– JLM Marine Boat Parts Limited

Mercury 40 (4-STROKE)(4 CYL.) (0P094500 THRU 0P206999) Parts & Diagrams

🔎 Mercury 40 (4-STROKE)(4 CYL.) Reference Library — Exploded parts diagrams (31 diagrams), specifications, common issues, and maintenance checklist.

The Mercury 40 (4-STROKE)(4 CYL.) is a 4-Stroke, Inline 4-Cylinder, EFI, SOHC outboard motor. Commonly used on jon boats, pontoons, and mid-size utility craft.

Quick Reference Specifications

Specification	Value
Engine Type	4-Stroke, Inline 4-Cylinder, EFI, SOHC
Horsepower	40 HP
Displacement	995 cc
Bore x Stroke	65 mm x 75 mm
Spark Plug (Type & Gap)	NGK IZFR6F-11
Engine Oil Capacity	3.0 L (3.17 quart)
Recommended Engine Oil	SAE 25W-40 Mercury FourStroke Oil
Gear Case Oil Capacity	440 mL (14.9 fl oz)
Idle Speed (in gear)	700 ± 50 RPM (in gear)
Full Throttle RPM Range	5500-6000
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 40 (4-STROKE)(4 CYL.):

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

Parts Diagrams & OEM Part Numbers

Expand the sections below to view detailed exploded parts diagrams and find the exact OEM replacement components for your Mercury 40 (4-STROKE)(4 CYL.).

▶ACCESSORIES (1 parts)

Ref	OEM Part #	Part Name
-	12092A18	EXTENSION KIT, Driveshaft - 5 Inch Comment: (BIGFOOT)

▶ADAPTOR PLATE (25 parts)

Ref	OEM Part #	Part Name
-	27-859352A01	GASKET SET
1	8M0162935	DIPSTICK
2	825989003	DIPSTICK TUBE
3	8560552	SEAL
4	8289151	HEAT SHIELD
5	17-23784	PIN, Dowel
6	22-629101	FITTING, Elbow - 90 Degree (.125-27)
7	54-816311T	TIE STRAP, (8.00 Inches)
8	26-66301	SEAL, Oil
9	23-859594	BUSHING
10	22-384073	PLUG, Pipe (.500-14)
11	825228A17	ADAPTOR PLATE KIT
12	19-822464	PLUG
13	19-48323	PLUG
14	25-845746	O-RING
15	10-8M0204741	SCREW, (M6 x 20) Stainless Steel
16	8M0210772	BODY, Oil Pressure Relief Comment: (DESIGN II)
17	893765	PLATE, Oil Pickup-Top
18	32-854793	HOSE, Oil Pickup
19	893700	BAFFLE
20	54-855228	CLAMP
21	10-4007455	SCREW, (M6 x 50)
22	856592	DEFLECTOR, Oil Comment: (DESIGN I)
23	8M0210772	BODY ASSEMBLY, Oil Pressure Relief Comment: (DESIGN I)
24	27-8M0213113	GASKET

▶BOTTOM COWL (18 parts)

Ref	OEM Part #	Part Name
1	4020-826277T1	BOTTOM COWL Comment: (LONG-PORT)
2	4020-826278T7	BOTTOM COWL Comment: (LONG-STBD.)
3	10-82684430	SCREW, (M6 x 30)
4	12-8M0204649	WASHER, (.281 x .500 x .060) Stainless Steel
5	825238002	SEAL
6	12-855576	WASHER
7	27-855627	GASKET
8	10-82684460	SCREW, (M6 x 60)
9	22-827948	FITTING
10	826273001	BOOT
11	54-816311T	TIE STRAP, (8.00 Inches)
12	825782F1	LEVER, Cowl Latch
13	23-812707	BUSHING
14	13-12134	WASHER, Wave
15	893766	LATCH HOOK
16	10-1993716	SCREW, (M6 x 16)
17	25-19565002	GROMMET
18	87-8M0235191	SWITCH, Trim

▶CAMSHAFT (11 parts)

Ref	OEM Part #	Part Name
-	893505T01	CYLINDER HEAD ASSEMBLY
1	400-8M0183247	CAMSHAFT
2	857087T1	PUMP ASSEMBLY, Oil
3	25-857096	O-RING
4	NSS	NOT SOLD SEPARATE
5	25-857094	O-RING
6	25-857093	O-RING
7	10-875206	SCREW, (M6 x 16)
8	10-4000333	SCREW, (M6 x 40)
9	17-878183	PIN, Dowel
10	17-826149	PIN

▶CARBURETOR (36 parts)

Ref	OEM Part #	Part Name
-	8542561	REPAIR KIT, Carburetor Comment: (1 Per Carburetor)
1	3329-857102T4	CARBURETOR Comment: (BOTTOM)
2	10-854246	SCREW
3	854245	PLATE
4	27-8542572	GASKET
5	854254T3	ENRICHENER
6	NSS	NOT SOLD SEPARATE
7	854255	PLATE
8	19-880814	CAP
9	10-880841	SCREW, Adjusting
10	25-880842	O-RING
11	24-880815	SPRING
12	803912	JET (SLOW)
13	25-880843	O-RING
14	19-880844	PLUG
15	98,803915	JET (MAIN)
16	8039142	MAIN NOZZLE
17	854247	VALVE, Float
18	8542531	FLOAT
19	17-8542581	PIN, Float
20	10-880845	SCREW
21	27-8542573	GASKET
22	8039171	FLOAT BOWL Comment: (CENTERS/BOTTOM)
23	10-8542463	SCREW
24	10-8542464	SCREW, Drain
25	12-8542591	WASHER
26	10-803925	SCREW, Synchronization Comment: (TOP/CENTERS)
27	24-880846	SPRING Comment: (TOP/CENTERS)
28	24-803923	SPRING Comment: (TOP/CENTERS)
29	10-803913	SCREW Comment: (BOTTOM)
30	24-854249	SPRING Comment: (BOTTOM)
31	24-880847	SPRING
32	8542511	PLUNGER
33	10-880848	SCREW
34	NSS	NOT SOLD SEPARATE
35	880849	PLUNGER ROD

