Mercury 40 (4-STROKE) (0G760300 THRU 0T408999) Parts & Diagrams

OEM and aftermarket replacement parts for Mercury 40 (4-STROKE). Scroll down for exploded parts diagrams (37), specifications, and maintenance reference.

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Carburetor Repair Kit – Fits Yamaha/Mercury/Mariner 25HP - 40HP 4 - Stroke Outboards - JLM Marine Boat Parts Limited
Kit de reparación de carburador para Yamaha 25 HP 4 tiempos 65W-W0093-11
$17.58
$23.00
$17.58
files/19CR009-1.jpgDefault Title
$17.58
Lower Unit Seal Kit – Fits Mercury/Mariner Outboard 30 - 125 HP (Replaces 26 - 43035A4) - JLM Marine Boat Parts Limited
Kit de sellos de caja de engranajes de unidad inferior para motor fueraborda Mercury Mariner de 30 a 125 HP 26-43035A4
$37.99
$37.99
files/Lower_Unit_Gearcase_Seal_Kit_for_Mercury_Mariner_Outboard_30-125_HP_Motor__26-43035A4_-_JLM_MARINE-8287879.webpDefault Title
$37.99
jlm marine water pump impeller kit for mercury 25-50hp 821354a2 black impeller with bronze insert and six rubber blades
Kit de impulsor de bomba de agua para Mercury 25/30/40/45/50 HP 821354A2
$25.50
$25.50
files/Water_Pump_Impeller_Kit_for_Mercury_25_-_30_-_40_-_45_-_50_HP_821354A2_-_JLM_MARINE-8290152.jpgDefault Title
$25.50
jlm marine water pump impeller kit for mercury 35-300 hp 47-43026q06 black six-bladed rubber impeller with splined hub and assorted gaskets and seals
Kit de impulsor de bomba de agua para Mercury 35-300 HP 47-43026Q06
$31.00
$36.00
$31.00
files/Water_Pump_Impeller_Kit_for_Mercury_35-300_HP_47-43026Q06_-_JLM_MARINE-8286357.jpgDefault Title
$31.00
magnetic oil plug 8m0058389 jlm marine for mercury mariner outboard mercruiser sterndrive stainless steel with yellow gasket
Tapón de aceite magnético de unidad inferior para motores fueraborda Mercury Mariner y MerCruiser Sterndrive 8M0058389
$18.39
$18.39
files/Lower_Unit_Magnetic_Oil_Plug_for_Mercury_Mariner_Outboard_and_MerCruiser_Sterndrive___8M0058389_-_JLM_MARINE-8287063.jpgDefault Title
$18.39
Inline Fuel Filter – Fits Mercury & Mariner 25-90HP 4-Stroke Outboards (Replaces 35-877565T1, 35-877565T)
Inline Fuel Filter – Fits Mercury & Mariner 25-90HP 4-Stroke Outboards (Replaces 35-877565T1, 35-877565T)
$18.99
$18.99
files/23FF051_1.jpgDefault Title
$18.99
Water Pump Impeller Kit – Fits Mercury/Mercruiser Alpha 1 Gen 2 Drives & Outboards (Replaces 47 - 43026Q06) - JLM Marine Boat Parts Limited
Kit de impulsor de bomba de agua para motor fueraborda Mercury/MerCruiser Alpha 1 Gen 2 Sterndrive 43026Q06
$30.00
$41.00
$30.00
files/Water_Pump_Impeller_Kit_for_Mercury_Outboard-MerCruiser_Alpha_1_Gen_2_Sterndrive_____43026Q06_-_JLM_MARINE-8288063.jpgDefault Title
$30.00
photo of JLM Marine water pump impeller kit 821354a2, black impeller with six flexible blades and brass hub, silver metal plate with hexagonal outer shape, and two black gaskets
Kit de impulsor de bomba de agua para Mercury 25-50 HP 821354A2
$35.68
$38.00
$35.68
files/Water_Pump_Impeller_Kit_for_Mercury_25-50_HP__821354A2_-_JLM_MARINE-8286336.jpgDefault Title
$35.68
8H033307 Service Kit for Honda BF115 BF130 | JLM Marine
8H033307 Service Kit for Honda BF115 BF130 | JLM Marine
$33.80
$33.80
files/kit-25KH301.pngDefault Title
$33.80
11-52707Q1 Propeller Nut Tab Washer Kit for Mercury Force | JLM Marine
11-52707Q1 Propeller Nut Tab Washer Kit for Mercury Force | JLM Marine
$17.96
$17.96
files/12_1f442b5b-5eb3-4dbd-87cf-30a2bbe49863.jpgDefault Title
$17.96
Boot Protector 822158 for Mercury 25 - 50HP Outboard – Fits Mercury 25 - 50HP 4 - Stroke (Replaces 822158) - JLM Marine Boat Parts Limited
Boot Protector 822158 for Mercury 25-50HP Outboard – Fits Mercury 25-50HP 4-Stroke (Replaces 822158)
$21.55
$21.55
files/23BS362_fe73e243-1883-4544-9f82-c205d467431f.jpgDefault Title
$21.55
Thermostat (60°C/140°F) – Fits Honda, Mercury, Yamaha 8 - 255 HP (Replaces 19300 - ZY3 - 023, 19300 - ZW9 - 003) - JLM Marine Boat Parts Limited
Termostato para Honda 8-255HP Mercury 15-90HP Yamaha 9.9-70HP 3852215
$21.49
$21.49
files/Thermostat_for_Honda_8-255HP_Mercury_15-90HP_Yamaha_99-70HP_3852215_-_JLM_MARINE-8290872.jpgDefault Title
$21.49
06211-ZY9-505 Maintenance Kit for Honda BF75D BF90D | JLM Marine
06211-ZY9-505 Maintenance Kit for Honda BF75D BF90D | JLM Marine
$76.50
$76.50
files/kit-23KH759-4N.pngDefault Title
$76.50
Gearcase Drain Plug – Fits Mercury/MerCruiser Marine Engines (Replaces 10 - 79953Q04, 79953Q04) - JLM Marine Boat Parts Limited
Tapón de aceite no magnético de unidad inferior para motores fueraborda Mercury Mariner y MerCruiser Sterndrive 79953Q04
$21.50
$21.50
files/Lower_Unit_Non-Magnetic_Oil_Plug_for_Mercury_Mariner_Outboard_and_MerCruiser_Sterndrive_______79953Q04_-_JLM_MARINE-8287053.jpgDefault Title
$21.50
Water Pump Impeller – Fits Mercury/Mariner 15 - 50 HP (Replaces 47 - 8508910, 0755466) - JLM Marine Boat Parts Limited
Impulsor de bomba de agua para Mercury 15-50 HP 18-3057
$16.50
$16.50
files/Water_Pump_Impeller_for_Mercury_15-50_HP__18-3057_-_JLM_MARINE-8288073.jpgDefault Title
$16.50
Water Pump Impeller – Fits Mercury/Mariner 15 - 50 HP (Replaces 47 - 8508910) - JLM Marine Boat Parts Limited
Impulsor de bomba de agua para Mercury 15-50 HP 47-8508910 / 0755466
$16.50
$16.50
files/Water_Pump_Impeller_for_Mercury_15-50_HP_47-8508910_-_0755466_-_JLM_MARINE-8289726.jpgDefault Title
$16.50
Water Pump Impeller Kit – Fits Honda 70–90 HP Outboard Motors (Replaces 47 - 43026Q02, 19210 - ZW1 - 003) - JLM Marine Boat Parts Limited
Impulsor de bomba de agua para Honda 30-250 HP 18-3056
$21.50
$21.50
files/Water_Pump_Impeller_for_Honda_30-250_HP___18-3056_-_JLM_MARINE-8288262.jpgDefault Title
$21.50
photo jlm marine water pump impeller for mercury mariner honda 40-300 hp 47-43026t2 black six-blade star-shaped rubber impeller with central grey-lined opening
Impulsor de bomba de agua para Mercury/Mariner/Honda KIT DE BOMBA DE AGUA 40-300 HP 47-43026T2
$15.49
$15.49
files/Water_Pump_Impeller_for_Mercury-Mariner-Honda_WATER_PUMP_KIT_40-300_HP_47-43026T2_-_JLM_MARINE-8289750.jpgDefault Title
$15.49
8M0251133 Water Pump Impeller Kit for Mercury 30HP 40HP | JLM Marine
8M0251133 Water Pump Impeller Kit for Mercury 30HP 40HP | JLM Marine
$68.50
$68.50
files/kit-25KM356_fbc9f2e9-5011-4090-9d93-304e5964e85b.pngDefault Title
$68.50
8M0251122 Service Kit for Mercury 15HP 18HP | JLM Marine
8M0251122 Service Kit for Mercury 15HP 18HP | JLM Marine
$68.50
$68.50
files/kit-25KM264-2N_e09c2dfe-14ab-45b2-8d92-06840cdc018a.pngDefault Title
$68.50

Mercury 40 (4-STROKE) (0G760300 THRU 0T408999) Parts & Diagrams

🔎 Mercury 40 (4-STROKE) Reference Library — Exploded parts diagrams (37 diagrams), specifications, common issues, and maintenance checklist.

