Mercury 500 (1639473 THRU 1755548) Parts & Diagrams

OEM and aftermarket replacement parts for Mercury 500. Scroll down for exploded parts diagrams (16), specifications, and maintenance reference.

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06211-ZW0-505 Maintenance Kit for Honda BF75A BF90A | JLM Marine
06211-ZW0-505 Maintenance Kit for Honda BF75A BF90A | JLM Marine
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Mercury 500 (1639473 THRU 1755548) Parts & Diagrams

🔎 Mercury 500 Reference Library — Exploded parts diagrams (16 diagrams), specifications, common issues, and maintenance checklist.

The Mercury 500 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 50 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) 650 ± 50 RPM (in gear)
Full Throttle RPM Range 5000-6000
Fuel Unleaded Gasoline, 87 Octane min.

Always verify specifications against your owner's manual for your specific serial number range.

Common Issues & Recommended Parts

Below are common maintenance scenarios for the Mercury 500:

  • 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 500.

▶BOTTOM COWL ASSEMBLY (53 parts) BOTTOM COWL ASSEMBLY
Ref OEM Part # Part Name
1 103-2354A2 BOTTOM COWL ASSEMBLY
2 29206 COVER, PLUG - BOTTOM COWL HARNESS HOLE
3 10-45893 SCREW, PLUG COVER TO BOTTOM COWL
4 13-26995 LOCKWASHER, PLUG COVER FATENING SCREW
5 11-26419 NUT, PLUG COVER FASTENING SCREW
6 26552 SUPPORT, EXTERNAL WIRING HARNESS
7 10-20639 SCREW, HARNESS SUPPORT TO BOTTOM COWL
8 12-20084 WASHER, HARNESS SUPPORT FASTENING SCREW
9 11-29250 NUT, HARNESS SUPPORT FASTENING SCREW
10 23760 BAFFLE, BOTTOM COWL
11 10-21106 SCREW, BAFLE TO BOTTOM COWL
12 30999 BRACKET, LOCK KNOB - COWL FRONT COVER
13 10-21091 SCREW, BRACKET TO BOTTOM COWL (1 1/8")
14 11-8M0207775 NUT, BRACKET FASTENING SCREW
15 21104A2 CONNECTOR BASE ASSEMBLY
16 13-21972 LOCKWASHER, CONNECTOR BASE
17 11-21971 NUT, CONNECTOR BASE TO BOTTOM COWL
18 54-25231 CLIP, CONNECTOR BASE LEAD WIRE
19 10-22815 SCREW, LEAD WIRE CLIP TO BOTTOM COWL
20 32-8M0108355 TUBE, VENT - MAGNETO OUTLET (10 1/2")
21 22-996642 ELBOW, MAGNETO VENT TUBE
22 19-824928001 PLUG, BOTTOM COWL HOLE
23 20557 BRACKET, CABLE END ANCHOR
24 10-29200 SCREW, ANCHOR BRACKET TO BOTTOM COWL
25 29532 LEVER, THROTTLE CONTROL
26 30612 LEVER, SHIFT CONTROL
27 23-29529 BUSHING, THROTTLE AND SHIFT LEVER
28 12-8M0042641 WASHER, THROTTLE AND SHIFT LEVER SCREW
29 10-37612 SCREW, THROTTLE AND SHIFT LEVER FASTENING
30 17-30978A1 PIN ASSEMBLY, CLEVIS YOKE
31 17-239281 ROLL PIN, CLEVIS YOKE PIN
32 10-20584 SCREW, CLEVIS YOKE PIN TO CONTROL LEVER
33 13-29402 WASHER, WAVE - CLEVIS PIN FASTENING SCREW
34 11-8M0204718 NUT, CLEVIS PIN FASTENING SCREW
35 25180 SHIFT SHAFT ASSEMBLY, UPPER
36 27714 ROD (SLEEVE), SHIFT CONTROL END
37 11-25168 NUT, ADJUSTING - SHIFT SHAFT END
38 25134 ROD, LINK - SHIFT SHAFT END
39 18-25191 COTTER PIN, LINK ROD TO SHIFT SHAFT
40 12-20583 WASHER, SHIFT CONTROL END ROD
41 24-25065 SPRING, DETENT - SHIFT SHAFT
42 10-98256 SCREW, DETENT SPRING TO BOTTOM COWL
43 12-69057 WASHER, DETENT SPRING SCREW
44 11-20013 NUT, DETENT SPRING FASTENING SCREW
45 30109 GROUND STRAP, CYLINDER BLOCK TO BOTTOM COWL
46 27-20390 GASKET, POWERHEAD TO BOTTOM COWL
47 35392A1 TRIM MOULDING ASSEMBLY, BOTTOM COWL
48 29998 SPLICER, TRIM MOULDING - REAR
49 10-29226 SCREW, DECORATIVE - TRIM MOULDING TO COWL
50 12-24671 WASHER, FIBRE - MOULDING FASTENING SCREW
51 11-29225 NUT, NYLON CAP - MOULDING FASTENING SCREW
52 13-26995 LOCKWASHER, MOULDING FASTENING SCREW
53 11-26419 NUT, BRASS - MOULDING FASTEING SCREW
▶CARBURETOR ASSEMBLY (38 parts) CARBURETOR ASSEMBLY
Ref OEM Part # Part Name
-- 1395-92621 REPAIR PARTS KIT (1 PER CARBURETOR)
1 1333-2099 CARBURETOR ASSEMBLY, COMPLETE (KA-19A)