▶CRANKSHAFT (13 parts)

Ref	OEM Part #	Part Name
-	27-859352A01	GASKET SET
1	413-857077T02	CRANKSHAFT
2	8M0151047	SEAL
3	8M0151048	SEAL
4	600-893530T01	CONNECTING ROD
5	10-8M0049884	BOLT
6	23-893630002	BEARING, Blue
7	700-893524T02	PISTON, w/o Rings Comment: (.50MM Oversized)(Bare Piston)
8	39-893525A03	RING, Piston (TOP) Comment: (.50MM Oversized)
9	NSS	NOT SOLD SEPARATE, Piston (SECOND) Comment: (.50MM Oversized)
10	39-893950	RING, Oil
11	41-893863	PIN, Piston
12	40-825017	RETAINER

▶CYLINDER BLOCK AND CRANKCASE (28 parts)

Ref	OEM Part #	Part Name
-	27-859352A01	GASKET SET
1	800-893502T02	CYLINDER BLOCK
2	17-825010	PIN, Dowel
3	22-479452	PLUG
4	22-384073	PLUG, Pipe (1/2-14)
5	22-416223	PLUG, Pipe (.750-14)
6	23-893631002	BEARING, Blue
7	822625	NIPPLE, (M20)
8	10-82506182	SCREW, (M8 x 82)
9	10-8M0205943	SCREW, (M6 x 35)
10	27-8M0213112	GASKET
11	35-8M0162829	FILTER, Oil
12	27-8M0224375	GASKET
13	8M0188836	COVER, Exhaust
14	22-479452	PLUG
15	14586	THERMOSTAT
16	27-8M0204714	GASKET
17	27-8M0177107	GASKET
18	8M0188835	COVER
19	10-8M0205943	SCREW, (M6 x 35)
20	22-996642	FITTING, Elbow 90 Degree (.125-27 x .250) Nylon
21	54-816311T	TIE STRAP, (8.00 Inches)
22	32-8M0108349	TUBING, (.312) (70.00 Inches Bulk) (Cut to 11 IN.)
23	8M0214984	SENSOR ASSEMBLY, Temperature
24	25-627021	O-RING, (.301 x .070)
25	893697	LIFTING EYE
26	10-857139	SCREW, (M8 x 35)
27	NSS	NOT SOLD SEPARATE

▶CYLINDER HEAD (28 parts)

Ref	OEM Part #	Part Name
-	893505T01	CYLINDER HEAD ASSEMBLY
1	893505T06	CYLINDER HEAD ASSEMBLY
2	858266	GUIDE
3	10-4000325	SCREW, (M6 x 8)
4	12-859768	WASHER
5	26-893549	SEAL, Oil
6	22-875209	PIPE PLUG
7	25-8M0011870	SEAL
8	8M0174400	COVER
9	NSS	NOT SOLD SEPARATE
10	858277	PLATE, Baffle
11	10-4005685	SCREW, (M4 x 10)
12	22-629101	FITTING, Elbow - 90 Degree (.125-27)
13	27-8M0118179	GASKET
14	10-8M0204741	SCREW, (M6 x 20) Stainless Steel
15	10-82503395	SCREW, (M9 x 95)
16	17-825010	PIN, Dowel
17	859578A1	PLUG ASSEMBLY, Oil
18	25-8M0204673	O-RING, (.921 x .139)
19	NSS	NOT SOLD SEPARATE, Decal
20	NSS	NOT SOLD SEPARATE, Decal
21	NSS	NOT SOLD SEPARATE, POWERHEAD ID
22	826060	DIAPHRAGM
23	877844	DASHPOT Comment: (NON HANDLE)
24	10-40011126	SCREW, (M6 x 13) Stainless Steel
25	32-77653101	HOSE, (48.00 Inches Bulk) (Cut to 19 IN.)
26	54-816311T	TIE STRAP, (8.00 Inches)
27	10-893745025	SCREW, (M6 x 25)

▶DRIVESHAFT HOUSING (26 parts)

Ref	OEM Part #	Part Name
1	1503-852421T07	HOUSING, Driveshaft
2	825220T06	PIPE, Exhaust
3	10-824459110	SCREW, (M8 x 110) Stainless Steel
4	10-88960845	SCREW, (M8 x 45)
5	8288181	PLUG, Drain
6	27-8M0204692	GASKET
7	826276	BUMPER
8	8M0151042	GROMMET
9	16-903501	STUD, (M10 x 100) Comment: (BIGFOOT)
10	12-8M0214963	WASHER, (.406 x .750 x .105) Stainless Steel
11	11-40140	NUT, (M10)
12	32-897971A01	TUBE, Water
13	54-828529	GUIDE
14	8M0043364	BUMPER Comment: (LONG)
15	42941001	SEAL, Water Tube
16	893770	PLATE
17	10-1993325	SCREW, (M10 x 25 MM)
18	22-85822A7	SPEEDOMETER PICK UP
19	22-85822T	CONNECTOR, Straight
20	22-8M0181450	FITTING
21	23-813745	SPACER
22	43585	COUPLING
23	23-855623	BUSHING
24	12-45176	WASHER, (.453 x .812 x .105) Stainless Steel
25	11-40140	NUT, (M10)
26	54-816311T	TIE STRAP, (8.00 Inches)