The Mercury 40 (4-STROKE) 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):

  • 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).

▶Accessories (1 parts) Accessories
Ref OEM Part # Part Name
- 821455A22 TILLER HANDLE KIT, Electric Start Comment: (NON-BIGFOOT)
▶Adaptor Plate (29 parts) Adaptor Plate
Ref OEM Part # Part Name
1 8M0162935 DIPSTICK
2 825989003 DIPSTICK TUBE Comment: SN# 0T178499 & Below
3 825989003 DIPSTICK TUBE Comment: SN# 0T178500 & Up
4 8560552 SEAL
5 825228A24 ADAPTOR PLATE Comment: SN# 0T178499 & Below
6 17-23784 PIN, Dowel Comment: SN# 0T178499 & Below
7 8289151 HEAT SHIELD
8 825228A17 ADAPTOR PLATE Comment: SN# 0T178500 & Up
9 19-822464 PLUG
10 10-4007455 SCREW, (M6 x 55) Comment: SN# 0T178500 & Up
11 54-855228 CLAMP
12 17-23784 PIN, Dowel
13 22-629101 FITTING, Elbow - 90 Degree (.125-27)
14 54-816311T TIE STRAP, (8.00 Inches)
15 26-16977 SEAL, Oil Comment: (BIGFOOT)
16 23-856743 BUSHING Comment: (NON-BIGFOOT)
17 22-384073 PLUG, Pipe
18 25-822408001 GROMMET Comment: (NON-BIGFOOT)
19 27-8M0213113 GASKET
20 25-845746 O-RING
21 10-8M0204741 SCREW, (M6 x 20) Stainless Steel
22 856592 DEFLECTOR, Oil
23 8M0210772 BODY ASSEMBLY, Oil Pressure Relief
24 18-45882 COTTER PIN
25 8252151 PLUNGER
26 24-825216 SPRING
27 893765 PLATE, Oil Pickup-Top
28 32-854793 HOSE, Oil Pickup
29 893700 BAFFLE
▶Bottom Cowl (21 parts) Bottom Cowl
Ref OEM Part # Part Name
1 4020-826277T1 BOTTOM COWL Comment: (LONG-PORT)
2 4020-826278T7 BOTTOM COWL Comment: (LONG-STARBOARD)
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 Comment: (SPLIT - POWER TRIM)
18 812830T01 PLUG Comment: (NON POWER TRIM)
19 87-8M0235191 SWITCH, Trim Comment: (POWER TRIM - DESIGN II)
20 87-8M0042301 SWITCH ASSEMBLY Comment: (POWER TRIM - DESIGN I)
21 8M0032848 RETAINER Comment: (NON POWER TRIM)
▶Camshaft/Oil Pump (14 parts) Camshaft/Oil Pump
Ref OEM Part # Part Name
- 27-825231A99 GASKET SET, Engine
1 10-82761140 SCREW, (M10 x 40)
2 12-4002319 WASHER
3 8M0151040 BELT
4 833104T6 GEAR, Driven
5 17-825956 PIN, Dowel
6 400-8M0183249 CAMSHAFT Comment: (MANUAL)
7 402-834781T1 CAMSHAFT Comment: (ELECTRIC)
8 17-826149 PIN
9 825058A1 PUMP ASSEMBLY, Oil
10 25-826152 O-RING
11 25-826154 O-RING
12 25-826153 O-RING
13 10-4000333 SCREW, (M6 x 40)
▶Carburetor(0T178499 and Below) (30 parts) Carburetor(0T178499 and Below)
Ref OEM Part # Part Name
- 854256 REPAIR KIT, Carburetor
1 3329-830276T12 CARBURETOR Comment: (BOTTOM)
2 10-854246 SCREW
3 854245 PLATE
4 NSS NOT SOLD SEPARATE, Gasket
5 854254T ENRICHENER
6 NSS NOT SOLD SEPARATE, O Ring
7 854255 PLATE
8 803919 IDLE JET
9 803912 JET
10 19-854248 PLUG, Rubber
11 803915 JET
12 854247 VALVE, Float
13 803914 MAIN NOZZLE
14 854253 FLOAT
15 NSS NOT SOLD SEPARATE, Float Pin
16 NSS NOT SOLD SEPARATE, Gasket
17 803917 FLOAT BOWL Comment: (CENTER/BOTTOM)
18 10-8542463 SCREW
19 10-8542462 SCREW, Drain
20 NSS NOT SOLD SEPARATE, Washer
21 10-803913 SCREW Comment: (BOTTOM)
22 24-803923 SPRING Comment: (TOP/CENTER)
23 24-803924 SPRING Comment: (TOP/CENTER)
24 24-854249 SPRING Comment: (BOTTOM)
25 NSS NOT SOLD SEPARATE, Spring
26 854251 PLUNGER
27 NSS NOT SOLD SEPARATE, Rubber Bellows
28 NSS NOT SOLD SEPARATE, Screw-Plunger Retaining
29 NSS NOT SOLD SEPARATE, Plunger Rod
▶Carburetor(0T178500 and Up) (36 parts) Carburetor(0T178500 and Up)
Ref OEM Part # Part Name
- 8542561 REPAIR KIT, Carburetor
1 3329-830276T33 CARBURETOR Comment: (Bottom)
2 10-854246 SCREW
3 854245 PLATE
4 27-8542572 GASKET
5 854254T2 ENRICHENER
6 NSS NOT SOLD SEPARATE, O Ring
7 854255 PLATE
8 19-880814 CAP
9 10-880841 SCREW, Adjusting
10 25-880842 O-RING
11 24-880815 SPRING
12 80391242 JET, Pilot
13 25-880843 O-RING
14 19-880844 PLUG
15 80391595 JET, Main
16 8039143 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: (Center/Bottom)
23 10-8542463 SCREW
24 10-8542464 SCREW, Drain
25 12-8542591 WASHER
26 10-803925 SCREW, Synchronization Comment: (Top/Center)
27 24-880846 SPRING Comment: (Top/Center)
28 24-803923 SPRING Comment: (Top/Center)
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, Rubber Bellows
35 880849 PLUNGER ROD
▶Crankshaft, Piston and Connecting Rods (16 parts) Crankshaft, Piston and Connecting Rods
Ref OEM Part # Part Name
- 61-803016T01 POWERHEAD ASSEMBLY Comment: (BIGFOOT)
1 401-834774T2 CRANKSHAFT Comment: (BIGFOOT)
2 28-893761 KEY
3 28-91800 KEY, Woodruff
4 8M0151047 SEAL
5 8M0151048 SEAL
6 600-893530T01 CONNECTING ROD
7 10-8M0049884 BOLT
8 23-893630002 BEARING, Blue
9 700-893524T02 PISTON Comment: (.50 O/S)(BARE PISTON)
10 39-893525A03 RING, Piston (TOP) Comment: (.50MM O/S)
11 39-893525A03 RING, Piston (Second) Comment: (.50MM O/S)
12 39-893950 RING, Oil
13 41-893863 PIN, Piston
14 40-825017 RETAINER
15 833102T GEAR, Drive