2 1395-8673 FLOAT ASSEMBLY
3 17-20853 PIN, FLOAT LEVER PINION
4 1399-102 LEVER, FLOAT (LOWER)
5 1399-101 LEVER, FLOAT (UPPER)
6 1395-92581 INLET NEEDLE, SEAT AND GASKET
7 27-25033 GASKET, INLET SEAT
8 1399-99 GASKET, FLOAT BOWL COVER
9 1399-1133 COVER, FLOAT BOWL
10 10-22625 SCREW, FLOAT BOWL COVER (SHORT)
11 10-25850 SCREW, FLOAT BOWL COVER (LONG)
12 27-25851 GASKET, STRAINER COVER (LARGE)
13 1399-3938 SCREEN, FILTER
14 27-25849 GASKET, STRAINER COVER (SMALL)
15 1399-1135 COVER, STRAINER
16 27-25848 GASKET, STRAINER COVER SCREW
17 10-25822 SCREW, STRAINER COVER FASTENING
18 1395-6027 SCREW, THROTTLE STOP LEVER
19 8146791 LEVER, THROTTLE STOP (SEE NOTE BELOW)
20 1399-2012 SHAFT, THROTTLE
21 1399-1710 TUBE, IDLE
22 27-23180 GASKET, IDLE TUBE
23 10-23035 SCREW AND LOCKWASHER, THROTTLE SHUTTER
24 1399-1711 SHUTTER, THROTTLE
25 24-27160 SPRING, IDLE ADJUSTMENT SCREW
26 1399-1713 SCREW, IDLE ADJUSTMENT
27 10-28405 SCREW, PLUG - MAIN FUEL JET CHANNEL
28 27-28406 GASKET, JET CHANNEL PLUG SCREW
29 1399-1655 JET, MAIN FUEL (.055)
30 27-28409 GASKET, MAIN FUEL JET
31 1399-1888 NOZZLE, MAIN
32 10-23178 SCREW, PLUG - MAIN NOZZLE
33 24-20869 SPRING, THROTTLE SHAFT RETURN (UPPER CARBURETOR)
34 10-23030 SCREW, PLUG - BODY CHANNEL
35 19-20011 WELCH PLUG, BODY CHANNEL
36 27-757911 GASKET, CARBURETOR FLANGE
37 11-29250 NUT, CARBURETOR MOUNTING STUD
▶CARBURETOR LINKAGE AND CHOKE SOLENOID (33 parts) CARBURETOR LINKAGE AND CHOKE SOLENOID
Ref OEM Part # Part Name
1 31593 CHOKE SOLENOID, TOP COWL
2 22647 DISCONNECT, KNIFE - CHOKE SOLENOID LEAD
3 10-20540 SCREW, CHOKE SOLENOID TO TOP COWL
4 13-26992 LOCKWASHER, CHOKE SOLENOID SCREW
5 26716A1 GROUND STRAP ASSEMBLY, CHOKE SOLENOID TO ADAPTOR
6 10-24773 SCREW, CHOKE SOLENOID TO TOP COWL
7 13-26991 LOCKWASHER, CHOKE SOLENOID SCREW
8 32-26693A1 SLEEVE, CHOKE SOLENOID LEAD
9 54-22783 "S" CLIP, CHOKE SOLENOID LEAD TO TOP COWL
10 90242A1 KNOB, CHOKE ROD
11 25-20116 GROMMET, CHOKE RD
12 22462 "U" LINK, CHOKE ROD TO CHOKE KNOB
13 13-26996 LOCKWASHER, "U" LINK SCREW
14 10-69022 SCREW, "U" LINK TO CHOKE KNOB
15 18-210711 COTTER PIN, "U" LINK TO CHOKE ROD
16 38604 SHUTTER, CHOKE - CARBURETOR (UPPER)
17 23-30438 BUSHING, NYLON-UPPER CHOKE SHUTTER
18 31519 ROD, CHOKE
19 17-25319 RIVET, CHOKE SHUTTER TO CHOKE ROD
20 16-30172 STUD, CARBURETOR - CHOKE SHUTTER PIVOT
21 12-30164 WASHER, CHOKE SHUTTER CARBURETOR STUD
22 11-20110 NUT, CHOKE SHUTTER TO CARBURETOR STUD
23 24-28965 SPRING, TENSION - CHOKE ROD
24 10-28713 SCREW, RETAINER TO LOWER CARBURETOR
25 27711 RETAINER, CHOKE ROD SPRING TO CARBURETOR
26 1333-2099 CARBURETOR ASSEMBLY, COMPLETE
27 53719A2 THROTTLE PICK-UP BRACKET ASSEMBLY
28 10-29239 SCREW, THROTTLE PICK-UP BRACKET MOUNTING
29 27917 CLUSTER, THROTTLE LEVER (UPPER CARBURETOR)
30 1395-6027 SCREW, CLUSTER TO THROTTLE LEVER
31 48315A4 PLUNGER AND LINK ASSEMBLY, CHOKE SOLENOID
32 12-30164 WASSHER, PLUNGER AND LINK
33 18-26953 COTTER PIN, LINK TO UPPER CHOKE SHUTTER
▶CLAMP AND SWIVEL BRACKET ASSEMBLY (40 parts) CLAMP AND SWIVEL BRACKET ASSEMBLY
Ref OEM Part # Part Name
1 1401-1977A1 CLAMP BRACKET ASSEMBLY
2 28403A3 THUMB SCREW ASSEMBLY
3 12-28404 WASHER, THUMB SCREW
4 8M0041936 TUBE, TILT - CLAMP BRACKET TO SWIVEL BRACKET
5 12-52864 SHIM, CLAMP BRACKET TO SWIVEL BRACKET
6 11-858869 NUT, TILT TUBE FASTENING
7 53078 CAP, PLASTIC - TILT TUBE ENDS
8 16-59625 STUD, CLAMP BRACKET
9 23-59624 SPACER, CLAMP BRACKET STUD
10 13-8M0204647 LOCKWASHER, CLAMP BRACKET STUD
11 11-22053 NUT, STUD TO CLAMP BRACKETS
12 17-8M0026068 TILT LOCK PIN ASSEMBLY
13 26903A3 REVERSE LOCK ASSEMLY
14 18-45882 COTTER PIN, REVERSE LOCK TO SHAFT
15 24-29821 SPRING, TENSION - REERSE LOCK
16 17-25598 ROLL PIN, REVERSE LOCK SPRING ATTACHING
17 56349 SHAFT, REVERSE LOCK TO SWIVEL BRACKET