▶ELECTRICAL COMPONENTS (47 parts)

Ref	OEM Part #	Part Name
-	61-893678T03	POWERHEAD ASSEMBLY
1	825096T01	RELAY
2	8M0010250	BRACKET
3	825074	SOLENOID PLATE
4	11-401386	NUT, (M6) Stainless Steel
5	84-88439A9	CABLE ASSEMBLY, Battery - Positive
6	85-880786	BOOT, Insulator - Red
7	84-93388A16	CABLE ASSEMBLY, (8.50 Inches)
8	84-88439A4	CABLE ASSEMBLY, Battery - Negative
9	50-893888T	STARTER MOTOR ASSEMBLY (SEE BREAKDOWN ON STARTER MOTOR)
10	10-40011153	SCREW, (M8 x 45) Stainless Steel
11	87-8M0098207	PRESSURE SWITCH
12	8M0082988	SENSOR
13	10-40011107	SCREW, (M5 x 16) Stainless Steel
14	10-82130025	SCREW, (M6 x 25)
15	12-8M0214930	WASHER
16	859224	PLATE
17	856836001	RETAINER
18	856040	BRACKET
19	10-82129114	SCREW, (M6 x 14)
20	92753	RETAINER
21	23-856954	BUSHING
22	25-8M0190980	GROMMET
23	87843303S	ECM, Engine Control Module
24	23-8539201	BUSHING
25	10-82129140	SCREW, (M6 x 40)
26	33-827858Q	SPARK PLUG, NGK-DPR6EA-9
27	339-859738T1	COIL ASSEMBLY, Ignition
28	NSS	NOT SOLD SEPARATE, Decal Comment: (COIL ID #1)
29	NSS	NOT SOLD SEPARATE, Decal Comment: (COIL ID #2)
30	NSS	NOT SOLD SEPARATE, Decal Comment: (COIL ID #3)
31	NSS	NOT SOLD SEPARATE, Decal Comment: (COIL ID #4)
32	10-82684430	SCREW, (M6 x 30)
33	84-857111T2	HARNESS ASSEMBLY, Engine Wiring
34	88-812619	FUSE, Yellow - 20 Ampere (SFE)
35	828054	COVER, Fuse
36	84-852375A6	HARNESS ASSEMBLY, Extension Comment: (HANDLE)
37	54-816311T	TIE STRAP, (8.00 Inches)
38	883071T1	REGULATOR, Voltage
39	893771	BRACKET
40	8308971	FOAM PAD
41	10-8248329	SCREW, (M6 x 40)
42	10-82129110	SCREW, (M6 x 10)
43	10-8248324	SCREW, (M6 x 16)
44	13541	PLUG, Male
45	10-40011149	SCREW, (M8 x 25) Stainless Steel
46	11-94330	NUT, (.250-20) Brass

▶FLYWHEEL (21 parts)

Ref	OEM Part #	Part Name
-	893505T01	CYLINDER HEAD ASSEMBLY
1	859284T2	FLYWHEEL COVER
2	10-8248326	SCREW, (M6 x 25 MM)
3	37-804655A01	DECAL, EPA Label Information Comment: (SEE NOTE)
4	284-832010T32	FLYWHEEL
5	8331045	GEAR, Driven
6	NSS	NOT SOLD SEPARATE, Decal
7	NSS	NOT SOLD SEPARATE, Decal
8	NSS	NOT SOLD SEPARATE, Decal
9	11-893789	NUT
10	12-893762	WASHER
11	10-4013930	SCREW, (M5 x 30)
12	398-852387T7	STATOR
13	834838	LOAD RING
14	833102T	GEAR, Drive
15	10-82761140	SCREW, (M10 x 40)
16	12-4002320	WASHER
17	28-91800	KEY, Woodruff
18	28-893761	KEY
19	8M0151040	BELT
20	54-816311T	TIE STRAP, (8.00 Inches)

▶FUEL LINES (19 parts)

Ref	OEM Part #	Part Name
1	22-822771	CONNECTOR
2	22-878404	FITTING, 45 Degree
3	22-878593	Y-CONNECTOR
4	54-878425	CLIP
5	32-878181	HOSE
6	32-85682239	TUBING, (17.00 Inches Bulk) (Cut to 3-1/2 IN)
7	32-82381310	HOSE
8	8566101	LINKAGE
9	23-803896	BUSHING
10	18-880850	COTTER PIN
11	12-8542592	WASHER
12	32-856607	HOSE
13	32-856609	HOSE
14	32-856611	HOSE and SLEEVE
15	32-880773	HOSE
16	32-856613	HOSE
17	32-880772	HOSE
18	54-816311T	TIE STRAP, (8.00 Inches)
19	56762	TIE STRAP, (4.00 Inches)

▶FUEL PUMP (24 parts)