▶Cylinder Block (31 parts) Cylinder Block
Ref OEM Part # Part Name
- 61-803016T01 POWERHEAD ASSEMBLY Comment: (BIGFOOT)
1 800-893500T02 CYLINDER BLOCK Comment: (BIGFOOT)
2 17-825010 PIN, Dowel
3 22-479452 PLUG
4 22-384073 PLUG, Pipe (1/2-14)
5 22-416223 PIPE PLUG (3/4-14)
6 23-893631002 BEARING, Blue Comment: (BLUE)
7 822625 NIPPLE, (M20)
8 10-82506182 SCREW, (M8 x 82)
9 10-8M0205943 SCREW, (M6 x 35)
10 27-8M0213112 GASKET
11 35-8M0162830 FILTER ASSEMBLY, Oil
12 27-8M4500244 GASKET
13 8M0183025 COVER, Exhaust
14 22-479452 PLUG
15 855676003 THERMOSTAT
16 27-8M0177107 GASKET
17 8M0188835 COVER
18 10-8M0205943 SCREW, (M6 x 35)
19 22-996642 FITTING, Elbow 90 Degree (.125-27 x .250) Nylon
20 54-816311T TIE STRAP, (8.00 Inches)
21 32-8M0108349 TUBING, (28.00 Inches Bulk) (Cut to 11 Inches)
22 8M0214984 SENSOR ASSEMBLY, Temperature
23 25-627021 O-RING, (.301 x .070)
24 893697 LIFTING EYE
25 10-857139 SCREW, (M8 x 35)
26 NSS NOT SOLD SEPARATE, Plug-Serial Number
27 32-77653101 HOSE, (48.00 Inches Bulk) (Cut to 18 Inches) Comment: SN# 0T178499 & Below
28 882831 BRACKET, Trim Relay Comment: (Power Trim) SN# 0T294232 & Up
29 10-8248324 SCREW, (M6 x 16) Comment: (Power Trim) SN# 0T294232 & Up
30 10-82129130 SCREW, (M6 x 30) Comment: (Power Trim) SN# 0T294232 & Up
▶Cylinder Head (32 parts) Cylinder Head
Ref OEM Part # Part Name
- 61-803016T01 POWERHEAD ASSEMBLY Comment: (BIGFOOT)
1 834778T2 CYLINDER HEAD
2 8M0054272 GUIDE
3 53-825038 CIRCLIP
4 826887M ANODE
5 25-825040 GROMMET
6 826888M COVER
7 10-8M0204741 SCREW, (M6 x 20) Stainless Steel
8 10-827607 BOLT
9 27-827610 GASKET
10 10-84088M SCREW, (M6 x 10)
11 27-827610 GASKET
12 26-825048 SEAL, Oil
13 22-822644 PIPE PLUG
14 25-8M0162934 O-RING
15 8M0174399 COVER
16 NSS NOT SOLD SEPARATE, Decal-Servicing Referral
17 NSS NOT SOLD SEPARATE, Decal-Engine Oil/Valve Clearance
18 27-8M0118180 GASKET
19 10-8M0204741 SCREW, (M6 x 20) Stainless Steel
20 10-893745025 SCREW, (M6 x 25)
21 10-82503395 SCREW, (M9 x 95)
22 17-825010 PIN, Dowel
23 859578A1 PLUG ASSEMBLY, Oil
24 NSS NOT SOLD SEPARATE, O Ring
25 855236 PLATE, Baffle
26 10-4005785 SCREW, (M4 x 10)
27 22-629101 FITTING, Elbow - 90 Degree (.125-27)
28 22-825054 BREATHER PIPE
29 830294T1 BRACKET Comment: (HANDLE)
30 10-40011126 SCREW, (M6 x 13) Stainless Steel Comment: (HANDLE)
31 54-8M0024808 J CLIP Comment: (USE WHERE APPLICABLE)
▶Driveshaft Housing (26 parts) Driveshaft Housing
Ref OEM Part # Part Name
1 42941001 SEAL, Water Tube
2 3532-825218T5 HOUSING ASSEMBLY, Driveshaft Comment: (Long) SN# 0T178499 & Below
3 825220T06 PIPE, Exhaust Comment: (LONG)
4 10-824459110 SCREW, (M8 x 110) Stainless Steel
5 10-88960845 SCREW, (M8 x 45) (M8 X 45)
6 8288181 PLUG, Drain
7 27-8M0204692 GASKET
8 826276 BUMPER
9 8M0151042 GROMMET Comment: (LONG)
10 16-903501 STUD, (M10 x 100) Comment: (BIGFOOT)
11 12-8M0214963 WASHER, (.406 x .750 x .105) Stainless Steel
12 11-40140 NUT, (M10)
13 32-897971A01 TUBE, Water Comment: (LONG)
14 54-828529 GUIDE
15 8M0043364 BUMPER Comment: (LONG)
16 1503-852421T3 HOUSING ASSEMBLY, Driveshaft Comment: (Bigfoot) SN# 0T178499 & Below
17 893770 PLATE Comment: (BIGFOOT)
18 10-1993325 SCREW, (M10 x 25 MM) Comment: (BIGFOOT)
19 22-85822A7 SPEEDOMETER PICK UP Comment: (BIGFOOT)
20 22-85822T CONNECTOR, Straight Comment: (BIGFOOT)
21 22-8M0181450 FITTING Comment: (BIGFOOT)
22 23-813745 SPACER Comment: (BIGFOOT)
23 43585 COUPLING Comment: (BIGFOOT)
24 23-855623 BUSHING Comment: (BIGFOOT)
25 12-45176 WASHER, (.453 x .812 x .105) Stainless Steel Comment: (BIGFOOT)
26 54-816311T TIE STRAP, (8.00 Inches) Comment: (BIGFOOT)
▶Electrical Components(0G960499 and Below) (44 parts) Electrical Components(0G960499 and Below)
Ref OEM Part # Part Name
- 61-803016T01 POWERHEAD ASSEMBLY Comment: (BIGFOOT)
1 89-8M0185146 SOLENOID ASSEMBLY Comment: (ELECTRIC)
2 23-8M0214955 BUSHING Comment: (ELECTRIC)
3 25-818967 GROMMET Comment: (ELECTRIC)
4 8-32,11-26419 NUT, Brass Comment: (ELECTRIC)
5 11-94330 NUT, (.250-20) Brass Comment: (ELECTRIC)
6 84-88439A9 CABLE ASSEMBLY, Battery - Positive Comment: (ELECTRIC)
7 85-79695T BOOT, Insulator - Black Comment: (ELECTRIC)
8 84-93388A13 CABLE ASSEMBLY Comment: (ELECTRIC)
9 84-88439A4 CABLE ASSEMBLY, Battery - Negative Comment: (ELECTRIC)
10 50-893887T STARTER MOTOR ASSEMBLY Comment: (ELECTRIC)
11 10-40011149 SCREW, (M8 x 25) Stainless Steel Comment: (MANUAL)
12 10-8248324 SCREW, (M6 x 16) Comment: (MANUAL)
13 54-8M0024808 J CLIP Comment: (ELECTRIC)
14 87-8M0098207 PRESSURE SWITCH
15 8M0082988 SENSOR
16 10-40011107 SCREW, (M5 x 16) Stainless Steel
17 10-82130025 SCREW, (M6 x 25)
18 12-65567 WASHER, (.265 x .750 x .048) Stainless Steel
19 859224 PLATE
20 23-822003 BUSHING
21 25-8M0190980 GROMMET
