Starter |
| 18 | 17-22896 | PIN, RETAINER, STARTER CABLE |
| 19 | 30596 | PAWL, STARTER |
| 20 | 13-36206 | WAVE WASHER, STARTER PAWL |
| 21 | 23-28919 | BUSHING, NYLON-SHEAVE SHAFT SPACER |
| 22 | 23-61005 | SPACER, SHEAVE SHAFT |
| 23 | 26179 | RETAINER, SHEAVE SHAFT TO STARTER SHEAVE |
| 24 | 12-35559 | WASHER, SHEAVE SHAFT RETAINER |
| 25 | 13-20160 | WAVE WASHER, RETAINER TENSION |
| 26 | 30595 | PLATE, RETAINER-STARTER PAWL |
| 27 | 35558 | SHAFT, Sheave |
| 28 | 93695 | PULLEY, STARTER CABLE |
| 29 | 23-309772 | SPACER, CALBE PULLEY |
| 30 | 12-22887 | WASHER, PULLEY FASTENING SCREW |
| 31 | 10-28789 | SCREW, (.190-24 x .750), PULLEY TO TOP COWL |
| 32 | 50-12066Q10 | ROPE |
| 33 | 79470A1 | RETAINER KIT, Rope |
100-Hour / Annual Service Checklist
Regular maintenance keeps your Mercury 4.5 (1 CYL.) running reliably season after season. Most of these tasks can be performed with basic tools and the factory service manual.
- Replace water pump impeller and inspect wear plate
- Change engine oil and oil filter (check drain plug washer)
- Replace spark plugs and check ignition timing
- Drain and refill lower unit gear oil; inspect for water contamination
- Inspect fuel lines, primer bulb, and fuel filter for deterioration
- Check and replace sacrificial anodes (zinc or aluminum)
- Inspect propeller for damage; check shaft seal and cotter pin
- Check valve clearance (refer to service manual for specifications)
- Lubricate all grease points (steering, tilt tube, shift linkage)
- Inspect control cables and throttle/shift linkage for smooth operation
- Pro Tip: Always flush the engine with fresh water after saltwater use — even a quick 10-minute flush significantly extends component life.
- Pro Tip: Use fuel stabilizer in the tank before winter storage, and fog the cylinders to prevent internal corrosion during extended periods of non-use.
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