Ref	OEM Part #	Part Name
-	27-859352A01	GASKET SET
1	35-877565T1	FILTER, Fuel
2	54-816311T	TIE STRAP, (8.00 Inches)
3	32-8M0108355	HOSE, (57.00 Inches Bulk) (Cut to 14 IN.)
4	32-8M0108355	HOSE, (57.00 Inches Bulk) (Cut to 19 IN.)
5	22-8M0148585	CONNECTOR ASSEMBLY, Fuel
6	826398T3	PUMP, Fuel
7	10-809564	SCREW, (M5 x 35)
8	809565	COVER
9	8095611	DIAPHRAGM
10	10-41889M	SCREW, (M3 x 5)
11	11-82537M	NUT
12	21-41888M	CHECK VALVE
13	8095612	DIAPHRAGM
14	17-8095661	PIN
15	24-809562	SPRING
16	11-82388M	NUT, (M5)
17	24-8095621	SPRING
18	8095631	PLUNGER
19	25-8M0052669	O-RING
20	10-82684430	SCREW, (M6 x 30)
21	19-854310	PLUG
22	54-8M0024808	J CLIP
23	8M0007776	DEFLECTOR, Cowl

▶GEAR HOUSING(DRIVESHAFT)(1.83:1 GEAR RATIO) (37 parts)

Ref	OEM Part #	Part Name
-	46-812966A12	REPAIR KIT, Water Pump
1	1671-9760T42	GEAR HOUSING ASSEMBLY, Basic
2	10-79953Q04	SCREW KIT, (.375-16 x .250) Drain
3	10-79953Q04	SCREW KIT, (.375-16 x .250) Drain
4	12-191833	WASHER
5	17-8M0084244	PIN, Dowel - With Hole (.375 x .625)
6	17-43044	PIN, Dowel - Without Hole (.375 x .625)
7	22-878089	PLUG, Pipe (.0625-27)
8	31-812768	BEARING, Roller
9	818226A1	SEAL/PLATE KIT
10	NSS	NOT SOLD SEPARATE
11	43-859103T	GEAR, Pinion - 12 Teeth
12	11-55910	NUT, (.437-20)
13	859607A1	SHIFT SHAFT ASSEMBLY
14	53-29641	E RING
15	23-813696A2	BUSHING ASSEMBLY
16	25-45258	O-RING, (.987 x .103)
17	26-8M0204708	SEAL, Oil
18	45-859102	DRIVESHAFT, Long
19	15-812770A1	SHIM SET
20	31-8M0166756	BEARING ASSEMBLY, Roller
21	NSS	NOT SOLD SEPARATE
22	11-8128201	NUT
23	46-812966A7	BASE ASSEMBLY, Water Pump
24	25-8M0204651	O-RING, (1.859 x .139)
25	26-814669	SEAL, Oil
26	26-814670	SEAL, Oil
27	47-19453T	IMPELLER
28	28-8M0032831	KEY
29	12-8M0204720	WASHER
30	46-812966A12	PUMP ASSEMBLY, Water
31	27-8M0224241	GASKET (LOWER)
32	27-822189	GASKET, Upper Water Pump
33	19700A2	FACE PLATE
34	10-8248324	SCREW, (M6 x 16)
35	760394	CAM, Shift Control
36	8M0151045	COUPLER

▶GEAR HOUSING(DRIVESHAFT)(2.31:1 GEAR RATIO) (43 parts)

Ref	OEM Part #	Part Name
-	47-8M0100526	REPAIR KIT, Water Pump Impeller
1	1667-9011G59	GEAR HOUSING ASSEMBLY, Basic Comment: (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
12	97-826134Q	ANODE
13	11-401386	NUT, (M6) Stainless Steel
14	10-4000333	SCREW, (M6 x 40)
15	43-44484T	GEAR, Pinion (13 Teeth)
16	11-35921	NUT, (.625-18)
17	850307	CAM, Shift Control
18	31-42677A1	BEARING ASSEMBLY, Tapered Roller
19	15-44492A1	SHIM SET
20	45-859105A1	DRIVESHAFT ASSEMBLY
21	42461A1	SLEEVE/RING KIT
22	NSS	NOT SOLD SEPARATE
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	10-8M0214957	SCREW, (M6 x 30)
32	8M0204658	SEAL
33	28-8M0204723	KEY
34	47-43026T2	IMPELLER
35	10-8248326	SCREW, (M6 x 25 MM)
36	853906A1	SHIFT SHAFT ASSEMBLY
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	10-8248326	SCREW, (M6 x 25 MM)
42	26-861415	FACE SEAL

▶GEAR HOUSING(PROP SHAFT)(1.83:1 GEAR RATIO) (33 parts)

Ref	OEM Part #	Part Name
-	26-814669A2	SEAL KIT, Gear Housing
1	1671-9760T42	GEAR HOUSING ASSEMBLY, Basic
37	15-812769A1	SHIM SET
38	31-8M0103476	BEARING ASSEMBLY, Tapered Roller
39	NSS	NOT SOLD SEPARATE
40	43-859101T2	GEAR, Forward - 22 Teeth
41	31-21739	BEARING, Roller
42	8129291	FOLLOWER, Cam
43	20843	SLIDE
44	24-38114	SPRING
45	52-813697T	CLUTCH
46	17-8M0020942	PIN, Cross
47	24-815418	SPRING
48	44-14493	PROPELLER SHAFT
49	43-859104T	GEAR, Reverse - 22 Teeth
50	30-20839T	BEARING, Ball
51	8M0168900	CARRIER ASSEMBLY, Bearing
52	25-815460	O-RING
53	31-21700	BEARING, Needle
54	26-8M0205511	SEAL, Oil
55	26-8M0203757	SEAL, Oil
56	10-85594030	SCREW, (M8 x 30)
57	12-855941	WASHER, (.323 x .590 x .112) Stainless Steel
58	8227731	INSERT, Threaded
59	NSS	NOT SOLD SEPARATE
60	17264T2	TRIM TAB, Zinc
61	10-4000377	SCREW, (M10 x 30)
62	12-8M0214963	WASHER, (.406 x .750 x .105) Stainless Steel
63	73345A1	THRUST HUB
64	11-69578Q1	PROP NUT KIT
65	14-8M0214942	TAB WASHER
66	12-8M0214963	WASHER, (.406 x .750 x .105) Stainless Steel
67	10-4000380	SCREW, (M10 x 45)