22 87843302S ECM, Engine Control Module
23 23-8539201 BUSHING
24 10-82129140 SCREW, (M6 x 40)
25 33-827858Q SPARK PLUG, NGK-DPR6EA-9
26 NSS NOT SOLD SEPARATE, Decal-Coil Identification
27 339-830404T3 COIL, Ignition
28 10-8M0204741 SCREW, (M6 x 20) Stainless Steel
29 84-854781A2 HARNESS ASSEMBLY, Engine Wiring Comment: (ELECTRIC)
30 88-812619 FUSE, Yellow - 20 Ampere Comment: (ELECTRIC)
31 828054 COVER, Fuse Comment: (ELECTRIC)
32 8261151 CLAMP, Connector Comment: (ELECTRIC)
33 10-8248324 SCREW, (M6 x 16) Comment: (ELECTRIC)
34 84-852375A6 HARNESS ASSEMBLY, Extension Comment: (ELECTRIC HANDLE)
35 54-816311T TIE STRAP, (8.00 Inches)
36 54-47483 J CLIP Comment: (MANUAL)
37 883071T REGULATOR, Voltage Comment: (ELECTRIC)
38 54-8M0024808 J CLIP Comment: (ELECTRIC)
39 10-8248324 SCREW, (M6 x 16) Comment: (MANUAL)
40 10-82129110 SCREW, (M6 x 10) Comment: (ELECTRIC)
41 13541 PLUG, Male Comment: (Quantity of 2 on Manual)
42 10-8248324 SCREW, (M6 x 16)
43 84-858884A1 CABLE ASSEMBLY
▶Electrical Components(0G960500 and Up) (48 parts) Electrical Components(0G960500 and Up)
Ref OEM Part # Part Name
- 61-803016T01 POWERHEAD ASSEMBLY Comment: (BIGFOOT)
1 89-8M0185146 SOLENOID ASSEMBLY Comment: (ELECTRIC)
2 23-8M0214955 BUSHING Comment: (ELECTRIC)
3 25-818967 GROMMET Comment: (ELECTRIC)
4 8-32,11-26419 NUT, Brass Comment: (ELECTRIC)
5 11-94330 NUT, (.250-20) Brass Comment: (ELECTRIC)
6 84-88439A9 CABLE ASSEMBLY, Battery - Positive Comment: (ELECTRIC)
7 85-8500671 BOOT, Insulator - Red Comment: (ELECTRIC)
8 84-93388A13 CABLE ASSEMBLY Comment: (ELECTRIC)
9 84-88439A4 CABLE ASSEMBLY, Battery - Negative Comment: (ELECTRIC)
10 50-893887T STARTER MOTOR ASSEMBLY Comment: (ELECTRIC)
11 10-40011149 SCREW, (M8 x 25) Stainless Steel Comment: (MANUAL)
12 10-8248324 SCREW, (M6 x 16) Comment: (MANUAL)
13 87-8M0098207 PRESSURE SWITCH
14 8M0082988 SENSOR
15 10-40011107 SCREW, (M5 x 16) Stainless Steel
16 10-82130025 SCREW, (M6 x 25)
17 12-8M0214930 WASHER
18 859224 PLATE
19 856836001 RETAINER Comment: (ELECTRIC)
20 856040 BRACKET Comment: (ELECTRIC)
21 10-82129114 SCREW, (M6 x 14) Comment: (ELECTRIC)
22 92753 RETAINER Comment: (ELECTRIC)(Quantity of 2 on Handle)
23 23-856954 BUSHING
24 25-8M0190980 GROMMET
25 87843302S ECM, Engine Control Module Comment: SN# 0T178499 & Below
26 23-8539201 BUSHING
27 10-82129140 SCREW, (M6 x 40)
28 33-827858Q SPARK PLUG, NGK-DPR6EA-9
29 339-858942T1 COIL ASSEMBLY, Ignition
30 10-8M0204741 SCREW, (M6 x 20) Stainless Steel
31 84-859196T1 HARNESS ASSEMBLY, Engine Wiring Comment: (MANUAL)
32 84-859197T1 HARNESS ASSEMBLY, Engine Wiring Comment: (ELECTRIC) SN# 0T178499 & Below
33 88-812619 FUSE, Yellow - 20 Ampere Comment: (ELECTRIC)
34 828054 COVER, Fuse Comment: (ELECTRIC)
35 84-852375A6 HARNESS ASSEMBLY, Extension Comment: (ELECTRIC HANDLE)
36 54-816311T TIE STRAP, (8.00 Inches)
37 54-8M0024808 J CLIP Comment: (MANUAL)
38 883071T1 REGULATOR, Voltage Comment: (ELECTRIC)
39 893771 BRACKET Comment: (ELECTRIC)
40 8308971 FOAM PAD Comment: (ELECTRIC)
41 10-8248324 SCREW, (M6 x 16) Comment: (MANUAL)
42 10-82129110 SCREW, (M6 x 10) Comment: (ELECTRIC)
43 13541 PLUG, Male Comment: (MALE)
44 84-877860T1 CABLE ASSEMBLY Comment: (Use where Applicable)
45 10-8248324 SCREW, (M6 x 16)
46 54-8M0024808 J CLIP Comment: (ELECTRIC-NON POWER TRIM)
47 10-8248324 SCREW, (M6 x 16) Comment: (ELECTRIC-NON POWER TRIM)
▶Flywheel (13 parts) Flywheel
Ref OEM Part # Part Name
1 859284T2 FLYWHEEL COVER Comment: (ELECTRIC)
2 10-8248326 SCREW, (M6 x 25 MM) Comment: (ELECTRIC)
3 37-804654A01 DECAL, EPA Label Information Comment: (ELECTRIC)(2001)
4 284-832010T32 FLYWHEEL Comment: (ELECTRIC)
5 284-832010T27 FLYWHEEL Comment: (MANUAL)
6 NSS NOT SOLD SEPARATE, Decal-Warning Spinning Flywheel
7 NSS NOT SOLD SEPARATE, Decal-Timing Marks
8 NSS NOT SOLD SEPARATE, Decal-Warning-Neutral
9 11-893789 NUT
10 12-893762 WASHER
11 10-4013930 SCREW, (M5 x 30) Comment: (Electric) SN# 0G960500 & Up
12 398-852386T8 STATOR Comment: (Manual) SN# 0G960499 & Below
13 834838 LOAD RING
▶Fuel Lines (17 parts) Fuel Lines
Ref OEM Part # Part Name
1 32-856607 HOSE
2 32-856609 HOSE
3 856610 LINKAGE
4 23-803896 BUSHING
5 823548T TIE STRAP
6 32-856613 HOSE
7 32-856611 HOSE and SLEEVE
8 22-822771 CONNECTOR
9 22-878404 FITTING, 45 Degree Comment: SN# 0T178500 & Up
10 32-878423 HOSE Comment: SN# 0T178500 & Up
11 32-85682239 TUBING, (17.00 Inches Bulk) (Cut to 3-1/2 Inches) Comment: SN# 0T178500 & Up
12 32-82381310 HOSE (90MM) Comment: SN# 0T178500 & Up
13 54-878425 CLIP Comment: SN# 0T178500 & Up
14 56762 TIE STRAP, (4.00 Inches)
15 12-8542592 WASHER
16 18-880850 COTTER PIN
17 22-878593 Y-CONNECTOR Comment: SN# 0T178500 & Up
▶Fuel Pump (24 parts) Fuel Pump
Ref OEM Part # Part Name
