🔎 Mercury 200 (DFI) Reference Library — Exploded parts diagrams (41 diagrams), specifications, common issues, and maintenance checklist.
The Mercury 200 (DFI) is a 4-Stroke, V6 64-degree, DOHC, 24-valve outboard motor. Designed for large center-consoles, offshore sport-fishing boats, and multi-engine configurations.
Quick Reference Specifications
| Specification |
Value |
| Engine Type |
4-Stroke, V6 64-degree, DOHC, 24-valve |
| Horsepower |
200 HP |
| Displacement |
3400 cc (3.4L / 209 CID) |
| Bore x Stroke |
93.3 mm x 83.3 mm |
| Spark Plug (Type & Gap) |
NGK LKAR7C-9 |
| Engine Oil Capacity |
6.6 L (7.0 qt) |
| Recommended Engine Oil |
Mercury FourStroke Oil 25W-40 |
| Gear Case Oil Capacity |
26 oz |
| Idle Speed (in gear) |
600 ± 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 200 (DFI):
-
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 200 (DFI).
▶ACCESSORIES (1 parts)
| Ref |
OEM Part # |
Part Name |
| 0 |
84-877561A2 |
HARNESS ASSEMBLY |
▶AIR COMPRESSOR COMPONENTS (31 parts)
| Ref |
OEM Part # |
Part Name |
| - |
25-832804A03 |
O-RING KIT |
| 1 |
8M0063279 |
COMPRESSOR ASSEMBLY, Air |
| 2 |
1100-8M0050792 |
END CAP ASSEMBLY |
| 3 |
NSS |
NOT SOLD SEPARATE, SNAP RING |
| 4 |
10-82130020 |
SCREW, (M6 x 20) |
| 5 |
25-89224 |
O-RING |
| 6 |
25-832804 |
O-RING, (2.739 x .070) |
| 7 |
653-833146T06 |
CONNECTING ROD ASSEMBLY |
| 8 |
828222A4 |
PISTON ASSEMBLY |
| 9 |
53-8348101 |
RING, Lock |
| 10 |
835088A10 |
REED PLATE ASSEMBLY |
| 11 |
25-67207 |
O-RING, (3.489 x .070) |
| 12 |
25-832804 |
O-RING, (2.739 x .070) |
| 13 |
26-828225 |
SEAL |
| 14 |
835087A3 |
HEAD ASSEMBLY, Compressor |
| 15 |
22-8307532 |
FITTING, Straight |
| 16 |
10-82446035 |
SCREW, (M8 x 35) |
| 17 |
22-151331 |
FITTING |
| 18 |
22-996642 |
FITTING, Elbow 90 Degree (.125-27 x .250) Nylon |
| 19 |
21-428641 |
FITTING, Check Valve |
| 20 |
22-856744 |
FITTING |
| 21 |
22-16604 |
FITTING, Straight (.125-27) |
| 22 |
25-831985 |
O-RING, (.468 x .078) |
| 23 |
13536A14 |
SENSOR ASSEMBLY, Temperature Comment: (DESIGN II) |
| 24 |
13536A12 |
SENSOR ASSEMBLY, Temperature Comment: (DESIGN I) |
| 25 |
10-81893412 |
SCREW, (M8 x 12) |
| 26 |
22-390721 |
PLUG, Pipe (.125-27) Brass |
| 27 |
137151 |
RETAINER |
| 28 |
8M0175171 |
PULLEY |
| 29 |
10-81893450 |
SCREW, (M8 x 50) |
| 30 |
10-85593912 |
SCREW, (M6 x 12) |
▶AIR HANDLER (28 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
850296T4 |
COVER |
| 2 |
25-86361 |
GROMMET |
| 3 |
25-13467 |
GROMMET, (.88 Inside Diameter) |
| 4 |
25-8M0153609 |
GROMMET |
| 5 |
35-853333T |
FILTER |
| 6 |
8544932 |
COVER |
| 7 |
10-40056106 |
SCREW, (M5 x 13) |
| 8 |
878112T1 |
AIR HANDLER ASSEMBLY |
| 9 |
37-881865 |
DECAL, Caution-Start in Gear |
| 10 |
855756A1 |
BRACKET KIT |
| 11 |
10-1993716 |
SCREW, (M6 x 16) |
| 12 |
8M0047624 |
PUMP ASSEMBLY |
| 13 |
25-856928 |
GROMMET |
| 14 |
22-855802A1 |
ELBOW |
| 15 |
54-8M0214911 |
CLAMP, (15.7) |
| 16 |
32-856825 |
HOSE |
| 17 |
23-85686953 |
SLEEVE, (27.00 Inches Bulk) |
| 18 |
22-880862A1 |
FITTING |
| 19 |
25-805062 |