▶GEAR HOUSING(PROP SHAFT)(2.31:1 GEAR RATIO) (36 parts)

Ref	OEM Part #	Part Name
-	26-43035A4	SEAL KIT, Gear Housing
1	1667-9011G59	GEAR HOUSING ASSEMBLY, Basic
2	31-30894A1	BEARING SET, Cup And Cone
3	NSS	NOT SOLD SEPARATE
4	43-859472A3	GEAR ASSEMBLY, Forward - 30 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
10	24-850327	SPRING
11	52-850048T	CLUTCH
12	17-8M0100263	PIN, Cross
13	24-30893	SPRING
14	44-8M0140445	PROPELLER SHAFT
15	43-850034T	GEAR, Reverse (30 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
30	NSS	NOT SOLD SEPARATE, Decal
31	13191Q01	THRUST WASHER
32	11-52707Q1	PROP NUT KIT, (.750-16)
33	14-816629Q	TAB WASHER
34	10-4000380	SCREW, (M10 x 45)
35	12-8M0214963	WASHER, (.406 x .750 x .105) Stainless Steel

▶INTAKE (19 parts)

Ref	OEM Part #	Part Name
-	27-859352A01	GASKET SET
1	10-82615890	SCREW, (M6 x 90)
2	857105T	INTAKE, Air
3	25-8250572	O-RING
4	857103T	PLATE
5	857104T1	ISOLATOR Comment: (40/50 HP)
6	19-827633	PLUG
7	857106A1	ATTENUATOR KIT, Sound Comment: (USE W/TAPERED BUSHING)
8	23-856954	BUSHING Comment: (TAPERED)
9	10-8M0204741	SCREW, (M6 x 20) Stainless Steel
10	54-850181	TIE STRAP, (11.750 Inches)
11	26-856128001	SEAL
12	25-8250572	O-RING
13	25-856525	O-RING
14	17-23784	PIN, Dowel
15	10-8248326	SCREW, (M6 x 25 MM)
16	32-8M0182223	BREATHER HOSE
17	54-816311T	TIE STRAP, (8.00 Inches)
18	37-881865	DECAL, Caution, Start In Gear

▶INTAKE/EXHAUST VALVE (19 parts)

Ref	OEM Part #	Part Name
-	893505T01	CYLINDER HEAD ASSEMBLY
1	8M0065029	VALVE, Exhaust
2	832990T3	VALVE, Intake
3	26-858271	SEAL
4	24-893552	SPRING, Valve - Outer
5	822650	RETAINER
6	28-893554	KEY
7	898821A01	ROCKER ARM
8	10-825046	SCREW
9	11-826150	NUT
10	8570851	SHAFT, Rocker
11	NSS	NOT SOLD SEPARATE
12	893560	BRACKET
13	893561	BRACKET
14	24-893562	SPRING
15	10-875218	SCREW, (M8 x 23)
16	27-893645	GASKET
17	17-859575	PIN
18	24-893563	SPRING, Overload

▶LINKAGE(HANDLE) (32 parts)

Ref	OEM Part #	Part Name
1	10-40011158	SCREW, (M8 x 70) Stainless Steel
2	10-8147763	SCREW, (M6 x 60)
3	11-401196	NUT, (M6)
4	42942	CAP
5	822682A4	LEVER ASSEMBLY, Throttle
6	23-825078	BUSHING
7	10-8248326	SCREW, (M6 x 25 MM)
8	858245	SHIFT GUIDE
9	10-82239312	SCREW, (M5 x 12)
10	858246	SHIFT SLIDE
11	12016A2	DETENT/SPRING KIT
12	NSS	NOT SOLD SEPARATE
13	858247	SHIFT ROD
14	18-210711	COTTER PIN
15	11-401386	NUT, (M6) Stainless Steel
16	12-8M0204649	WASHER, (.281 x .500 x .060) Stainless Steel
17	858248	SHIFT LINK
18	23-48475	BUSHING
19	850166T2	LEVER ASSEMBLY, Shift Shaft
20	23-850165	BUSHING
21	8535853	CAM, Throttle
22	23-309772	SPACER
23	12-4002314	WASHER
24	10-40056107	SCREW, (M5 x 16)
25	87-8M0052927	SWITCH
26	824923	PLATE
27	10-88075020	SCREW, (M3.5 x 20) Stainless Steel
28	830294T1	BRACKET Comment: (HANDLE)
29	877844	DASHPOT Comment: (NON-HANDLE)
30	10-40011126	SCREW, (M6 x 13) Stainless Steel
31	822682A4	LEVER, Throttle
32	826587	RETAINER

▶LINKAGE(REMOTE) (29 parts)