- 27-825231A99 GASKET SET, Engine
1 35-877565T1 FILTER, Fuel
2 54-816311T TIE STRAP, (8.00 Inches)
3 32-8M0108355 HOSE, (57.00 Inches Bulk) (Cut to 14 Inches)
4 32-8M0108355 HOSE, (57.00 Inches Bulk) (Cut to 19 Inches)
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-2.31:1 Gear Ratio) (43 parts) Gear Housing(Driveshaft-2.31:1 Gear Ratio)
Ref OEM Part # Part Name
- 47-8M0100526 REPAIR KIT, Water Pump Impeller
1 1667-9011G59 GEAR HOUSING ASSEMBLY, Basic
2 17-8M0084244 PIN, Dowel - With Hole (.375 x .625) (FRONT)
3 43046 TUBE, Oiler
4 22-8M0058389 FITTING KIT, Magnetic, Plug Fill/Drain
5 12-191833 WASHER, Fiber
6 17-43044 PIN, Dowel - Without Hole (.375 x .625) (REAR)
7 31640T07 TRIM TAB
8 10-825427 SCREW, (.437-14 x 1.250) Stainless Steel
9 12-451761 WASHER, (.453 x .812 x .105) Black Oxide
10 43040T1 CARRIER ASSEMBLY
11 NSS NOT SOLD SEPARATE, Needle Bearing
12 97-826134Q ANODE
13 11-401386 NUT, (M6)
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 45-854808A1 DRIVESHAFT ASSEMBLY
21 42461A1 SLEEVE/RING KIT
22 NSS NOT SOLD SEPARATE, Ring Seal
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(Driveshaft-2:1 Gear Ratio) (39 parts) Gear Housing(Driveshaft-2:1 Gear Ratio)
Ref OEM Part # Part Name
- 821354A2 REPAIR KIT, Water Pump
1 1682-821306T12 GEAR HOUSING ASSEMBLY, Basic Comment: (BASIC)
2 818226A1 SEAL/PLATE KIT
3 NSS NOT SOLD SEPARATE, Plate
4 10-79953Q04 SCREW KIT, (.375-16 x .250) (.375-16 X .25)
5 12-191833 WASHER, Fiber
6 22-8M0058389 FITTING KIT, Magnetic, Plug Fill/Drain Comment: (MAGNETIC)
7 12-191833 WASHER, Fiber
8 11-55910 NUT, (.437-20)
9 43-821326T1 GEAR, Pinion - 13 Teeth
10 31-821321A2 BEARING ASSEMBLY
11 NSS NOT SOLD SEPARATE, Cup
12 10-8248324 SCREW, (M6 x 16)
13 46-821351A3 HOUSING ASSEMBLY, Water Pump Upper
14 8235471 SEAL Comment: (LONG - 2-1/4)
15 12-866451 WASHER
16 28-8M0214993 KEY
17 12-866451 WASHER
18 27-822189 GASKET, Upper Water Pump
19 27-8M0214956 GASKET, Lower Water Pump (LOWER)
20 8213542 FACE PLATE
21 47-8M0204712 IMPELLER
22 46-821307A2 BASE ASSEMBLY, Water Pump
23 26-821309 SEAL
24 26-821310 SEAL
25 25-821308 O-RING, (1.421 x .139)
26 45-826194A1 DRIVESHAFT Comment: (LONG)
27 30-821311 BEARING, Ball
28 823548T TIE STRAP
29 822158 BOOT
30 821827 RETAINER
31 25-26855 O-RING, (1.609 x .139)
32 25-85594 O-RING, (.239 x .174)
33 12-814803 WASHER
34 827865A1 SHIFT SHAFT Comment: (LONG)
35 12-8M0204649 WASHER, (.281 x .500 x .060) Stainless Steel
36 17-85593 PIN, (.078 x .437)
37 8213161 CAM, Shift
38 17-822369 PIN, (.125 x .625)
▶Gear Housing(Prop Shaft - 2.31:1 - S/N-0T625303 and below) (36 parts) Gear Housing(Prop Shaft - 2.31:1 - S/N-0T625303 and below)
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, Cup
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, Slide
10 24-850327 SPRING
11 52-850048T CLUTCH
12 17-8M0100263 PIN, Cross
13 24-30893 SPRING
14 44-8M0140445 PROPELLER SHAFT
15 43-850034T 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-Prop Operation
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
▶Gear Housing, Propeller Shaft - 2:1 Gear Ratio (37 parts) Gear Housing, Propeller Shaft - 2:1 Gear Ratio
Ref OEM Part # Part Name
- 823547A2 SEAL KIT
1 1682-821306T12 GEAR HOUSING ASSEMBLY, Basic Comment: (BASIC)
39 17-821327 PIN, Dowel
40 27-823942 GASKET
41 32-8M0026108 TUBE
42 19-824928001 PLUG, Rubber
43 821829 SCREEN
44 822157T2 TRIM TAB
45 10-82497020 SCREW, (M8 x 20)
46 12-72397 WASHER
47 43-821315T1 GEAR ASSEMBLY, Forward - 26 Teeth
48 31-8M0103470 BEARING ASSEMBLY, Roller
49 NSS NOT SOLD SEPARATE, Cup
50 31-41326 BEARING, Roller
51 821578 FOLLOWER, Cam
52 24-8261991 SPRING
53 17-8M0020999 PIN
54 52-821314T CLUTCH
55 24-38114 SPRING
56 44-8M0140441 PROPELLER SHAFT
57 43-821312T1 GEAR, Reverse - 26 Teeth
58 30-20839T BEARING, Ball
59 8M0168900 CARRIER ASSEMBLY, Bearing
60 25-815460 O-RING
61 31-21700 BEARING, Needle
62 26-8M0205511 SEAL, Oil
63 26-8M0203757 SEAL, Oil
64 12-855941 WASHER, (.323 x .590 x .112) Stainless Steel
65 10-85594030 SCREW, (M8 x 30)
66 8227731 INSERT, Threaded
67 NSS NOT SOLD SEPARATE, Decal (2:1)
68 73345A1 THRUST HUB
69 11-69578Q1 PROP NUT KIT
70 14-8M0214942 TAB WASHER
71 10-4000380 SCREW, (M10 x 45)
72 12-8M0214963 WASHER, (.406 x .750 x .105) Stainless Steel
73 19-95925 PLUG
▶Intake (17 parts) Intake
Ref OEM Part # Part Name
- 27-825231A99 GASKET SET, Engine
1 10-82615890 SCREW, (M6 x 90)
2 856126T INTAKE, Air
3 25-856525 O-RING
4 834783T PLATE
5 834784T1 ISOLATOR Comment: (30)
6 19-827633 PLUG
7 856127A2 ATTENUATOR, Sound
8 10-8M0204741 SCREW, (M6 x 20) Stainless Steel
9 23-17044M BUSHING
10 54-850181 TIE STRAP, (11.750 Inches)
11 26-856128001 SEAL
12 25-8250572 O-RING
13 17-23784 PIN, Dowel