O-RING, (.530 x .082) |
| 20 |
32-856778 |
HOSE |
| 21 |
37-804658A01 |
DECAL, EPA Label Information Comment: (2001)(SEE NOTE 1) |
| 22 |
10-82130045 |
SCREW, (M6 x 45) |
| 23 |
854343T7 |
ATTENUATOR ASSEMBLY, Air |
| 24 |
54-23567 |
CLIP |
| 25 |
10-69570 |
SCREW, (#10-16 x .750) |
| 26 |
84-88807A27 |
CABLE ASSEMBLY |
| 27 |
10-16955 |
SCREW, (M6 x 8) |
| 28 |
61990 |
TIE STRAP, (14.00 Inches) |
▶AIR HANDLER COMPONENTS (35 parts)
| Ref |
OEM Part # |
Part Name |
| - |
854198A01 |
POWERHEAD ASSEMBLY Comment: (200) |
| 1 |
858541T1 |
ADAPTOR PLATE |
| 2 |
27-804680 |
GASKET |
| 3 |
828623T6 |
REED BLOCK |
| 4 |
10-8555252 |
SCREW, (M6) |
| 5 |
23-855364 |
BUSHING |
| 6 |
25-855362001 |
GROMMET |
| 7 |
10-81893435 |
SCREW, (M8 x 35) |
| 8 |
12-817274 |
WASHER, (.344 x 1.00 x .063) Stainless Steel |
| 9 |
855631A2 |
PLENUM KIT, Air |
| 10 |
10-1993716 |
SCREW, (M6 x 16) |
| 11 |
27-804679004 |
GASKET |
| 12 |
854445 |
SENSOR, MAP |
| 13 |
884522 |
BRACKET |
| 14 |
8M0214984 |
SENSOR ASSEMBLY, Temperature |
| 15 |
25-627021 |
O-RING, (.301 x .070) |
| 16 |
855425A1 |
THROTTLE BODY KIT |
| 17 |
10-82130040 |
SCREW, (M6 x 40) |
| 18 |
25-855426 |
O-RING |
| 19 |
10-81893430 |
SCREW, (M8 x 30) |
| 20 |
8M0185614 |
PUMP ASSEMBLY, Oil |
| 21 |
677483 |
ROLLER |
| 22 |
8588511 |
LEVER ASSEMBLY, Throttle |
| 23 |
10-40056107 |
SCREW, (M5 x 16) |
| 24 |
12-89302 |
WASHER, (.203 x .406 x .040) |
| 25 |
10,13-69432 |
LOCKWASHER, External |
| 26 |
53-8237951 |
RING, Retaining |
| 27 |
858353A2 |
CAM ASSEMBLY Comment: SN# 0T408999 & Below |
| 28 |
23-856895 |
BUSHING Comment: SN# 0T408999 & Below |
| 29 |
10-81893440 |
SCREW, (M8 x 40) Comment: SN# 0T408999 & Below |
| 30 |
8235694 |
BALL, Threaded |
| 31 |
23-8M0215006 |
BUSHING |
| 32 |
54-804842 |
CLAMP |
| 33 |
10-82130040 |
SCREW, (M6 x 40) |
| 34 |
22-856827 |
FITTING |
▶AIR HOSES (8 parts)
| Ref |
OEM Part # |
Part Name |
| - |
854198A01 |
POWERHEAD ASSEMBLY Comment: (200) |
| 1 |
22-856842 |
ELBOW |
| 2 |
54-816311T |
TIE STRAP, (8.00 Inches) |
| 3 |
32-8M0064783 |
HOSE, Pulse Line |
| 4 |
54-8M0214964 |
CLAMP, Hose (15.3) |
| 5 |
32-8567631 |
HOSE ASSEMBLY |
| 6 |
32-804828 |
HOSE |
| 7 |
32-804829 |
HOSE ASSEMBLY |
▶BOTTOM COWL (24 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
113-850302A1 |
BOTTOM COWL, Port |
| 2 |
854367001 |
PLUG |
| 3 |
113-850301A1 |
BOTTOM COWL, Starboard |
| 4 |
8M0109218 |
SEAL, (44.00 Inches) |
| 5 |
10-82130040 |
SCREW, (M6 x 40) |
| 6 |
10-824868 |
SCREW, (M6 x 75) |
| 7 |
12-8M0204649 |
WASHER, (.281 x .500 x .060) Stainless Steel |
| 8 |
8M0053903 |
FRONT HANDLE |
| 9 |
23-335891 |
BUSHING |
| 10 |
25-48462 |
O-RING, (.614 x .070) |
| 11 |
8219423 |
PAWL |
| 12 |
12-69057 |
WASHER, (.281 x .734 x .063) |
| 13 |
11-401366 |
NUT, (M6) Stainless Steel |
| 14 |
10-8214281 |
SCREW, (#10-16 x .625) |
| 15 |
54-822873 |
CLIP |
| 16 |
87-8M0235191 |
SWITCH, Trim |
| 17 |
8M8027677 |
RIGGING KIT (UPPER) |
| 18 |
NSS |
NOT SOLD SEPARATE, CLAMP (LOWER) |
| 19 |
10-82130012 |
SCREW, (M6 x 12) |
| 20 |
NSS |
NOT SOLD SEPARATE, STRAP |