Ref	OEM Part #	Part Name
1	10-40011158	SCREW, (M8 x 70) Stainless Steel
2	10-8147763	SCREW, (M6 x 60)
3	11-401196	NUT, (M6)
4	42942	CAP Comment: (50/60)
5	822682A4	LEVER ASSEMBLY, Throttle
6	883160	RETAINER
7	23-825078	BUSHING
8	822459	RETAINER
9	8259571	LEVER, Shift
10	827706A4	BRACKET
11	98889	LATCH
12	10-8248324	SCREW, (M6 x 16)
13	23-15885	SLEEVE
14	893777	SHIFT ROD
15	8501631	GUIDE, Shift Rod
16	893769A01	SHIFT LINK
17	23-48475	BUSHING
18	12-8M0204649	WASHER, (.281 x .500 x .060) Stainless Steel
19	11-401386	NUT, (M6) Stainless Steel
20	18-210711	COTTER PIN
21	850166T2	LEVER ASSEMBLY, Shift Shaft
22	23-850165	BUSHING
23	8535853	CAM, Throttle
24	23-309772	SPACER
25	12-4002314	WASHER
26	10-40056107	SCREW, (M5 x 16)
27	881283F	SPACER, Throttle Stop Comment: (40)
28	822682A4	LEVER, Throttle
29	826587	RETAINER

▶POWER TRIM (27 parts)

Ref	OEM Part #	Part Name
-	84-826802T18	HARNESS/RELAY ASSEMBLY, Trim
1	893943A01	SHOCK ROD KIT
2	8M0171822	PISTON ASSEMBLY, Memory
3	25-8M0171819	O-RING KIT, Rebuild
4	NSS	NOT SOLD SEPARATE
5	893904T01	CYLINDER ASSEMBLY
6	893944A01	VALVE KIT, Trim Limit Comment: (BIGFOOT)
7	893906A02	PUMP ASSEMBLY
8	893907A02	MOTOR KIT
9	22-8134351	PLUG
10	893929A01	MANUAL RELEASE ASSEMBLY
11	893909A02	MANIFOLD KIT
12	10-809876A1	SCREW KIT (MOTOR)
13	809877A1	DRIVESHAFT/SEAL KIT
14	35-893912A02	FILTER KIT
15	893913A02	POPPET KIT
16	88238A18	CABLE ASSEMBLY
17	17-821539	PIN, Trilobe
18	17-19607	PIN
19	17-822869001	PIN
20	84-826802T17	HARNESS ASSEMBLY, Trim
21	8M0207773	RELAY ASSEMBLY
22	828102	BRACKET
23	25-818967	GROMMET
24	23-8M0214955	BUSHING
25	NSS	NOT SOLD SEPARATE
26	10-82684430	SCREW, (M6 x 30)

▶SERVICE/SUPPORT MATERIAL (1 parts)

Ref	OEM Part #	Part Name
-	37-804655A02	DECAL, EPA Label Information Comment: (SEE NOTE)

▶STARTER MOTOR (11 parts)

Ref	OEM Part #	Part Name
1	50-893888T	STARTER MOTOR ASSEMBLY
2	15384	THRU BOLT
3	891752	DRIVE KIT
4	8236386	ARMATURE
5	68575T2	PINION
6	8236392	DRIVE CAP
7	8119013	CAP, Commutator
8	898265016	BRUSH/SPRING KIT
9	898265014	HOLDER
10	F15158	SCREW
11	37-8272822	DECAL, Warning, High Voltage

▶STEERING ARM (30 parts)

Ref	OEM Part #	Part Name
1	11-896963	NUT, (M12)
2	893773002	STRAP Comment: (DESIGN III)(THICK STRAP)
3	8M0224385	MOUNT
4	10-8M0204741	SCREW, (M6 x 20) Stainless Steel
5	8M0156878	BUMPER
6	53-89531	RING, Retaining
7	8M0118183	ARM, Steering
8	816667F1	BRACKET Comment: (NON-HANDLE)
9	14-8M0009820	TAB WASHER Comment: (NON-HANDLE)
10	10-4000377	SCREW, (M10 x 30) Comment: (NON-HANDLE)
11	10-898835001	BOLT, (M12 x 154)
12	23-8279971	SPACER
13	8M0219909	SWIVEL TUBE
14	84-88238T01	CABLE ASSEMBLY
15	8M0207768	CABLE ASSEMBLY, Ground
16	10-823567105	SCREW, (M10 x 105) Hex Flange - Stainless Steel
17	893703	BRACKET
18	10-878607	SCREW, (#10-16 x .375) Comment: (SELF-TAPPING)
19	11-8M0204726	NUT, (.375-24) Stainless Steel Comment: (HANDLE)
20	823792	LEVER Comment: (HANDLE)
21	12-29330	WASHER Comment: (HANDLE)
22	821961	ROD (THREADED) Comment: (HANDLE)
23	821957	BRAKE PLATE Comment: (HANDLE)
24	8165621	DISC Comment: (HANDLE)
25	8M0007471	PLATE Comment: (HANDLE)
26	8165621	DISC Comment: (HANDLE)
27	10-768042	SHOULDER SCREW, Hex Comment: (HANDLE)
28	12-4002321	WASHER, (12.80 mm x 24.0 mm x 2.4 mm) Stainless Steel Comment: (DESIGN I)
29	893773002	STRAP Comment: (Qty. of 1 used on DESIGN I)
30	12-20959	WASHER Comment: (DESIGN II)

▶SWIVEL BRACKET (16 parts)