18 1442-2501A1 SWIVEL BRACKET ASSEMBLY
19 22-69059 FITTING, GREASE - SWIVEL BRACKET
20 26-32911 OIL SEAL, SWIVEL BRACKET
21 19-77633Q LUBRICAP, SWIVEL BRACKET GREASE FITTING
22 29057 LEVER, TILT STOP - PORT SIDE
23 29056 LEVER, TILT STOP - STARBOARD SIDE
24 10-27791 SCREW, ANCHOR - TILT STOP LEVER
25 23-29055 SPACER, TILT STOP LEVER ANCHOR SCREW
26 10-27790 SCREW, RETAINING - TILT STOP LEVER
27 15-20473A1 SHIM, RETAINING SCREW - PORT SIDE Comment: SEE NOTE BELOW
28 13-20846 WASHER, WAVE - RETAINING SCREW - PORT SIDE Comment: SEE NOTE BELOW
29 11-24652 NUT, ANCHOR AND RETINING SCREW
30 12-26837 WASHER, SWIVEL PIN TO BOTTOM YOKE (.065)
31 77416T1 YOKE, BOTTOM
32 17-28418A4 SWIEL PIN AND TOP YOKE ASSEMBLY
33 30711 BUMPER, TOP YOKE
34 10-33986 BOLT, UPPER MOUNT TO SWIVEL PIN
35 11-71956 NUT, RETINING - SWIVEL PIN
36 38-56267 SERIAL PLATE
37 10-25612 SCREW, DRIVE - SERIAL PLATE TO SWIVEL BRACKET
38 10-68298 BOLT, CLAMP BRACKET TO BOAT TRANSOM
39 12-68410 WASHER, CLAMP BRACKET TRANSOM BOLT
40 11-82670912 NUT, CLAMP BRACKET TRANSOM BOLT
▶COWLING AND FRONT COVER (21 parts) COWLING AND FRONT COVER
Ref OEM Part # Part Name
-- 92-86166Q1 GLUE, ADHESIVE - SOUND BLANKET FASTENING
1 2182-7927A5 COWL FRONT COVER ASSEMBLY
2 37-37839 DECAL, "MERC 500"
3 37-37838 DECAL, FRONT COVER EMBLEM
4 56848 KNOB, COWL FRONT COVER FASTENING
5 12-30771 WASHER, COVER FASTENING KNOB (RUBBER)
6 12-27129 WASHER, COVER FASTENING KNOB (STEEL)
7 24-30772 SPRING, TENSION - COVER FASTENING KNOB
8 17-29077 ROLL PIN TENSION SPRING TO KNOB
9 38674 BLANKET, SOUND ABSORBING - FRONT COVER
10 31095 SEAL, SOUND - LOWER SECTION
11 35552 SEAL, SOUND - UPPER SECTION
12 2106-2353A2 WRAP AROUND COWL ASSEMBLY
13 21060 HANDLE, COWL LATCH
14 17-21057 PIN, HINGE - HANDLE TO COWL LATCH
15 53-21058 "E" RING, HANDLE TO COWL LATCH HINGE PIN
16 25690 SWIVEL, COWL LATCH
17 25691 HOOK, COWL LATCH FASTENING
18 37-35505 DECAL, WRAP AROUND COWL - STARBOARD
19 37-35504 DECAL, WRAP AROUND COWL - PORT
20 24825 BLANKET, SOUND ABSORBING - WRAP AROUND COWL
▶CRANKSHAFT, PISTON AND CONNECTING ROD (29 parts) CRANKSHAFT, PISTON AND CONNECTING ROD
Ref OEM Part # Part Name
- 39-28616A12 RING, PISTON (/015) OVERSIZED
1 11-8M0214915 NUT, FLYWHEEL
2 12-26617 WASHER, FLYWHEEL NUT
3 28-20094 KEY, FLYWHEEL DRIVE
4 400-2976A2 CRANKSHAFT
5 25-29619 "O" RING, DRIVE SHAFT SPLINE
6 500-5345A4 CENTER MAIN BEARING ASSEMBLY
7 17-20032 DOWEL PIN, CENTER MAIN BEARING
8 29-20046T BEARING, NEEDLE
9 20047 RACE, OUTER
10 53-20048 RING, SNAP - OUTER RACE CLAMPING
11 10-28666 SCREW, CENTER MAIN BEARING CLAMPING
12 17-20379 DOWEL PIN (STEPPED)
13 527-1619A4 MAIN BEARING ASSEMBLY (VALVE TYPE)
14 17-20032 DOWEL PIN, MAIN BEARING
15 10-25313 SCREW, MAIN BEARING CLAMPING (1/2")
16 11-29469 NUT, MAIN BEARING CLAMPING SCREW
17 34-88498A1 REED SET, MATCHED - MAIN BEARING
18 34-20053 REED STOP, MAIN BEARING REED VALVES
19 10-77280 SCREW, REED STOP MOUNTING (1/2")
20 11-29469 NUT, REED STOP MOUNTING SCREW
21 724-2537A2 PISTON AND PISTON PIN ASSEMBLY
23 39-27841A12 RING, PISTON
24 600-2748A2 CONNECTING ROD AND CAP ASSEMBLY (SEE NOTE BELOW)
25 10-45379 SCREW, CAP TO CONNECTING ROD
26 11-20061 NUT, CONNECTING ROD SCREW
27 29-20046T BEARING, NEEDLE - CRANKPIN
28 29-20063 BEARING,NEEDLE - PISTON PIN
29 12-28121 WASHER, NEEDLE LOCATING
▶CYLINDER BLOCK AND CRANKCASE ASSEMBLY (54 parts) CYLINDER BLOCK AND CRANKCASE ASSEMBLY
Ref OEM Part # Part Name
-- 13-8M0204647 LOCKWASHER, EXHAUST EXTENSION FASTENING SCREW Comment: SERIAL 01674193-09999999
1 1100-339A1 END CAP ASSEMBLY, UPPER
2 26-41953 OIL SEAL
3 25-20081 "O" RING, UPPER END CAP
4 30-63742T BALL BEARING, UPPER END CAP
5 15-20082A1 SHIM, UPPER END CAP TO CRANKCASE AND BLOCK
6 10-29198 SCREW, UPPER END CAP MOUNTING
7 831-2414A2 CYLINDER BLOCK AND CRANKCASE ASSEMBLY