| 21 |
859343 |
FOAM |
| 22 |
54-850181 |
TIE STRAP, (11.750 Inches) |
| 23 |
852361T1 |
HANDLE, Cowl |
| 24 |
13-29402 |
WAVE WASHER |
▶COIL PLATE (27 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
850295T4 |
PLATE |
| 2 |
339-856991A1 |
COIL KIT |
| 3 |
10-82129130 |
SCREW, (M6 x 30) |
| 4 |
84-881908T |
CABLE SET, Hi Tension |
| 5 |
NSS |
NOT SOLD SEPARATE, BOOT |
| 6 |
33-889597Q |
SPARK PLUG |
| 7 |
859595T |
DRIVER, Dual Coil |
| 8 |
84-858414A1 |
CABLE ASSEMBLY, Braided |
| 9 |
10-82129110 |
SCREW, (M6 x 10) |
| 10 |
12-8M0204649 |
WASHER, (.281 x .500 x .060) Stainless Steel |
| 11 |
25-833155 |
GROMMET |
| 12 |
12-4002318 |
WASHER |
| 13 |
23-8502341 |
BUSHING |
| 14 |
10-81893435 |
SCREW, (M8 x 35) |
| 15 |
71-8M0157742 |
SENSOR KIT, (0-50 PSI) Comment: SN# 0T409000 & Up |
| 16 |
22-8M0207782 |
FITTING Comment: SN# 0T409000 & Up |
| 17 |
54-883066 |
CLIP, (.865) Comment: SN# 0T409000 & Up |
| 18 |
54-816311T |
TIE STRAP, (8.00 Inches) Comment: SN# 0T409000 & Up |
| 19 |
32-85978571 |
TUBING, (44.00 Inches Bulk) (cut to 18 IN.) Comment: SN# 0T409000 & Up |
| 20 |
10-82129114 |
SCREW, (M6 x 14) |
| 21 |
12-36001 |
WASHER |
| 22 |
71-8M0157742 |
SENSOR, (0-50 PSI) Comment: SN# 0T408999 & Below |
| 23 |
22-856594 |
FITTING, Barbed Comment: SN# 0T408999 & Below |
| 24 |
54-858954 |
CLIP, (.625) Comment: SN# 0T408999 & Below |
| 25 |
54-816311T |
TIE STRAP, (8.00 Inches) Comment: SN# 0T408999 & Below |
| 26 |
32-9912878 |
HOSE, (.187) (26.00 Inches Bulk) (Cut to15 IN.) Comment: SN# 0T408999 & Below |
| 27 |
22-859092 |
FITTING Comment: SN# 0T408999 & Below |
▶CRANKSHAFT, PISTONS - AND CONNECTING RODS (23 parts)
| Ref |
OEM Part # |
Part Name |
| - |
854198A01 |
POWERHEAD ASSEMBLY Comment: (200) |
| 1 |
482-9784A11 |
CRANKSHAFT ASSEMBLY Comment: SN# 0T325117 & Up |
| 2 |
NSS |
NOT SOLD SEPARATE, WEAR SLEEVE |
| 3 |
30-67923T |
BEARING, Ball (LOWER) |
| 4 |
53-67446 |
RING |
| 5 |
39-843198T01 |
RING |
| 6 |
28-91800 |
KEY, Woodruff |
| 7 |
25-35126 |
O-RING, (.859 x .139) |
| 8 |
817001A1 |
RACE ASSEMBLY, Bearing Comment: SN# 0T325116 & Below |
| 9 |
NSS |
NOT SOLD SEPARATE, NEEDLE ROLLER Comment: SN# 0T325116 & Below |
| 10 |
2720-859445A2 |
PISTON ASSEMBLY Comment: (PORT - .030 O.S) |
| 11 |
53-8320811 |
LOCK RING |
| 12 |
39-875257A12 |
RING SET, Piston Comment: (.030 O/S) |
| 13 |
NSS |
NOT SOLD SEPARATE, PISTON RING (LOWER) |
| 14 |
600-8M0125869 |
CONNECTING ROD ASSEMBLY |
| 15 |
10-94320 |
SCREW, (.375-24 x 1.250) |
| 16 |
31-844338A01 |
BEARING/CAGE KIT |
| 17 |
NSS |
NOT SOLD SEPARATE, NEEDLE ROLLER BEARING |
| 18 |
12-88263 |
THRUST WASHER |
| 19 |
29-8M0204715 |
NEEDLE, Roller Bearing |
| 20 |
31-816773A2 |
BEARING ASSEMBLY (UPPER) |
| 21 |
26-859093 |
SEAL |
| 22 |
25-823683 |
O-RING, (1.989 x .070) |
▶CYLINDER BLOCK AND END CAP (63 parts)
| Ref |
OEM Part # |
Part Name |
| - |
854198A01 |
POWERHEAD ASSEMBLY Comment: (200) |
| 1 |
885-9811A65 |
CYLINDER BLOCK Comment: (200) |
| 2 |
10-81893440 |
SCREW, (M8 x 40) |
| 3 |
8M0111325 |
COVER |
| 4 |
16-903509 |
STUD, (M10 x 1.5 x 64) |