14 10-8248326 SCREW, (M6 x 25 MM)
15 32-8M0182223 BREATHER HOSE
16 54-816311T TIE STRAP, (8.00 Inches)
▶Intake/Exhaust Valves (18 parts) Intake/Exhaust Valves
Ref OEM Part # Part Name
- 27-825231A99 GASKET SET, Engine
1 8M0119204 VALVE, Exhaust
2 832990T1 VALVE, Intake
3 12-825044 WASHER, Valve Spring
4 26-822647 SEAL, Valve Stem
5 24-823678 SPRING, Valve Outer
6 822650 RETAINER
7 28-893554 KEY
8 898821A01 ROCKER ARM
9 10-825046 SCREW
10 11-826150 NUT
11 834780T1 SHAFT, Rocker
12 19-825042 PLUG
13 825050 BRACKET
14 825051 PLATE
15 24-825052 SPRING
16 24-854713 SPRING
17 10-82641030 SCREW, (M8 x 30)
▶Linkage(Electric Bigfoot) (28 parts) Linkage(Electric Bigfoot)
Ref OEM Part # Part Name
1 10-40011158 SCREW, (M8 x 70) Stainless Steel
2 10-814776 SCREW, Adjusting (M6 x 55)
3 11-401196 NUT, (M6)
4 42942 CAP
5 822682A4 LEVER ASSEMBLY, Throttle Comment: (DESIGN II)
6 883160 RETAINER Comment: (DESIGN II)
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)
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 822682A4 LEVER, Throttle Comment: (DESIGN I)
28 826587 RETAINER Comment: (DESIGN I)
▶Linkage(Manual Bigfoot-0G960499 and Below) (28 parts) Linkage(Manual Bigfoot-0G960499 and Below)
Ref OEM Part # Part Name
1 10-40011158 SCREW, (M8 x 70) Stainless Steel
2 10-814776 SCREW, Adjusting (M6 x 55)
3 11-401196 NUT, (M6)
4 42942 CAP
5 826587 RETAINER
6 822682A4 LEVER, Throttle
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 8501631 GUIDE, Shift Rod
15 893769A01 SHIFT LINK
16 23-48475 BUSHING
17 12-8M0204649 WASHER, (.281 x .500 x .060) Stainless Steel
18 11-401386 NUT, (M6)
19 18-210711 COTTER PIN
20 850166T2 LEVER ASSEMBLY, Shift Shaft
21 23-850165 BUSHING
22 8535853 CAM, Throttle
23 23-309772 SPACER
24 12-4002314 WASHER
25 10-40056107 SCREW, (M5 x 16)
26 854467 ROD
27 12016A2 DETENT/SPRING KIT
28 NSS NOT SOLD SEPARATE, Spring
▶Linkage(Manual Bigfoot-0G960500 and Up) (24 parts) Linkage(Manual Bigfoot-0G960500 and Up)
Ref OEM Part # Part Name
1 10-40011158 SCREW, (M8 x 70) Stainless Steel
2 10-814776 SCREW, Adjusting (M6 x 55)
3 11-401196 NUT, (M6)
4 42942 CAP
5 822682A4 LEVER ASSEMBLY, Throttle Comment: (DESIGN II)
6 10-8248326 SCREW, (M6 x 25 MM)
7 858245 SHIFT GUIDE
8 10-82239312 SCREW, (M5 x 12)
9 858246 SHIFT SLIDE
10 12016A2 DETENT/SPRING KIT
11 NSS NOT SOLD SEPARATE, Spring
12 858247 SHIFT ROD
13 18-210711 COTTER PIN
14 11-401386 NUT, (M6)
15 12-8M0204649 WASHER, (.281 x .500 x .060) Stainless Steel
16 858248 SHIFT LINK
17 23-48475 BUSHING
18 850166T2 LEVER ASSEMBLY, Shift Shaft
19 23-850165 BUSHING
20 8535853 CAM, Throttle
21 23-309772 SPACER
22 12-4002314 WASHER
23 10-40056107 SCREW, (M5 x 16)
24 822682A4 LEVER, Throttle Comment: (DESIGN I)
▶Linkage(Non Bigfoot) (34 parts) Linkage(Non Bigfoot)
Ref OEM Part # Part Name
1 10-40011158 SCREW, (M8 x 70) Stainless Steel
2 10-814776 SCREW, Adjusting (M6 x 55) Comment: (30 HP)
3 11-401196 NUT, (M6) Comment: (30 HP)
4 23-823807 BUSHING Comment: (30 HP)
5 10-814776 SCREW, Adjusting (M6 x 55) Comment: (40 HP)
6 11-401196 NUT, (M6) Comment: (40 HP)
7 42942 CAP Comment: (40 HP)
8 822682A4 LEVER ASSEMBLY, Throttle Comment: (DESIGN II)
9 883160 RETAINER Comment: (ELECTRIC)(DESIGN II)
10 23-825078 BUSHING
11 822459 RETAINER Comment: (NON HANDLE)
12 8259571 LEVER, Shift Comment: (NON HANDLE)
13 827706A4 BRACKET Comment: (NON HANDLE)
14 98889 LATCH Comment: (NON HANDLE)
15 10-8248324 SCREW, (M6 x 16) Comment: (NON HANDLE)
16 23-15885 SLEEVE Comment: (NON HANDLE)
17 882820 SHIFT ROD Comment: (NON HANDLE)
18 8535853 CAM, Throttle
19 23-309772 SPACER
20 12-4002314 WASHER
21 10-40056107 SCREW, (M5 x 16)
22 826588A4 SHIFT SHAFT ASSEMBLY, Horizontal
23 8277071 RETAINER
24 12-8M0204649 WASHER, (.281 x .500 x .060) Stainless Steel
25 18-210711 COTTER PIN
26 24-826077 SPRING, Detent
27 24-824993 SPRING, Backing
28 824994 SPRING, Plate
29 10-40011107 SCREW, (M5 x 16) Stainless Steel
30 87-8M0052927 SWITCH Comment: (ELECTRIC HANDLE MODELS)
31 10-88075020 SCREW, (M3.5 x 20) Stainless Steel Comment: (ELECTRIC HANDLE MODELS)
32 824923 PLATE Comment: (ELECTRIC HANDLE MODELS)
33 822682A4 LEVER, Throttle Comment: (DESIGN I)
34 826587 RETAINER Comment: (DESIGN I)
▶Manual Starter (33 parts) Manual Starter
Ref OEM Part # Part Name
- 835253A13 STARTER ASSEMBLY, Recoil
1 835253A12 HOUSING ASSEMBLY, Recoil
2 8167122 CAM
3 24-8267911 SPRING
4 8M0026455 SEAL
5 835256T ROLLER
6 23-852987T BUSHING
7 826414T WASHER
8 10-82684430 SCREW, (M6 x 30)
9 13-826229 LOCKWASHER
10 24-86857T01 SPRING
11 50-854317T5 SHEAVE ASSEMBLY, Starter
12 868501 CAM
13 24-86851T02 SPRING
14 53-86849T01 RING, Retaining
15 24-868523 SPRING
16 86853T01 CAM
17 10-826253 SCREW, (.250-20 x .625)
18 50-12066Q10 ROPE
19 856073 LEVER, Interlock
