Propeller Cotter Pin – Fits Yamaha, Suzuki, Johnson/Evinrude Outboard Motors (Replaces 09204-03001, 91401-40025)

Propeller Cotter Pin – Fits Yamaha, Suzuki, Johnson/Evinrude Outboard Motors

This aftermarket propeller cotter pin is designed to secure the propeller on a wide range of outboard motors, including models from Yamaha, Suzuki, and Johnson/Evinrude. It is manufactured from marine-grade 304 stainless steel for high corrosion resistance and durability in harsh saltwater environments.

It serves as a direct replacement for multiple OEM part numbers, ensuring a secure fit for many popular engine series. Please consult the cross-reference and compatibility tables below to confirm this part is correct for your specific application.

• Material: 304 Stainless Steel
• Dimensions: Approximately 4mm x 25mm
• Installation: Inserts through the propeller shaft and is bent to secure the propeller nut.

Part Number Cross-Reference

Use this table to confirm equivalent part numbers across OEM and aftermarket brands.

Compatible Engine Models

Confirm your engine model/year in the table below. For Yamaha owners, here’s a guide to help you identify your engine’s serial/model: Yamaha Serial Number Guide. You can also review exploded diagrams to verify part numbers: Yamaha Parts Diagrams & Catalog.

For Suzuki owners, You can review exploded diagrams here to verify part numbers: Suzuki Parts Diagrams & Catalog.

Confirm your engine model/year in the table below. For Johnson/Evinrude owners, here’s a guide to help you identify your engine’s serial/model: Johnson Serial Number Guide.

Yamaha Outboards

Suzuki Outboards

Johnson/Evinrude Outboards

Technical Specifications

Package Contents

• 12 x Propeller Cotter Pins (Replaces Suzuki 09204-03001, Johnson Evinrude 5030087, Yamaha 91401-40025-00)

Installation Guide

1. Remove the old cotter pin: Using pliers, straighten the two legs of the existing cotter pin and pull it out from the propeller shaft castle nut.
2. Unscrew the castle nut: Remove the propeller nut and any washers behind it. Keep them in a safe place.
3. Remove the propeller: Carefully slide the propeller off the propeller shaft.
4. Reinstall propeller and hardware: Slide the new or existing propeller back onto the shaft, followed by the washer(s) and the castle nut.
5. Tighten the nut: Tighten the castle nut to the manufacturer's recommended torque. Align a slot in the nut with the hole in the propeller shaft. Do not loosen the nut to align; tighten it slightly until the holes align.
6. Insert the new cotter pin: Slide the new cotter pin through the hole in the propeller shaft.
7. Secure the pin: Using pliers, bend the longer leg of the cotter pin up and over the end of the shaft, and bend the other leg down against the side of the nut to lock it in place.

Troubleshooting & FAQ

Q: How do I confirm this cotter pin fits my engine?
A: The best way is to check your original part number. This pin replaces Suzuki numbers (e.g., 09204-03001), Yamaha numbers (e.g., 91401-40025-00), and Johnson/Evinrude 5030087. You can also compare the dimensions (approx. 4mm x 25mm) with your old pin or consult your engine's service manual.

Q: Why is the pin made of 304 stainless steel?
A: 304 stainless steel offers an excellent balance of strength, corrosion resistance, and value, making it ideal for marine environments where parts are constantly exposed to water, especially saltwater. It is highly resistant to rust and wear.

Q: How often should I replace my propeller cotter pin?
A: It is highly recommended to use a new cotter pin every time you remove and reinstall your propeller. Reusing an old pin is unsafe, as bending the metal back and forth can weaken it, increasing the risk of failure and potential propeller loss.

Q: OEM vs. Aftermarket?
A: This listing is an aftermarket replacement part (not an OEM component). We build to OEM specifications using comparable-grade materials. Production is done in an ISO9002-certified facility, and each batch is inspected for consistent performance.

Q: How fast do you ship and how much does it cost?
A: We offer fast global shipping—typically 5–15 days worldwide—and standard shipping is free. Expedited options are available at checkout depending on your location.

Q: What is your warranty and return policy?
A: This product includes a 1-year warranty against manufacturing defects under normal use. If something goes wrong, contact our support team with your order details. Returns are accepted within our standard return window (unused & in original condition); please see our policy page or reach out for instructions.

Important Notes

• Verify that the product images and specifications match your original part. If discrepancies exist—even if your model is listed—do not proceed with the purchase.
• This product is an aftermarket replacement part and is not an OEM component.
• Professional installation is recommended to ensure safety and optimal performance.

Why Choose JLM MARINE?

• Quality Assured: As a trusted manufacturer for over 20 years, we supply top marine brands globally.
• Fast Global Shipping: Free delivery worldwide in 5–15 days.
• Direct from Manufacturer: Competitive pricing without compromising quality.