| 5 |
16-8154431 |
STUD, (M10 x 1.5 x 155) |
| 6 |
8248577 |
DEFLECTOR, Water |
| 7 |
21-8781051 |
CHECK VALVE |
| 8 |
17-8M0036405 |
PIN |
| 9 |
17-43044 |
PIN, Dowel - Without Hole (.375 x .625) |
| 10 |
19-850309001 |
PLUG |
| 11 |
10-81893435 |
SCREW, (M8 x 35) |
| 12 |
10-82446180 |
SCREW, (M10 x 80) |
| 13 |
8589521 |
BRACKET |
| 14 |
54-859376 |
CLIP |
| 15 |
8215832 |
PIN, Special |
| 16 |
8588641 |
RETAINER |
| 17 |
12-8M0214963 |
WASHER, (.406 x .750 x .105) Stainless Steel |
| 18 |
11-4013610 |
NUT, (M10) Stainless Steel |
| 19 |
8M0082988 |
SENSOR |
| 20 |
10-40011107 |
SCREW, (M5 x 16) Stainless Steel |
| 21 |
1171-9787A4 |
END CAP ASSEMBLY |
| 22 |
25-62700 |
O-RING, (3.237 x .103) |
| 23 |
26-8308981 |
SEAL |
| 24 |
10-82130020 |
SCREW, (M6 x 20) |
| 25 |
857186T02 |
PLATE ASSEMBLY |
| 26 |
23-855729 |
MOUNT |
| 27 |
10-82130145 |
SCREW, (M10 x 45) |
| 28 |
10-82130012 |
SCREW, (M6 x 12) |
| 29 |
25-19565002 |
GROMMET |
| 30 |
12-855725 |
WASHER |
| 31 |
54-858424 |
CLAMP |
| 32 |
54-858951 |
J CLIP |
| 33 |
10-82130012 |
SCREW, (M6 x 12) |
| 34 |
818574 |
SEAL, Cylinder Head |
| 35 |
878453 |
SEAL |
| 36 |
900-858483T07 |
CYLINDER HEAD Comment: (PORT) |
| 37 |
26-854639001 |
SEAL, Thermostat |
| 38 |
NLA |
No Longer Available, THERMOSTAT Comment: (Refer to Service Bulletin 2002-08) |
| 39 |
27-8503181 |
GASKET, Thermostat Cover |
| 40 |
858857 |
THERMOSTAT COVER Comment: (STARBOARD) |
| 41 |
10-82130025 |
SCREW, (M6 x 25) |
| 42 |
10-8M0045380 |
SCREW, (M8 x 50) |
| 43 |
8M0214984 |
SENSOR ASSEMBLY, Temperature |
| 44 |
25-627021 |
O-RING, (.301 x .070) |
| 45 |
10-82130012 |
SCREW, (M6 x 12) |
| 46 |
8266241 |
CLAMP |
| 47 |
8583561 |
LEVER, TPI |
| 48 |
10-82130025 |
SCREW, (M6 x 25) |
| 49 |
23-856954 |
BUSHING |
| 50 |
25-8M0190980 |
GROMMET |
| 51 |
12-65567 |
WASHER, (.265 x .750 x .048) Stainless Steel |
| 52 |
10-40011113 |
SCREW, (M5 x 45) Stainless Steel |
| 53 |
8M6005165 |
INDICATOR, Throttle Position |
| 54 |
10-81893420 |
SCREW, (M8 x 20) |
| 55 |
22-328022 |
PLUG, Pipe (.125-27) Brass |
| 56 |
8M0084743 |
LINK |
| 57 |
54-858902 |
CLAMP |
| 58 |
12-858950 |
WASHER |
| 59 |
10-82130016 |
SCREW, (M6 x 16) |
| 60 |
54-858932 |
CLIP |
| 61 |
8582261 |
COVER |
| 62 |
8544862 |
BRACKET |
▶DIGITAL ELECTRIC PARTS (3 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
84-859244T1 |
HARNESS ASSEMBLY, Digital Adaptor |
| 2 |
84-859316T1 |
HARNESS ASSEMBLY, Diagnostic Adaptor |
| 3 |
859187A1 |
SENDER ASSEMBLY, Trim |
▶DRIVESHAFT HOUSING & EXHAUST TUBE (31 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
3519-832938A06 |
HOUSING ASSEMBLY, Driveshaft Comment: (X/XX-LONG) |
| 2 |
16-8M0008031 |
STUD, (M12 x 52) Comment: (LONG/X-LONG) |
| 3 |
10-857136 |
SCREW, (M12 x 35) Comment: (LONG/X-LONG) |
| 4 |
25-8331231 |
GROMMET |
| 5 |
12-856982 |
WASHER, (.500 x .810 x .090) Stainless Steel |
| 6 |
11-896895 |
NUT, (M12 x 1.75) |
| 7 |
19-64649 |
PLUG |
| 8 |
10-898834 |
SCREW, (M14 x 178) |
| 9 |
88238A10 |
CABLE ASSEMBLY, Ground |
| 10 |
12-815432 |