Ref	OEM Part #	Part Name
1	19608A14	ATTACHING KIT, Engine Steering Comment: (ELECTRIC NON HANDLE)
2	10-823919	SCREW, (.375-24 x 1.500) Comment: (ELECTRIC NON HANDLE)
3	12-8M0109680	WASHER, (.390 x .546 x .12) Comment: (ELECTRIC NON HANDLE)
4	12-37828	WASHER, (.390 x .625 x .062) Stainless Steel Comment: (ELECTRIC NON HANDLE)
5	11-8M0204726	NUT, (.375-24) Stainless Steel Comment: (ELECTRIC NON HANDLE)
6	822397	PUCK Comment: (ELECTRIC NON HANDLE)
7	23-8217711	BUSHING
8	1401-850066T01	SWIVEL BRACKET
9	23-19606	BEARING
10	22-8M0169589	FITTING, Grease Comment: (QTY. OF 3 REQUIRED ON HANDLE VERSIONS)
11	37-8237011	DECAL, Co-Pilot Comment: (HANDLE)
12	NSS	NOT SOLD SEPARATE, Decal
13	23-821777	BUSHING (LOWER)
14	26-8M0205512	SEAL
15	10-40011149	SCREW, (M8 x 25) Stainless Steel Comment: (NON-HANDLE)
16	8282451	SEAL Comment: (NON-HANDLE)

▶TILLER HANDLE (38 parts)

Ref	OEM Part #	Part Name
1	822148T06	COVER KIT
2	822150	PULLEY
3	NSS	NOT SOLD SEPARATE
4	10-878608	SCREW, (#10-16 x .500) Comment: (SELF TAPPING)
5	4324210	CABLE ASSEMBLY, Throttle (30.50 Inches)
6	4324211	CABLE ASSEMBLY, Throttle (41.50 Inches)
7	85-960099	SLEEVE, (12.00 Inches)
8	10-82526225	SCREW, (M8 x 25 MM)
9	8M0072298	COVER
10	23-821477	BUSHING
11	828813T1	ARM, Steering Handle
12	822441	RETAINER
13	10-40011107	SCREW, (M5 x 16) Stainless Steel
14	10-8M0204707	SCREW, (M6 x 25)
15	892995	LOCK, Throttle
16	24-96203	SPRING
17	821972T	KNOB, Throttle
18	8M0138696	TILLER TUBE
19	37-8242004	DECAL
20	821465	HANDLE, Throttle
21	8M0221732	GRIP
22	87-8M0104614	SWITCH, Stop
23	823687	CLIP
24	87-11083A31	SWITCH, Stop
25	8M0032846	RETAINER, Brass
26	821455A4	BRACKET, Tiller
27	13-826792	WAVE WASHER
28	23-821477	BUSHING
29	12-827314	WASHER
30	32-828547633	CONDUIT, (.620 Inside Diameter x 3.00 Feet Bulk)
31	54-816311T	TIE STRAP, (8.00 Inches)
32	37-82409316	DECAL, F-N-R Shift
33	15920Q54	LANYARD ASSEMBLY
34	10-40011151	SCREW, (M8 x 35) Stainless Steel
35	830180A01	HANDLE
36	23-830181	BUSHING
37	14-8M0009820	TAB WASHER
38	10-82484890	SCREW, (M10 x 90)

▶TOOLS (71 parts)

Ref	OEM Part #	Part Name
-	91-8M0053505	INDICATOR TOOL, Backlash (2.31:1 GEAR RATIO)
1	44357Q2	FLUSHING ATTACHMENT
2	802889Q1	PUMP, Crankcase Oil
3	91-802653Q02	WRENCH, Oil Filter
4	91-8M0161873	HOLDER TOOL, Flywheel
5	91-83164M	FLYWHEEL PULLER
6	91-99379	TIMING LIGHT
7	91-890451	ADAPTOR TOOL, Direct Voltage
8	91-854009A3	TACH MULTI METER, DMT 2000 Digital
9	91-823686A2	DIGITAL DIAGNOSTIC TESTER
10	91-8226086	CARTRIDGE
11	84-822560A7	HARNESS ASSEMBLY, Adaptor
12	84-822560A10	HARNESS ASSEMBLY, Adaptor
13	91-36392	GAUGE TOOL, Carburetor
14	91-809495001	REMOVER TOOL, Valve Guide
15	91-809496A1	INSTALLER TOOL, Valve Guide Bushing
16	91-809497A1	REAMER TOOL, Valve Guide
17	91-809494A1	COMPRESSOR TOOL, Valve Spring
18	NSS	NOT SOLD SEPARATE
19	FT2997	COMPRESSOR TOOL, Piston Ring
20	92-8M0071838	ANTI-CORROSION GREASE, 8 oz
21	91-24697	EXPANDER TOOL, Piston Ring
22	91-74951	SPANNER WRENCH
23	91-822778A3	DOWN PRESSURE KIT
24	91-63209	HEAT LAMP
25	91-877321A1	INSTALLATION TOOL, Bearing
26	91-804063	CLAMP TOOL, Tubing
27	NSS	NOT SOLD SEPARATE (P/N-CG-41-11)
28	NSS	NOT SOLD SEPARATE (P/N -CG-41-14)
29	11-24156	NUT, (.625-18)
30	12-34961	WASHER
31	91-29310	PLATE
32	91-31229	SHAFT
33	91-36571T	WRENCH TOOL, Driveshaft Bearing
34	91-37323	DRIVER ROD TOOL, Needle Bearings
35	91-15755T	MANDREL
36	91-36569T	DRIVE HEAD TOOL
37	91-27780	PULLER
38	91-37241	PULLER PLATE
39	91-37312T	DRIVER HEAD TOOL
40	91-817011T	INSTALLER TOOL, Needle Bearing
41	84-825003A1	CABLE ASSEMBLY, DDT, 10FT.
42	91-8098712	VACUUMMATE, Carburetor
43	91-817007T	INSTALLER TOOL, Seal
44	91-43506T	RETAINING TOOL, Bearing
45	91-817005	INSTALLER TOOL, Bearing
46	91-817006	INSTALLER TOOL, Water Pump Base Seal
47	91-817008A2	LOCATION TOOL, Pinion Gear
48	91-817009T	DRIVER TOOL, Bearing Cup
49	91-12349A05	LOCATION TOOL, Pinion
50	91-13945	INSTALLATION TOOL, Bearing
51	91-13949	DRIVER TOOL, Oil Seal
52	91-14308T02	RACE TOOL, Bearing
53	91-14309T02	INSTALLATION TOOL, Bearing
54	91-14310T1	WEAR SLEEVE INSTALLATION TOOL
55	91-14311A04	PRE LOAD TOOL, Bearing
56	91-196601	INDICATOR TOOL, Backlash
57	91-31106T	MANDREL, Bearing Driver Cup
58	91-31108T	DRIVER, Oil Seal
59	91-34569A1	PULLER ASSEMBLY, Slide Hammer
60	91-46086A1	PULLER JAW ASSEMBLY
61	91-37350T	MANDREL
62	91-817070	HOLDING TOOL, Driveshaft
63	91-58222A1	DIAL INDICATOR TOOL
64	91-85716	PULLER TOOL
65	91-83155	ADAPTER KIT, Dial Indicator
66	91-83165T	PULLER ASSEMBLY
67	91-856875A1	INSTALLATION TOOL, Bearing
68	91-817057A02	BACKLASH INDICATOR TOOL
69	91-817058A1	DRIVER TOOL, Bearing
70	91-877840A1	HOLDING TOOL, Driveshaft