8 23-26348 BUSHING, CRANKCASE
9 17-20032 DOWEL PIN, CYLINDER BLOCK TO MAIN BEARING
10 17-20323 DOWEL PIN, CYLINDER BLOCK TO CENTER MAIN BEARING
11 22-328022 PLUG, PIPE - WATER PRESSURE AND BALANCE TUBE HOLES
12 16-21831 STUD, CARBURETOR MOUNTING (1 1/4")
13 16-33111 STUD, CRANKCASE TO DRIVE SHAFT HOUSING (1 5/8")
14 17-43044 DOWEL PIN, CRANKCASE TO CYLINDER BLOCK
15 16-8M0034463 STUD, CYLINDER BLOCK TO DRIVE SHAFT HOUSING (3 7/16")
16 16-29989 STUD, CYLINDER BLOCK TO DRIVE SHAFT HOUSING (1 15/16")
17 36157 SCREW, EXHAUST EXTENSION TO CYLINDER BLOCK Comment: SERIAL 01674193-09999999
18 10-25299 SCREW, EXHAUSXT EXTENSION TO CYLINDER BLOCK STARTED WITH SER Comment: SERIAL 01674193-09999999
20 10-78841 SCREW, CRANKCASE TO CYLINDER BLOCK (1 1/2")
21 10-22039 SCREW, CRANKCASE TO CYLINDER BLOCK (2 3/4")
22 11-29250 NUT, CRANKCASE FASTENING SCREW
23 10-98260 SCREW, MAIN BEARING LOCKING
24 14-20091 TAB WASHER, BEARING LOCKING SCREW
25 10-20359 SCREW, CENTER MAIN BEARING LOCKING
26 1102-4181A3 END CAP ASSEMBLY, LOWER
27 21-28481A1 CHECK VALVE ASSEMBLY, LOWER END CAP
28 26-29478 OIL SEAL, LOWER
29 26-41953 OIL SEAL, UPPER
30 25-20081 "O" RING, LOWER END CAP
31 30-63742T BALL BEARING, LOWER END CAP
32 15-20085A1 SHIM, LOWER END CAP TO CRANKCASE AND BLOCK
33 10-29198 SCREW, LOWER END CAP MOUNTING
34 32-8M0108355 TUBE, BALANCE - MAIN BEARING
35 22-291112 CONNECTOR, BALANCE TUBE TO CYLINDER BLOCK
36 54-20386 CLAMP, BALANCE TUBE TO CONNECTORS
37 27-26923 GASKET, MANIFOLD PLATE TO EXHAUST COVER
38 26922 PLATE, EXHAUST MANIFOLD
39 28240 COVER, EXHAUST MANIFOLD
40 10-28666 SCREW, MANIFOLD COVER AND HIGH TENSION LEAD CLIP MOUNTING
41 12-20028 WASHER, MANIFOLD COVER AND HIGH TENSION LEAD CLIP SCREWS
42 27-22333 GASKET, CYLINDER BLOCK COVER
43 1000-1A1 CYLINDER BLOCK COVER ASSEMBLY
44 23-26348 BUSHING, CYLINDER BLOCK COVER
45 10-20653 SCREW, CYLINDER BLOCK COVER MOUNTING
46 11-24652 NUT, COVER MOUNTING SCREW
47 27-279361 GASKET, TRANSFER PORT COVER
48 27935 COVER, TRANSFER PORT
49 10-20540 SCREW, TRANSFER PORT COVER MOUNTING
50 22-62365A1 CHECK VALVE ASSEMBLY, BLEED HOSE (UPPER)
51 21-28481A1 CHECK VALVE ASSEMBLY, BLEED HOSE VALVE
52 32-9912688 HOSE, CYLINDER BLEEN (6 1/2")
53 22-67902 CONNECTOR, CYLINDER BLEED HOSE (LOWER)
54 54-20387 CLAMP, BLEED HOSE TO CHECK VALVE AND CONNECTOR
▶DRIVE SHAFT HOUSING ASSEMBLY (48 parts) DRIVE SHAFT HOUSING ASSEMBLY
Ref OEM Part # Part Name
1 1545-2337A4 DRIVE SHAFT HOUSING ASSEMBLY
2 16-8M0022145 STUD, DRIVE SHAFT HOUSING TO GEAR HOUSING (1 3/4")
3 16-57935 STUD, DRIVE SHAFT HOUSING TO GEAR HOUSING (3")
4 11-8M0204653 NUT, GEAR HOUSING TO DRIVE SHAFT HOUSING STUDS (7/16)
5 11-862902 NUT, POWERHEAD TO DRIVE SHAFT HOUSING (5/6)
6 19-32298 PLUG, PLASTIC - WATER PICK-UP SCREW HOLE
7 32-31998 TUBE, WATER INLET
8 23-23561 SLEEVE, WATER INLET TUBE
9 25-24961 RING, RUBBER - WATER INLET TUBE
10 26-25192 SEAL, WATER INLET TUBE
11 35394A1 TRIM COVER ASSEMBLY
12 37-35393 DECAL, TRIM COVER - PORT AND STARBOARD
13 10-30742 SCREW, TRIM COVER TO DRIVE SHAFT HOUSING
14 32016 BAFFLE, EXHAUST RELIEF
15 10-25255 SCREW, RELLIEF BAFFLE TO DRIVE SHAFT HOUSING
16 27-31995 GASKET, BOTTOM COWL TO DRIVE SHAFT HOUSING
17 25305 CAP, RUBBER - UPPER MOUNT BOLT NUT
18 11-23161 NUT, UPPER MOUNT BOLT
19 12-30519 WASHER, UPPER MOUNT BOLT (3/8 ID)
20 12-30521 WASHER, RUBBER - UPPER MOUNT BOLT
21 12-30520 WASHER, UPPER MOUNT BOLT (37/64/ID)
22 79680A1 COVER, UPPER MOUNT - OUTSIDE HALP
23 79680A1 COVER, UPPER MOUNT - INSIDE HALF
24 75305 MOUNT, RUBBER - UPPER
25 24929 PACKING, "U" CUP - UPPER MOUNT COVERS
26 10-28772 SCREW, UPPER MOUNT COVER - REAR (1 1/2")
27 10-37941 SCREW, UPPER MOUNT COVER - FRONT (1 3/4')
28 12-8M0204649 WASHER, MOUNT COVER FASTENING SCREW