WASHER, (.562 x 2.00 x .125) |
| 11 |
12-8154331 |
WASHER, (1.25 x 2.00 x .19) |
| 12 |
8137711 |
MOUNT |
| 13 |
12-825190 |
WASHER |
| 14 |
11-896602 |
NUT |
| 15 |
8186442 |
CLAMP |
| 16 |
10-81893435 |
SCREW, (M8 x 35) |
| 17 |
13-72521 |
LOCKWASHER, Internal Tooth |
| 18 |
8M0001136 |
COVER, Black |
| 19 |
10-69079 |
SCREW, (#10-16 x .440) |
| 20 |
8329321 |
SEAL |
| 21 |
833116A4 |
TUBE ASSEMBLY, Exhaust |
| 22 |
NSS |
NOT SOLD SEPARATE, STRAINER |
| 23 |
10-81893435 |
SCREW, (M8 x 35) |
| 24 |
32-8M0042787 |
TUBE, Water Comment: (XX-LONG) |
| 25 |
832940001 |
SEAL |
| 26 |
8329391 |
CLAMP |
| 27 |
10-41508 |
SCREW, (.250-20 x .500) Stainless Steel |
| 28 |
8M0105088 |
SPACER Comment: (XX-LONG) |
| 29 |
17-43044 |
PIN, Dowel - Without Hole (.375 x .625) Comment: (XX-LONG) |
| 30 |
16-8M0008047 |
STUD, (M12 x 179) Comment: (XX-LONG) |
| 31 |
10-857137 |
SCREW, (M12 x 160) Comment: (XX-LONG) |
▶Dual Engine Tie Bar Kit (21 parts)
| Ref |
OEM Part # |
Part Name |
| - |
92876A9 |
EXTENSION KIT, Dual Engine |
| 1 |
71565A2 |
TUBE ASSEMBLY |
| 2 |
25-48462 |
O-RING, (.614 x .070) |
| 3 |
41055 |
MOUNT |
| 4 |
14-42100 |
TAB WASHER |
| 5 |
11-8M0041651 |
NUT, (.875-14) |
| 6 |
88404 |
TAB WASHER |
| 7 |
10-38601 |
SCREW, (.250-28 x 1.250) |
| 8 |
17729A1 |
BRACKET |
| 9 |
10-62055 |
SCREW, (.312-24 x 1.250) |
| 10 |
17728 |
TAB WASHER |
| 11 |
10-140001 |
SCREW, (.375-24 x 1.38) |
| 12 |
11-8M0204726 |
NUT, (.375-24) Stainless Steel |
| 13 |
8M0026167 |
STEERING EYE |
| 14 |
23-23651 |
SLEEVE, (1.625) |
| 15 |
97931 |
TUBING, (4.00 Inches) |
| 16 |
8M0026098 |
COUPLER, (15.00 Inches) |
| 17 |
11-42099 |
NUT, (.562-18) |
| 18 |
22-821169 |
COUPLING |
| 19 |
12-37828 |
WASHER, (.390 x .625 x .062) Stainless Steel Comment: (.625 Outside Diameter) |
| 20 |
10-94319 |
SCREW, (.375-24 x 1.5) |
▶EXHAUST PLATE (42 parts)
| Ref |
OEM Part # |
Part Name |
| - |
854198A01 |
POWERHEAD ASSEMBLY Comment: (200) |
| 1 |
832935A17 |
PLATE ASSEMBLY, Exhaust |
| 2 |
27-8329335 |
GASKET |
| 3 |
27-8329344 |
GASKET (LOWER) |
| 4 |
8M0043157 |
SEAL |
| 5 |
22-8320761 |
FITTING, Check Valve |
| 6 |
35-8348084 |
STRAINER |
| 7 |
21-817519A1 |
CHECK VALVE ASSEMBLY, Drain |
| 8 |
17-43044 |
PIN, Dowel - Without Hole (.375 x .625) |
| 9 |
65663A2 |
COVER ASSEMBLY |
| 10 |
10-81893435 |
SCREW, (M8 x 35) |
| 11 |
814190 |
CARRIER |
| 12 |
25-814191 |
GROMMET |
| 13 |
814189 |
POPPET |
| 14 |
24-64878 |
SPRING |
| 15 |
65664A1 |
PLATE ASSEMBLY |
| 16 |
27-88907003 |
GASKET |
| 17 |
648771 |
DIAPHRAGM |
| 18 |
12-76451 |
WASHER |
| 19 |
10-69570 |
SCREW, (#10-16 x .750) |
| 20 |
10-81893435 |
SCREW, (M8 x 35) |
| 21 |
850306A04 |
BOOT, Idle Exhaust |
| 22 |
54-850896 |
CLAMP, (28.6) |
| 23 |
22-8M0077650 |
FITTING, Tell-Tale |
| 24 |
19-821908 |
PLUG |
| 25 |
12-821915 |
WASHER |
| 26 |
22-8596001 |
FITTING |
| 27 |
8219631 |
CHECK VALVE |
| 28 |
25-30641 |
O-RING, (.299 x .103) |
| 29 |
11-401386 |
NUT, (M6) Stainless Steel |
| 30 |
883142A03 |
SHIFT LINK KIT Comment: (DESIGN II) |
| 31 |
8539683 |
SLIDE Comment: (DESIGN II) |
| 32 |