▶TRANSOM BRACKET (33 parts)

Ref	OEM Part #	Part Name
1	3418-822866T04	BRACKET ASSEMBLY, Transom Comment: (PORT)
2	22-8M0169588	FITTING, Grease
3	17-99604	PIN, Groove
4	3418-822865T05	BRACKET, Transom Comment: (STARBOARD)
5	893704T01	LEVER ASSEMBLY, Tilt Lock
6	24-99622	SPRING
7	23-65830	NYLINER
8	24-812708	SPRING
9	812709	KNOB
10	17-99615	PIN, Groove
11	12-19619	WASHER
12	18486F5	BRACKET, Anchor
13	97-818298Q1	ANODE KIT
14	10-8M0204707	SCREW, (M6 x 25)
15	12-8M0204649	WASHER, (.281 x .500 x .060) Stainless Steel
16	10-4000354	SCREW, (M8 x 30) Comment: (30 MM)
17	10-4000355	SCREW, (M8 x 35) Comment: (35 MM)
18	13-400257	LOCKWASHER, (M8)
19	11-401388	NUT, (M8) Stainless Steel
20	8M0041938	TILT TUBE
21	11-858869	NUT, (.875-14)
22	19624A1	SEAL KIT Comment: (NON-HANDLE)
23	25-29619	O-RING, (.583 x .103) Comment: (NON-HANDLE)
24	23-78861	SPACER Comment: (NON-HANDLE)
25	54-22740	CLIP
26	8M0084613	C WASHER
27	10-878609	SCREW, (#10-16 x .600)
28	10-814259	SCREW, (.500-20 x 4.00)
29	12-8M0204648	WASHER, (1.5 x 3.05 x 0.13) Stainless Steel
30	11-82671117	NUT, (.500-20)
31	10-4009040	SCREW, (M10 x 40) Stainless Steel
32	12-4002319	WASHER
33	11-40140	NUT, (M10)

▶TRIM SWITCH KIT (8 parts)

Ref	OEM Part #	Part Name
-	87-18286A18	SWITCH KIT, Trim (10.00 Feet)
1	18861	RETAINER
2	814820	ADAPTOR
3	NSS	NOT SOLD SEPARATE
4	88-8M0207796	FUSE, 20 Ampere
5	84-95084A2	CABLE ASSEMBLY
6	84-11149A2	CABLE ASSEMBLY, (6.00 Inches)
7	10-813523	SCREW, (#10-16 x 2.25)

▶Top Cowl (16 parts)

Ref	OEM Part #	Part Name
1	4019-825239T4	TOP COWL ASSEMBLY Comment: (SILVER)
2	NSS	NOT SOLD SEPARATE
3	826291F1	LATCH Comment: (SILVER)
4	10-8231871	SCREW, (M4 x 14.5)
5	8,13-26995	LOCKWASHER, Stainless Steel
6	11-8237515	NUT, (M4)
7	8M0153618	SEAL
8	825243A03	SOUND BLANKET KIT
9	NSS	NOT SOLD SEPARATE
10	893763	BRACKET ASSEMBLY, Latch Roller
11	10-4006731	SCREW, (M6 x 16)
12	8M0038412	BRACKET
13	10-8231871	SCREW, (M4 x 14.5)
14	8,13-26995	LOCKWASHER, Stainless Steel
15	11-8237515	NUT, (M4)
16	47341A11	ROPE AND HANDLE KIT, Manual Starting

100-Hour / Annual Service Checklist

Regular maintenance keeps your Mercury 40 (4-STROKE)(4 CYL.) running reliably season after season. Most of these tasks can be performed with basic tools and the factory service manual.

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

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

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