29 11-35888 NUT, UPPER MOUNT COVER FASTENING SCREW
30 22-22946 BAMPER, RUBBER - LOWER MOUNT SCREW
31 10-75284 SCRWE, LOWER MOUNT (5 1/2")
32 12-28051 WASHER, LOWER MOUNT SCREW
33 12-28053 WASHER, RUBBER - LOWER MOUNG SCREW
34 75304T1 MOUNT, RUBBER - LOWER
35 12-30119 WASHER, LOWER MOUNT SCREW (1/8")
36 11-25196 NUT, LOWER MOUNT SCREW
37 69592F1 CLAMP, LOWER MOUNT TO DRIVE SHAFT HOUSING
38 24-35522 SPRING, TENSION - LOWER MOUNT CLAMP
39 10-29256 SCREW, LOWER MOUNT CLAMP TO DRIVE SHAFT HOUSING
40 11-35521 NUT, LOWER MOUNT CLAMP COVER
41 35474T COVER, LOWER MOUNT CLAMP
42 10-29722 SCREW, COVER TO LOWER MOUNT CLAMP
43 22-390721 PLUG, GREASE - REVERSE LOCK HOLE
44 52920 LEVER, REVERSE LOCK
45 24-25122 SPRING, TENSION - PUSH ROD
46 17-24887 PIN, REVERSE LOCK LEVER
47 28470 ROD, PUSH - REVERSE LOCK
48 18-25191 COTTER PIN, PUSH ROD TO REVERSE LOCK
▶FLYWHEEL ASSEMBLY AND STATOR (15 parts) FLYWHEEL ASSEMBLY AND STATOR
Ref OEM Part # Part Name
- 10-32417 SCREW, PLATE AND RATCHET TO FLYWHEEL HUB
1 11-8M0214915 NUT, FLYWHEEL
2 12-33001 WASHER, FLYWHEEL NUT
3 28-20094 KEY, FLYWHEEL DRIVE
4 223-2402A7 FLYWHEEL ASSEMBLY
5 223-2403A10 FLYWHEEL ASSEMBLY
6 29788 FLANGE, FLYWHEEL PULLEY
7 30306 PULLEY, FLYWHEEL
8 17-26618 DOWEL PIN, PULLEY TO FLYWHEEL
9 29787 HUB, FLANGE - FLYWHEEL PULLEY
10 398-2171 STATOR, ALTERNATOR - FLYWHEEL
11 10-57021 SCREW, STATOR TO UPPER END CAP
12 54-24836 CLAMP, STATOR LEAD TO CRANKCASE FLANGE
13 8M0084613 "D" WASHER, STATOR LEAD CLAMP SCREW
14 10-8M0113176 SCREW, STATOR LEAD CLAMP FASTENING
▶FUEL PUMP ASSEMBLY (26 parts) FUEL PUMP ASSEMBLY
Ref OEM Part # Part Name
1 30269A2 FUEL PUMP ASSEMBLY
2 27-23005 GASKET, CHECK VALVE TO HOUSING
3 21-8M0082362 VALVE, CHECK
4 23004 RETAINER, CHECK VALVE
5 10-43725 SCREW, RETAINER TO HOUSING
6 27-24863 GASKET, FUEL PUMP
7 23014 DIAPHRAGM, FUEL PUMP
8 23008 COVER, FUEL PUMP
9 27-30276 GASKET, FUEL PUMP COVER
10 10-29126 SCREW, FUEL PUMP MOUNTING (1 3/4") SEE NOTE BELOW
11 10-29029 SCREW, FUEL PUMP MOUNTING (1 1/2") SEE NOTE BELOW
12 22-22949 CONNECTOR, PUMP INLET TO FUEL LINE
13 22-22946 SLEEVE, RUBBER - CONNECTOR
14 22-22948 NUT, CONNECTOR TO FUEL LINE
15 32-32094 FUEL LINE, FUEL PUMP TO LOWER AND UPPER FILTER
16 22-22995 ELBOW, FUEL PUMP INLET
17 22-22946 SLEEVE, RUBBER
18 22-22948 NUT, ELBOW
19 32-30036 FUEL LINE, FUEL PUMP TO ADAPTOR
20 30186 ADAPTOR, CHECK UNIT (FUEL LINE)
21 30187 STEM, CHECK UNIT ADAPTOR
22 25-16524 "O" RING, ADAPTOR STEM
23 24-30189 SPRING, ADAPTOR STEM
24 30188 CUP WASHER, ADAPTOR
25 10-20784 SCREW, ADAPTOR TO BOTTOM COWL
26 11-24652 NUT, ADAPTOR SCREW
▶GEAR HOUSING ASSEMBLY, COMPLETE (PAGE 1) (43 parts) GEAR HOUSING ASSEMBLY, COMPLETE (PAGE 1)
Ref OEM Part # Part Name
- 1626-2040A3 GEAR HOUSING ASSEMBLY, COMPLETE (STANDARD)-SEE NOTE BELOW
1 1626-2040A1 GEAR HOUSING ASSEMBLY
2 16-32027 STUD, WATER PUMP BODY AND B ASE TO GEAR HOUSING
3 16-32017 STUD, GEAR HOUSING TO DRIVE SHAFT HOUSING
4 31-62091T BEARING, ROLLER - DRIVE SHAFT
5 56622A1 SHAFT, SHIFT - LOWER
6 53-29641 CLIP, RETAINING - SHIFT SHAFT
7 25-25439 "O" RING, SHIFT SHAFT BUSHING
8 23-46284A1 BUSHING ASSEMBLY, SHIFT SHAFT
9 26-892361 OIL SEAL, SHIFT SHAFT BUSHING
10 52918 CAM, LOWER - REVERSE LOCKING
11 52919 CAM, UPPER - REVERSE LOCKING
12 45-31996 DRIVE SHAFT (STANDARD)
13 15-20929A1 SHIM, BEARING TO GEAR HOUSING
14 30-72961 BEARING, BALL - DRIVE SHAFT
15 53-29116 RING, SNAP - BALL BEARING RETAINING
16 15-20929A1 SHIM, BEARING TO WATER PUMP BASE
17 43-20834 GEAR, PINION - DRIVE SHAFT
18 14-29163 TAB WASHER, PINION GEAR FASTENING SCREW
19 10-20925 SCREW, PINION GEAR TO DRIVE SHAFT
20 27-32771 GASKET, WATER PUMP BASE TO GEAR HOUSING
21 25-26855 "O" RING, WATER PUMP BASE
22 46-39531A1 WATER PUMP BASE ASSEMBLY
23 26-90562 OIL SEAL, WATER PUMP BASE