11-401386 |
NUT, (M6) Stainless Steel |
| 33 |
23-42994 |
BUSHING |
| 34 |
8240703 |
SHIFT SHAFT, Upper Comment: (XX-LONG) |
| 35 |
23-48237 |
BUSHING |
| 36 |
43585 |
COUPLING |
| 37 |
32-859626A1 |
FLUSH HOSE KIT |
| 38 |
25-12602002 |
GROMMET |
| 39 |
12-35459 |
WASHER |
| 40 |
883142A03 |
SHIFT LINK Comment: (DESIGN I) |
| 41 |
8539682 |
SLIDE Comment: (DESIGN I) |
▶FLYWHEEL/ALTERNATOR (18 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
8M6013461 |
ALTERNATOR |
| 2 |
24-8523742 |
SPRING |
| 3 |
23-42139 |
BUSHING |
| 4 |
850291T3 |
BELT TENSIONER |
| 5 |
23-8525622 |
BUSHING |
| 6 |
10-4007180 |
SCREW, (M10 x 45) |
| 7 |
8M6005030 |
PULLEY ASSEMBLY |
| 8 |
10-4010835 |
SCREW, (M10 x 35) Hex Flange - Stainless Steel |
| 9 |
57-828507Q5 |
BELT |
| 10 |
283-859619T1 |
FLYWHEEL |
| 11 |
11-42979 |
NUT, (M16) |
| 12 |
12-33001 |
WASHER, (.641 x 1.250 x .190) |
| 13 |
19-45907 |
PLUG, Yellow |
| 14 |
11-401386 |
NUT, (M6) Stainless Steel |
| 15 |
84-856583A4 |
CABLE ASSEMBLY |
| 16 |
12-4002319 |
WASHER |
| 17 |
10-82130150 |
SCREW, (M10 x 50) |
| 18 |
10-82130012 |
SCREW, (M6 x 12) |
▶FUEL PUMP (20 parts)
| Ref |
OEM Part # |
Part Name |
| - |
854198A01 |
POWERHEAD ASSEMBLY Comment: (200) |
| 1 |
NSS |
NOT SOLD SEPARATE, FUEL PUMP |
| 2 |
NSS |
NOT SOLD SEPARATE, DISC CHECK VALVE |
| 3 |
NSS |
NOT SOLD SEPARATE, DIAPHRAGM |
| 4 |
NSS |
NOT SOLD SEPARATE, RETAINER |
| 5 |
NSS |
NOT SOLD SEPARATE, SPRING |
| 6 |
NSS |
NOT SOLD SEPARATE, CAP |
| 7 |
NSS |
NOT SOLD SEPARATE, SPRING |
| 8 |
NSS |
NOT SOLD SEPARATE, CAP |
| 9 |
NSS |
NOT SOLD SEPARATE, DIAPHRAGM |
| 10 |
NSS |
NOT SOLD SEPARATE, GASKET, Boost |
| 11 |
NSS |
NOT SOLD SEPARATE, GASKET, Pulse |
| 12 |
27-8M0204705 |
GASKET |
| 13 |
987752 |
PLATE |
| 14 |
22-16604 |
FITTING, Straight (.125-27) |
| 15 |
10-82104540 |
SCREW, (M5 x 40) |
| 16 |
10-82130050 |
SCREW, (M6 x 50) |
| 17 |
144303 |
BASE |
| 18 |
54-8589781 |
CLIP, Fuel Hose |
| 19 |
12-8M0204649 |
WASHER, (.281 x .500 x .060) Stainless Steel |
▶FUEL RAILS (32 parts)
| Ref |
OEM Part # |
Part Name |
| - |
854198A01 |
POWERHEAD ASSEMBLY Comment: (200) |
| 1 |
8M6001743 |
INJECTOR, Air Comment: (SALTWATER) |
| 2 |
12-828694A1 |
WASHER ASSEMBLY, Cupped |
| 3 |
884429T16 |
FUEL RAIL ASSEMBLY (PORT) Comment: (REFERENCE SERVICE BULLETIN 2001-14) |
| 4 |
884430T06 |
FUEL RAIL ASSEMBLY (STARBOARD) Comment: (W/O FUEL INJECTORS) |
| 5 |
54-804830 |
CLAMP |
| 6 |
54-8048311 |
CLAMP |
| 7 |
54-804832 |
CLAMP |
| 8 |
8M0041097 |
CLAMP |
| 9 |
25-804529 |
O-RING KIT |
| 10 |
19-804835 |
PLUG |
| 11 |
22-804836 |
FITTING |
| 12 |
804837 |
VALVE ASSEMBLY, (.5 Inch Diameter) |
| 13 |
8M0047053 |
VALVE KIT, Fuel |
| 14 |
22-805515 |
CAP |
| 15 |
25-804840 |
O-RING KIT |
| 16 |
25-804530 |
O-RING KIT |
| 17 |
804533 |
DIAPHRAGM ASSEMBLY |
| 18 |
24-804534 |
SPRING |
| 19 |
25-804536 |
O-RING |
| 20 |
804535001 |
COVER |
| 21 |
804526 |
SCREW PACKAGE, (M5 x 16) (2 Per) |
| 22 |
804532 |
O-RING KIT Comment: (16 PER KIT) |
| 23 |
10-804525001 |
SCREW PACKAGE, (M5 x 8) (2 Per) |
| 24 |
8M0222160 |