20 856072T RETAINER
21 24-856138T03 SPRING
22 854779T BUSHING
23 10-8182491 SCREW, (#10-16 x 1.00)
24 85174A1 HANDLE ASSEMBLY
25 NSS NOT SOLD SEPARATE
26 10-8248326 SCREW, (M6 x 25 MM)
27 856754 CABLE, Interlock
28 10-8214281 SCREW, (#10-16 x .625)
29 12-73288 WASHER, (.220 x .500 x .030) Stainless Steel
30 18-26811 COTTER PIN
31 10-40011107 SCREW, (M5 x 16) Stainless Steel
32 37-804654A01 DECAL, EPA Label Information Comment: (2001)
▶Manual Tilt (15 parts) Manual Tilt
Ref OEM Part # Part Name
- 25-893922A01 O-RING KIT
1 8M0118572 SHOCK ROD ASSEMBLY
2 893903A01 PISTON ASSEMBLY, Trim Memory
3 25-893917A01 O-RING KIT, Cylinder
4 NSS NOT SOLD SEPARATE, O Ring
5 893918A01 CYLINDER ASSEMBLY
6 893919A01 SCREW AND SEAL KIT
7 893920A01 ACCUMULATOR ASSEMBLY
8 893921A01 VALVE BODY ASSEMBLY
9 893923A01 CAM KIT
10 893924A01 VALVE KIT, Velocity
11 893925A01 REPAIR KIT
12 8M0207768 CABLE ASSEMBLY, Ground
13 17-19607 PIN
14 17-821539 PIN, Trilobe
▶Power Trim (27 parts) Power Trim
Ref OEM Part # Part Name
- 84-826802A15 HARNESS/RELAY ASSEMBLY Comment: SN# 0T178499 & Below
1 893943A01 SHOCK ROD KIT
2 8M0171822 PISTON ASSEMBLY, Memory
3 25-8M0171819 O-RING KIT, Rebuild
4 NSS NOT SOLD SEPARATE, O Ring
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 84-826802A12 HARNESS ASSEMBLY Comment: SN# 0T178499 & Below
21 8M0207773 RELAY ASSEMBLY
22 828102 BRACKET
23 25-818967 GROMMET
24 23-8M0214955 BUSHING
25 NSS NOT SOLD SEPARATE, Decal-Trim Relay
26 10-82684430 SCREW, (M6 x 30) Comment: SN# 0T294064 & Below
▶Service and Support Material (1 parts) Service and Support Material
Ref OEM Part # Part Name
0 37-804654A01 DECAL, EPA Label Information Comment: (2001)
▶Starter Motor (12 parts) Starter Motor
Ref OEM Part # Part Name
1 50-893887T STARTER MOTOR ASSEMBLY Comment: (RETAINING RING DESIGN)
2 10-965661 THRU BOLT
3 891752 DRIVE KIT Comment: (NUT DESIGN)
4 803945 DRIVE KIT Comment: (RETAINING RING DESIGN)
5 8236384 ARMATURE Comment: (NUT DESIGN)
6 68575T2 PINION
7 8236392 DRIVE CAP
8 8119011 CAP, Commutator
9 898265016 BRUSH/SPRING KIT
10 898265014 HOLDER
11 F15158 SCREW
12 37-8272822 DECAL, Warning, High Voltage
▶Steering Arm (30 parts) Steering Arm
Ref OEM Part # Part Name
1 11-896963 NUT, (M12)
2 893773002 STRAP
3 8M0224385 MOUNT
4 12-4002321 WASHER, (12.80 mm x 24.0 mm x 2.4 mm) Stainless Steel Comment: (BIGFOOT)
5 10-8M0204741 SCREW, (M6 x 20) Stainless Steel
6 8M0156878 BUMPER
7 8M0156878 BUMPER Comment: (BIGFOOT)
8 53-89531 RING, Retaining
9 8M0118183 ARM, Steering
10 8M0184092 BRACKET Comment: (ELECTRIC)
11 14-8M0009820 TAB WASHER Comment: (ELECTRIC)
12 10-4000377 SCREW, (M10 x 30) Comment: (ELECTRIC)
13 10-898835001 BOLT, (M12 x 154)
14 23-8279971 SPACER Comment: (LONG)
15 893590T01 SWIVEL TUBE Comment: (LONG)
16 84-88238T01 CABLE ASSEMBLY
17 8M0207768 CABLE ASSEMBLY, Ground
18 10-823567105 SCREW, (M10 x 105) Hex Flange - Stainless Steel
19 893703 BRACKET
20 10-878607 SCREW, (#10-16 x .380)
21 11-40140 NUT, (M10)
22 11-8M0204726 NUT, (.375-24) Comment: (HANDLE)
23 823792 LEVER Comment: (HANDLE)
24 12-29330 WASHER Comment: (HANDLE)
25 821961 ROD (THREADED) Comment: (HANDLE)
26 821957 BRAKE PLATE Comment: (HANDLE)
27 8165621 DISC Comment: (HANDLE)
28 8M0007471 PLATE Comment: (HANDLE)
29 8165621 DISC Comment: (HANDLE)
30 10-768042 SHOULDER SCREW, Hex Comment: (HANDLE)
▶Swivel Bracket (16 parts) Swivel Bracket
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
12 NSS NOT SOLD SEPARATE, Decal-Serail Overlaminate
13 23-821777 BUSHING (LOWER)
14 26-8M0205512 SEAL
15 10-40011149 SCREW, (M8 x 25) Stainless Steel Comment: (ELECTRIC)
16 8282451 SEAL Comment: (ELECTRIC)
▶Tiller Handle (43 parts) Tiller Handle
Ref OEM Part # Part Name
- 37-8M0032728 DECAL, Lanyard, Black
1 822148T06 COVER KIT
2 822150 PULLEY
3 NSS NOT SOLD SEPARATE, Case
4 10-878608 SCREW, (#10-16 x .500)
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 Comment: (MANUAL)
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 10-82239312 SCREW, (M5 x 12) Comment: (MANUAL)
24 12-8M0214930 WASHER Comment: (MANUAL)
25 84-8M0088388 ALARM Comment: (MANUAL)
26 823687 CLIP
27 87-11083A31 SWITCH, Stop
28 8M0032846 RETAINER, Brass
29 821455A4 BRACKET, Tiller
30 13-826792 WAVE WASHER
31 23-821477 BUSHING
32 12-827314 WASHER
33 32-828547633 CONDUIT, (.620 Inside Diameter x 3.00 Feet Bulk)
34 54-816311T TIE STRAP, (8.00 Inches)
35 NSS NOT SOLD SEPARATE, Decal-Shift (F-N-R)
36 15920Q54 LANYARD ASSEMBLY
37 10-40011151 SCREW, (M8 x 35) Stainless Steel
38 830180A01 HANDLE
39 23-830181 BUSHING
40 8301821 SHIFT ROD
41 14-8M0009820 TAB WASHER
42 10-82484890 SCREW, (M10 x 90)
▶Tools (68 parts) Tools
Ref OEM Part # Part Name
- 91-31229A7 PULLER KIT, Bearing
1 44357Q2 FLUSHING ATTACHMENT