24 17-29596T DOWEL PIN, WATER PUMP BASE TO WATER PUMP BODY
25 27-19553 GASKET, LOWER - WATER PUMP BASE TO FACE PLATE
26 32768 PLTE, FACE - WATER PUMP BASE TO WATER PUMP BODY
27 27-19551 GASKET, UPPER - FACE PLATE TO WATER PUMP BODY
28 47-89983T IMPELLER, WATER PUMP
29 28-8M0032837 PIN, IMPELLER DRIVE
30 46-60366Q1 WATER PUMP BODY ASSEMBLY
31 32001 INSERT, WATER PUMP BODY
32 26-32121 OIL SEAL, WATER PUMP BODY
33 13-26992 LOCKWASHER, WATER PUMP BODY AND BASE STUDS
34 11-29598 NAT, WATER PUMP BODY AND BASE FASTENING STUDS
35 26-25192 SEAL, WATER PUMP BODY TO WATER INLET TUBE
36 25-20273 RING, RUBBER - CENTRIFUGALE SLINGER (DRIVE SHAFT)
37 25-29619 "O" RING, UPPER - DRIVE SHAFT
38 10-29608 SCREW, GEAR HOUSING FLUSHING HOLE
39 27-8M0214916 GASKET, GEAR HOUSING FLUSHING HOLE SCREW
40 26-8M0214917 SEAL HOUSING FLUSHING HOLE
41 10-79953Q04 SCREW, GREASE FILLER AND VENT HOLE
42 12-191833 WASHER, GREASE FILLER AND VENT HOLE SCREW
▶GEAR HOUSING ASSEMBLY, COMPLETE (PAGE 2) (35 parts) GEAR HOUSING ASSEMBLY, COMPLETE (PAGE 2)
Ref OEM Part # Part Name
- 1626-2040A3 GEAR HOUSING ASSEMBLY, COMPLETE (STANDARD) - SEE NOTE BELOW
1 1626-2040A1 GEAR HOUSING ASSEMBLY (SEE PAGE 26 FOR PARTS BREAKDOWN)
43 760394 CAM, SHIFT
44 20930 FOLLOWER, CAM
45 20843 SLIDE, CROSS PIN
46 24-20254 SPRING, COMPRESSION - CAM FOLLOWER
47 15-31154A1 SHIM, BEARING CUP TO GEAR HOUSING
48 43-20975A5 FORWARD GEAR ASSEMBLY
49 31-20249 BEARING,ROLLER - FORWARD GEAR ASSEMBLY
50 31-31215A1 TAPERED ROLLER BEARING ASSEMBLY
51 31-31216 CUP, TAPERED ROLLER BEARING
52 52-32189 RATCHET, SLIDING CLUTCH
53 17-20841 PIN, CROSS - RATCHET TO PROPELLER SHAFT
54 53-20842 RING, RETINING - CROSS PIN
55 44-32000 SHAFT, PROPELLER
56 43-20975A5 REVERSE GEAR ASSEMBLY
57 12-32004 WASHER, THRUST - REVERSE GEAR
58 30-20839T BEARING, BALL - REVERSE GEAR
59 15-20927A1 SHIM, THRUST WASHER TO GEAR HOUSING
60 25-31986 "O" RING, BEARING CARRIER
61 53014T1 BEARING CARRIER ASSEMBLY
62 31-20249 BEARING, ROLLER - BEARING CARRIER
63 26-90562 OIL SEAL, BEARING CARRIER
64 28-30281 KEY, LOCATING - BEARING CARRIER
65 12-31993 WASHER, GEAR HOUSING COVER
66 11-87763 COVER, GEAR HOUSING
67 12-25251 WASHER, BACKING - PROPELLER SHAFT (1/8)
68 38859A1 THRUST HUB AND WASHER ASSEMBLY
69 12-31992 WASHER, CUPPED - THRUST HUB
70 12-32007 WASHER, SPLINED - PROPELLER SHAFT
71 11-82671120 NUT, PROPELLER
72 97-31640Q4 TRIM TAB, GEAR HOUSING
73 10-32470 SCREW, TRIM TAB TO GEAR HOUSING
74 11-8M0204653 NUT, DRIVE SHAFT HOUSING TO GEAR HOUSING STUD (7/16)
75 11-23161 NUT, DRIVE SHAFT HOUSING TO GEAR HOUSING STUD (3/8)
▶MAGNETO ADAPTOR AND PILOT ASSEMBLY (63 parts) MAGNETO ADAPTOR AND PILOT ASSEMBLY
Ref OEM Part # Part Name
- 29321A7 MAGNETO ADAPTOR AND PILOT ASSEMBLY, COMPLETE
1 394-2271A2 MAGNETO ASSEMBLY, COMPLETE (4D-4)
2 45-27951 SHAFT, MAGNETO DRIVE
3 39560A1 MAGNETO ADAPTOR AND PILOT ASSEMBLY, COMPLETE
4 30-20066 BEARING, BALL - MAGNETO PILOT
5 24-27944 SPRING, HORSESHOE - MAGNETO PILOT
6 17-27962 PIN, ANCHOR - HORSESHOE SPRING TO PILOT
7 12-8M0204649 WASHER, HORSESHOE SPRING TO ANCHOR PIN
8 27946A1 ECONOMISER COLLAR AND PIN ASSEMBLY
9 17-27961 PIN, ECONOMISER COLLAR - SPRING RETAINER
10 22-25094 FITTING, GREASE - MAGNETO ADAPTOR
11 38230A1 THROTTLE ACTUATOR ASSEMBLY
12 23-26602 BUSHING, NYLON-THROTTLE ACTUATOR
13 10-31009 SCREW, THROTTLE ACTUATOR TO ECONOMISER COLLAR
14 27947 SWIVEL, LINKAGE - ECONOMISER COLLAR
15 25996A1 SWIVEL AND LINK ROD ASSEMBLY
16 66856A1 ADAPTOR, MAGNETO
17 22-25094 FITTING, GREASE - MAGNETO ADAPTOR
18 12-27939 WASHER, MAGNETO PILOT
19 14-27960 TAB WASHER, ADAPTOR CAP FASTENING
20 13-27959 WASHER, WAVE - MAGNETO BALL BEARING TENSION
21 27955 CAP, MAGNETO ADAPTOR AND PILOT FASTENING
22 10-30110 SCREW, ADAPTOR AND PILOT TO MAGNETO