REGULATOR, Air |
| 25 |
54-880808 |
CLAMP |
| 26 |
25-880809 |
O-RING KIT |
| 27 |
8M0222157 |
INJECTOR |
| 28 |
16-8M0063255 |
STUD, (M10 x 91) |
| 29 |
11-826292 |
NUT, (M10) Brass/Nickel Plated |
| 30 |
54-859376 |
CLIP |
| 31 |
26-804875 |
SEAL KIT |
▶FUEL SYSTEM (19 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
54-8M0214964 |
CLAMP, Hose (15.3) |
| 2 |
21-8557611 |
CHECK VALVE |
| 3 |
54-8583253 |
CLAMP |
| 4 |
10-858939 |
SCREW, (M5 x 35) |
| 5 |
54-816311T |
TIE STRAP, (8.00 Inches) |
| 6 |
22-822769 |
CONNECTOR |
| 7 |
32-8M0064780 |
HOSE/SLEEVE |
| 8 |
32-8M0064778 |
HOSE |
| 9 |
32-804825 |
HOSE, Fuel Supply |
| 10 |
32-804826 |
HOSE, Fuel Bypass |
| 11 |
32-804827 |
HOSE |
| 12 |
32-8M0108355 |
HOSE, (57.00 Inches Bulk) (Cut to 18 IN.) |
| 13 |
22-8589052 |
ELBOW |
| 14 |
32-856825 |
HOSE |
| 15 |
32-856778 |
HOSE |
| 16 |
32-85682239 |
TUBING, (17.00 Inches Bulk) |
| 17 |
23-85686953 |
SLEEVE, (27.00 Inches Bulk) (Cut to 14 IN.) |
| 18 |
23-85686953 |
SLEEVE, (27.00 Inches Bulk) (Cut to 8 IN.) |
| 19 |
NSS |
NOT SOLD SEPARATE, CAP |
▶GEAR HOUSING CHART (1 parts)
| Ref |
OEM Part # |
Part Name |
| - |
1623-859399T17 |
GEAR HOUSING ASSEMBLY, Complete (4.75 Inch/120.65 mm Torpedo Diameter) Comment: (COUNTER ROTATION)(XX-LONG) |
▶GEAR HOUSING(DRIVESHAFT)(COUNTER ROTATION) (48 parts)
| Ref |
OEM Part # |
Part Name |
| - |
47-8M0100526 |
REPAIR KIT, Water Pump Impeller |
| 1 |
1623-859399T18 |
GEAR HOUSING ASSEMBLY, Basic |
| 2 |
17-379721 |
PIN |
| 3 |
821526001 |
FILLER BLOCK |
| 4 |
859402 |
PITOT TUBE |
| 5 |
97-826134Q |
ANODE |
| 6 |
10-4000333 |
SCREW, (M6 x 40) |
| 7 |
11-401386 |
NUT, (M6) |
| 8 |
31-42647A1 |
BEARING ASSEMBLY, Roller |
| 9 |
17-43044 |
PIN, Dowel - Without Hole (.375 x .625) |
| 10 |
10-79953Q04 |
SCREW KIT, (.375-16 x .250) Drain |
| 11 |
12-191833 |
WASHER |
| 12 |
32-85944975 |
TUBING, (72.00 Inches Bulk) Comment: (XX-LONG - Cut to 17 inches) |
| 13 |
22-881866 |
FITTING |
| 14 |
858934 |
COVER |
| 15 |
27-858935 |
GASKET |
| 16 |
NSS |
NOT SOLD SEPARATE, PINION GEAR Comment: (1.75:1 - 12/21)(PART OF 43-828695A1) |
| 17 |
12-92721 |
WASHER |
| 18 |
11-35921 |
NUT, (.625-18) |
| 19 |
26-8M0204708 |
SEAL, Oil |
| 20 |
25-8M0214927 |
O-RING, (.799) |
| 21 |
10-1993716 |
SCREW, (M6 x 16) |
| 22 |
12-77674 |
WASHER |
| 23 |
824145 |
SHIFT SHAFT (LOWER) |
| 24 |
45-881943 |
DRIVESHAFT Comment: (XX-LONG) |
| 25 |
15-8M0063268 |
SHIM ASSEMBLY |
| 26 |
31-8M0146553 |
BEARING, Tapered Roller |
| 27 |
NSS |
NOT SOLD SEPARATE, CUP |
| 28 |
28-8M0204723 |
KEY |
| 29 |
15-42637A1 |
SHIM SET (006 THRU 048) |
| 30 |
31-8M0146566 |
BEARING, Roller |
| 31 |
NSS |
NOT SOLD SEPARATE, CUP |
| 32 |
8245191 |
RETAINER |
| 33 |
8M0214948 |
CARRIER ASSEMBLY |
| 34 |
25-8M0142854 |
O-RING, (2.175 x .175) |
| 35 |
26-8M0214939 |
SEAL, Oil |
| 36 |
26-8M0214939 |
SEAL, Oil |
| 37 |
817275A1 |
PUMP ASSEMBLY, Water |
| 38 |
26-816575A2 |
SEAL KIT |
| 39 |
27-430331 |
GASKET |
| 40 |
27-8172771 |
GASKET |
| 41 |
8M0204709 |
FACEPLATE |
| 42 |
47-43026T2 |
IMPELLER |
| 43 |
10-1993716 |