2 802889Q1 PUMP ASSEMBLY, 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
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, Valve Seat Cutter Kit Comment: (OBTAIN LOCALLY)
19 FT2997 COMPRESSOR TOOL, Piston Ring
20 91-827001A1 STAND TOOL, Powerhead
21 91-24697 EXPANDER TOOL, Piston Ring
22 91-74951 SPANNER WRENCH
23 91-822778A3 DOWN PRESSURE KIT
24 91-63209 HEAT LAMP
25 31-85560 BEARING, Thrust
26 91-13779 REMOVER TOOL, Bearing
27 NSS NOT SOLD SEPARATE, Expanding rod Comment: (P/N-CG-41-11)
28 NSS NOT SOLD SEPARATE, Collet Comment: (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 91-83180M HOLDING TOOL, Driveshaft
42 91-825197T INSTALLER TOOL, Oil Seal
43 91-817007T INSTALLER TOOL, Seal
44 91-825198 MANDREL
45 91-825199 PILOT
46 91-825200A1 HOOK TOOL, Spring
47 91-826872 INSTALLER TOOL, Bearing
48 FT8950 TESTER KIT
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 91-8M0053505 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 91-56775T 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
▶Top Cowl (18 parts) Top Cowl
Ref OEM Part # Part Name
1 102-834785T6 TOP COWL ASSEMBLY Comment: (MANUAL - SILVER)
2 102-834785T8 TOP COWL ASSEMBLY Comment: (ELECTRIC - SILVER)
3 NSS NOT SOLD SEPARATE, Induction Insert
4 826291F1 LATCH Comment: (SILVER)
5 10-8231871 SCREW, (M4 x 14.5)
6 8,13-26995 LOCKWASHER, Stainless Steel
7 11-8237515 NUT, (M4)
8 8M0153618 SEAL
9 834786A04 SOUND BLANKET KIT
10 NSS NOT SOLD SEPARATE, Sound Blanket-Top Comment: (ELECTRIC)
11 NSS NOT SOLD SEPARATE, Sound Blanket-Top Comment: (MANUAL)
12 893763 BRACKET ASSEMBLY, Latch Roller
13 10-4006731 SCREW, (M6 x 16)
14 8M0038412 BRACKET
15 10-8231871 SCREW, (M4 x 14.5)
16 8,13-26995 LOCKWASHER, Stainless Steel
17 11-8237515 NUT, (M4)
18 47341A11 ROPE AND HANDLE KIT, Manual Starting
▶Transom Bracket (48 parts) Transom Bracket
Ref OEM Part # Part Name
1 3420-8M0084195 CLAMP BRACKET ASSEMBLY Comment: (PORT - MANUAL LONG BIGFOOT)
2 22-8M0169588 FITTING, Grease
3 17-99604 PIN, Groove
4 3419-822867F1 CLAMP BRACKET Comment: (PORT - MANUAL LONG BIGFOOT)
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 10-4000355 SCREW, (M8 x 35) Comment: (35 MM)
17 13-400257 LOCKWASHER, (M8)
18 11-401388 NUT, (M8) Stainless Steel
19 17-8M0026068 PIN ASSEMBLY, Tilt Lock Comment: (NON POWER TRIM)
20 24-821461 SPRING Comment: (NON POWER TRIM)
21 8M0041938 TILT TUBE
22 11-858869 NUT, (7/8-14)
23 19624A1 SEAL KIT Comment: (NON-HANDLE)
24 25-29619 O-RING, (.583 x .103) Comment: (NON-HANDLE)
25 23-78861 SPACER Comment: (NON-HANDLE)
26 54-22740 CLIP Comment: (POWER TRIM)
27 8M0084613 C WASHER Comment: (POWER TRIM)
28 10-878609 SCREW, (#10-16 x .600) Comment: (POWER TRIM)
29 10-814259 SCREW, (.500-20 x 4.00)
30 12-8M0204648 WASHER, (1.5 x 3.05 x 0.13) Stainless Steel
31 11-82671117 NUT, (.500-20)
32 8M0084737 LINK Comment: (NON POWER TRIM)
33 19615A05 LEVER ASSEMBLY, Tilt Comment: (NON POWER TRIM)
34 23-812707 BUSHING Comment: (NON POWER TRIM)
35 12-8M0042643 WASHER, (.520 x .850 x .060) Nylon - Black Comment: (NON POWER TRIM)
36 13-99611 WAVE WASHER Comment: (NON POWER TRIM)
37 8M0007469 TILT KNOB Comment: (NON POWER TRIM)
38 10-19611 SCREW, (.375-16 x .62) Comment: (NON POWER TRIM)
39 10-4009040 SCREW, (M10 x 40) Stainless Steel
40 12-4002319 WASHER
41 11-40140 NUT, (M10)
42 37-830253 DECAL, Tilt Lock
43 10-818883A1 THUMB SCREW ASSEMBLY Comment: (MANUAL BIGFOOT)
44 12-818884 WASHER Comment: (MANUAL BIGFOOT)
45 10-768042 SHOULDER SCREW, Hex Comment: (MANUAL BIGFOOT)
46 NSS NOT SOLD SEPARATE, Handle Comment: (MANUAL BIGFOOT)
47 NSS NOT SOLD SEPARATE, Rivet Comment: (MANUAL BIGFOOT)
48 NSS NOT SOLD SEPARATE, Decal-Warning Comment: (MANUAL BIGFOOT)
▶Trim Switch Kit (8 parts) Trim Switch Kit
Ref OEM Part # Part Name
- 87-18286A18 SWITCH KIT, Trim (10.00 Feet)
1 18861 RETAINER
2 814820 ADAPTOR
3 NSS NOT SOLD SEPARATE, Switch
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)

100-Hour / Annual Service Checklist

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

  1. Replace water pump impeller and inspect wear plate
  2. Change engine oil and oil filter (check drain plug washer)
  3. Replace spark plugs and check ignition timing
  4. Drain and refill lower unit gear oil; inspect for water contamination
  5. Inspect fuel lines, primer bulb, and fuel filter for deterioration
  6. Check and replace sacrificial anodes (zinc or aluminum)
  7. Inspect propeller for damage; check shaft seal and cotter pin
  8. Check valve clearance (refer to service manual for specifications)
  9. Lubricate all grease points (steering, tilt tube, shift linkage)
  10. 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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