23 10-78841 SCREW, ADAPTOR AND PILOT TO CRANKCASE
24 12-20084 WASHER, ADAPTOR AND PILOT TO CRANKCASE SCREW
25 11-22053 NUT, ADAPTOR AND PILOT TO CRANKCASE SCREW
26 53458 PLATE, THROTTLE STOP
27 37-29315 DECAL, THROTTLE STOP PLATE (STOP THROTTLE STOP PLATE (STOP A
28 10-24933 SCREW, THROTTLE STOP ADJUSTING
29 11-20088 NUT, THROTTLE STOP ADJUSTING SCREW
30 26852 CAP, NYLON - ADJUSTING SCREW
31 10-69035 SCREW, THROTTLE STOP PLATE TO ADAPTOR
32 28-28657 KEY, MAGNETO DRIVING
33 29784 HUB, DRIVEN PULLY
34 29783A1 DRIVEN PULLEY ASSEMBLY
35 17-24873 ROLL PIN, FLANGE LOCATING
36 29785 FLANGE, DRIVEN PULLEY
37 12-20138 WASHER, PULLEY CLAMPING SCREW
38 10-32228 SCREW, PULLEY CLAMPING
39 20140 BELT, TIMING
40 27949 RUD, LINK - UPPER
41 11-25168 NUT, UPPER LINK ROD ADJUSTING
42 27948 SWIVEL, UPPER AND LOWER LINK RODS
43 28061 LEVER, LINKAGE - UPPER
44 27941 LEVER, LINKAGE - LOWER
45 27950 ROD, LINK - LOWER
46 27940 SHAFT, VERTICAL
47 32-35899 TUBE, VERTICAL SHAFT
48 23-22981 BUSHING, NYLON - VERTICAL SHAFT
49 17-25870 ROLL PIN, VERTICAL SHAFT AND LINKAGE LEVERS
50 12-8M0204649 WASHER, UPPER AND LOWER SWIVEL
51 11-8267089 NUT, UPPER AND LOWER SWIVEL TO LEVER AND BRACKET
52 10-25781 SCREW, SET - LINKAGE LEVER
53 12-25866 WASHER, VERTICAL SHAFT - CENTER
54 33-813416 SPARK PLUG
55 85-63709A1 PROTECTOR, SPARK PLUG
56 84-821945A46 CABLE, HIGH TENSION LEAD - SPARK PLUG
57 25-25429 "O" RING, HIGH TENSION HEAD CABLE TO END CAP COVER
58 54-29425 CLIP, HIGH TENSION LEAD CABLE FASTENING
59 54-25231 CLIP, MERCURY SWITCH AND HARNESS LEADS TO MAGNETO
60 10-20401 SCREW, LEAD CLIP TO MAGNETO
61 8M0084613 "D" WASHER, CLIP FASTENING SCREW
62 394-1134A1 GROUND STRAP ASSEMBLY, MAGNETO TO CRANKCASE
▶MAGNETO ASSEMBLY (INTERNAL PARTS) (45 parts) MAGNETO ASSEMBLY (INTERNAL PARTS)
Ref OEM Part # Part Name
- 394-2271A2 MAGNETO ASSEMBLY, COMPLETE (4D-4)
1 394-1570 FRAME, MAGNETO HOUSING
2 10-25510 SCREW, SET - COIL BRIDGE
3 394-1051 LOCKWIRE, COIL BRIDGE SET SCREW
4 30-24998 BEARING, BALL (DRIVE END)
5 394-1067A1 MAGNETIC ROTOR AND SHAFT
6 30-49090 BEARING, BALL (OPPOSITE DRIVE END)
7 394-1637 SUPPORT, BALL BEARING
8 10-25509 SCREW AND LOCKWASHER, SUPPORT TO FRAME
9 84-60466A13 WIRE ASSEMBLY, PRIMARY G ROUND LEAD
10 10,10-29182 SCREW, PRIMARY GROUND
11 12-30267 WASHER, PRIMARY GROUND TERMINAL HOLDING
12 394-1579 INSULATOR, PRIMARY GROUND TERMINAL
13 12-29099 WASHER, INSULATING - PRIMARY GROUND SCREW
14 23-62769 BUSHING, INSULATING - HOUSING FRAME
15 12-26014 WASHER, PRIMARY GROUND SCREW
16 11-24656 NUT, LOCK - PRIMARY GROUND SCREW
17 11-68219 NUT, PRIMARY GROUND SCREW
18 394-1128A1 COIL ASSEMBLY
19 394-1050 CLIP, COIL - HIGH TENSION
20 13-23836 LOCKWASHER, COIL TERMINAL
21 394-1131 NUT, COIL CLIP FASTENING
22 393-1504A11 BREAKER ASSEMBLY
23 393-1586 GROMMET, PLASTIC - BREAKER BRACKET
24 16-29230 STUD, PRIMARY LEAD AND TENSION SPRING
25 11-29236 NUT, PRIMARY LEAD FASTENING
26 394-1106A1 HOLDER AND CAM WICK ASSEMBLY
27 12-26439 WASHER, BREAKER PIVOT PIN
28 18-26953 COTTER PIN, BREAKER TO PIVOT PIN
29 10-20597 SCREW, BREAKER HOLDER TO HOUSING
30 394-1130A1 CONDENSER
31 10-25509 SCREW AND LOCKWASHER, CONDENSER FASTENING
32 27-29166 GASKET, MAGNETO COVER
33 394-1577A2 COVER, MAGNETO
34 10-29418 SCREW, COVER TO FRAME
35 14-29157 TAB WASHER, COVER FASTENING SCREW
36 394-2602A1 MAGNETO ROTOR SASEMBLY
37 394-1110 CLIP, SPRING
38 27-25725 GASKET, END CAP COVER
39 394-1561A2 END CAP COVER ASSEMBLY
40 394-1056A1 BRUSH AND SPRING ASSEMBLY
41 10-25517 SCREW, HIGH TENSION CABLE FASTENING
42 10-29418 SCREW, END CAP COVER TO MAGNETO COVER
43 14-29157 TAB WASHER, COVER FASTENING SCREW
44 22-996642 ELBOW, PLASTIC - MAGNETO COVER VENT
▶STARTER MOTOR, STARTER SOLENOID, RECTIFIER AND WIRING HARNES (32 parts) STARTER MOTOR, STARTER SOLENOID, RECTIFIER AND WIRING HARNES
