– JLM Marine Boat Parts Limited

Mercury 4.5 (1 CYL.) (9258281 & 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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