Ref OEM Part # Part Name
1 32177A2 RECTIFIER ASSEMBLY
2 13-8M0204647 LOCKWASHER, RECTIFIER MOUNTING SCREW
3 11-21929 NUT, RECTIFIER MOUNTING SCREW
4 32-28373 SLEEVE, RECTIFIER LEADS
5 10-35400 SCREW, HARNESS AND STATOR LEADS TO RECTIFIER
6 11-8M0204718 NUT, HARNESS AND STATOR LEAD FASTENING SCREW
7 28597 BRACKET, RECTIFIER MOUNTING
8 10-21091 SCREW, RECTIFIER BRACKET TO BOTTOM COWL
9 11-24652 NUT, BRACKET MOUNTING SCREW
10 50-55601A2 STARTER MOTOR (DELCO-REMY)
11 10-22698 SCREW, STARTER MOTOR TO CRANKCASE FLANGE
12 13-8M0204647 LOCKWASHER, STARTER MOTOR MOUNTING SCREW
13 84-93389A12 WIRE, STARTER MOTOR TO STARTER SOLENOID
14 10-69035 SCREW, GROUND WIRE TO STARTER MOTOR
15 13-26992 LOCKWASHER, GROUND WIRE FASTENING SCREW
16 28016A1 GROUND STRAP ASSEMBLY
17 32445A1 STARTER SOLENOID
18 10,13-26996 LOCKWASHER, SOLENOID TERMINAL
19 10,11-68219 NUT, SOLENOID TERMINAL
20 13-8M0204647 LOCKWASHER, SOLENOID TERMINAL (5/16)
21 11-22053 NUT, SOLENOID TERMINAL - INSIDE (5/16)
22 11-26062 NUT, CAP - SOLENOID TERMINAL - OUTSIDE (5/16)
23 10-29238 SCREW, STARTER SOLENOID TO STARTER MOTOR
24 54-24836 CLAMP, HARNESS LEAD WIRE (1/4)
25 54-25231 CLAMP, HARNESS LEAD WIRE (1/8)
26 8M0084613 "D" WASHER, CLAMP FASTENING SCREW
27 10-8M0113176 SCREW, HARNESS LEAD WIRE FASTENING
28 33401 WIRING HARNESS (INTERNAL)
29 26079A2 PLATE, BACKING - WIRING HARNESS
30 10-45893 SCREW, BACKING PLATE TO BOTTOM COWL
31 24-28975 SPRING,GARTER - INTERNAL WIRING HARNESS
32 54-22783 "S" CLIP, WIRING HARNESS LEAD TO BOTTOM COWL
▶TOP COWL AND STARTER ASSEMBLY (47 parts) TOP COWL AND STARTER ASSEMBLY
Ref OEM Part # Part Name
1 31875 HANDLE, CHROME - TOP COWL
2 31003 HANDLE, INSIDE - TOP COWL
3 35496 PAD, BUMPER - TOP COWL HANDLE
4 10-56500 SCREW, FRONT - HANDLE TO TOP COWL (1 1/4")
5 11-8267089 NUT, FRONT HANDLE FASTENING SCREW
6 23-29561 SPACER,REAR HANDLE STUD
7 13-26992 LOCKWASHER, REAR HANDLE STUD
8 11-21825 NUT, REAR HANDLE STUD
9 12-8M0204649 WASHER, CENTER HANDLE STUD !2/3" OD)
10 12-69057 WASHER, LOWER HANDLE STUD (3/4" OD)
11 11-21825 NUT, CENTER AND LOWER HANDLE STUD
12 10-29199 SCREW, CENTER - HANDLE TO TOP COWL (1")
13 14-20165 TAB WASHER, SHEAVE SHAFT NUT
14 11-20166 NUT, SHEAVE SHAFT (LEFT HAND THREAD)
15 28967 SCREEN, VENT - TOP COWL
16 10-26668 SCREW, VENT SCREEN TO TOP COWL
17 177-2355A3 TOP COWL ASSEMBLY
18 16-20500 STUD, REAR - TOP COWL TO COVER
19 16-20353 STUD, FRONT - TOP COWL TO CRANKCASE
20 25-20116 GROMMET, CHOKE KNOB
21 23-20326 SPACER, TOP COWL STUD
22 12-20028 WASHER, TOP COWL STUD (1/16")
23 12-69057 WASHER, TOP COWL STUD (3/4" OD)
24 12-20583 WASHER, TOP COWL STUD (1/32")
25 11-8267089 NUT, TOP COWL FASTENING STUDS
26 20155 RETAINER, STARTER SPRING
27 24-29340T02 SPRING, STARTER REWING
28 23-28912 BUSHING, SPRING GUIDE
29 50-30994 SHEAVE ASSEMBL
30 30596 PAWL, STARTER
31 13-36206 WASHER, WAVE - STARTER PAWL
32 23-28919 BUSHING, NYLON - SHEAVE SHAFT SPACER
33 45477A1 SPACER, SHEAVE SHAFT
34 26179 RETAINER, WAVE WASHER
35 13-20160 WASHER, WAVE - RETAINER TENSION
37 30595 PLATE, RETAINER - STARTER PAWL
38 45477A1 SHAFT, SHEAVE
39 35391A1 TRIM MOULDING ASSEMBLY, TOP COWL
40 34433 BRACKET, TENSION - TRIM MOULDING
41 12-34434 WASHER, BRACKET FASTENING SCREW
42 10-23015 SCREW, BRACKET AND TRIM MOULDING TO TOP COWL
43 11-20110 NUT, BRACKET FASTENING SCREW
44 50-12066Q10 STARTER CABLE ASSEMBLY
45 28747 HANDLE, STARTER CABLE
46 79470A1 RETAINER, STARTER CABLE AND HANDLE
47 35880 PLATE, CABLE GUIDE SEE NOTE BELOW
48 6-32,10-358811 SCREW, DRIVE - CABLE GUIDE PLATE TO TOP COWL Comment: SEE NOTE BELOW

100-Hour / Annual Service Checklist

Regular maintenance keeps your Mercury 500 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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