SCREW, (M6 x 16) |
| 44 |
832942A1 |
COUPLING ASSEMBLY |
| 45 |
25-8M0204645 |
O-RING, (.796 x .139) |
| 46 |
25-8M0204654 |
O-RING, (1.046) |
| 47 |
NSS |
NOT SOLD SEPARATE, DECAL, Counter Rotation |
▶GEAR HOUSING(DRIVESHAFT)(STANDARD ROTATION) (47 parts)
| Ref |
OEM Part # |
Part Name |
| - |
47-8M0100526 |
REPAIR KIT, Water Pump Impeller |
| 1 |
1623-859399T18 |
GEAR HOUSING ASSEMBLY, Basic |
| 2 |
17-379721 |
PIN |
| 3 |
821526001 |
FILLER BLOCK |
| 4 |
859402 |
PITOT TUBE |
| 5 |
97-826134Q |
ANODE |
| 6 |
10-4000333 |
SCREW, (M6 x 40) |
| 7 |
11-401386 |
NUT, (M6) |
| 8 |
31-42647A1 |
BEARING ASSEMBLY, Roller |
| 9 |
17-43044 |
PIN, Dowel - Without Hole (.375 x .625) |
| 10 |
10-79953Q04 |
SCREW KIT, (.375-16 x .250) Drain |
| 11 |
12-191833 |
WASHER |
| 12 |
32-85944975 |
TUBING, (72.00 Inches Bulk) Comment: (XX-LONG - Cut to 17 inches) |
| 13 |
22-881866 |
FITTING |
| 14 |
858934 |
COVER |
| 15 |
27-858935 |
GASKET |
| 16 |
NSS |
NOT SOLD SEPARATE, PINION GEAR Comment: (1.75:1 - 12/21)(PART OF 43-859321A3) |
| 17 |
12-92721 |
WASHER |
| 18 |
11-35921 |
NUT, (.625-18) |
| 19 |
26-8M0204708 |
SEAL, Oil |
| 20 |
25-8M0214927 |
O-RING, (.799) |
| 21 |
10-1993716 |
SCREW, (M6 x 16) |
| 22 |
12-77674 |
WASHER |
| 23 |
824145 |
SHIFT SHAFT (LOWER) |
| 24 |
45-881943 |
DRIVESHAFT Comment: (XX-LONG) |
| 25 |
15-8M0063268 |
SHIM ASSEMBLY |
| 26 |
31-8M0146553 |
BEARING, Tapered Roller |
| 27 |
NSS |
NOT SOLD SEPARATE, CUP |
| 28 |
28-8M0204723 |
KEY |
| 29 |
15-42637A1 |
SHIM SET |
| 30 |
31-8M0146566 |
BEARING, Roller |
| 31 |
NSS |
NOT SOLD SEPARATE, CUP |
| 32 |
8245191 |
RETAINER |
| 33 |
8M0214948 |
CARRIER ASSEMBLY |
| 34 |
25-8M0142854 |
O-RING, (2.175 x .175) |
| 35 |
26-8M0214939 |
SEAL, Oil |
| 36 |
26-8M0214939 |
SEAL, Oil |
| 37 |
817275A1 |
PUMP ASSEMBLY, Water |
| 38 |
26-816575A2 |
SEAL KIT |
| 39 |
27-430331 |
GASKET |
| 40 |
27-8172771 |
GASKET |
| 41 |
8M0204709 |
FACEPLATE |
| 42 |
47-43026T2 |
IMPELLER |
| 43 |
10-1993716 |
SCREW, (M6 x 16) |
| 44 |
832942A1 |
COUPLING ASSEMBLY |
| 45 |
25-8M0204645 |
O-RING, (.796 x .139) |
| 46 |
25-8M0204654 |
O-RING, (1.046) |
▶GEAR HOUSING(PROP SHAFT)(COUNTER ROTATION) (39 parts)
| Ref |
OEM Part # |
Part Name |
| - |
26-816575A4 |
SEAL KIT, Gear Housing |
| 1 |
1623-859399T18 |
GEAR HOUSING ASSEMBLY, Basic |
| 48 |
22-859403 |
PLUG |
| 49 |
8M0226861 |
SHIFT CRANK |
| 50 |
8M0235940 |
SPOOL ASSEMBLY |
| 51 |
NSS |
NOT SOLD SEPARATE, SPOOL |
| 52 |
NSS |
NOT SOLD SEPARATE, SLEEVE |
| 53 |
18-469501 |
COTTER PIN |
| 54 |
15-44491A1 |
SHIM SET |
| 55 |
828830A2 |
ADAPTOR ASSEMBLY, Bearing |
| 56 |
31-814653T |
BEARING ASSEMBLY, Needle Rollers |
| 57 |
12-815481 |
THRUST WASHER |
| 58 |
31-815480 |
BEARING, Thrust |
| 59 |
43-828696T2 |
GEAR, Reverse (12/21) Comment: (1.75:1 - 12/21) |
| 60 |
31-15844 |
BEARING ASSEMBLY, Roller |
| 61 |
24-30893 |
SPRING |
| 62 |
52-859340T |
CLUTCH |
| 63 |
17-8M0100263 |
PIN, Cross |
| 64 |
17-828356 |
PIN, Detent |
| 65 |
44-8M0140448 |
PROPELLER SHAFT |
| 66 |
43-828695A1 |
GEAR SET, Forward/Pinion (12/21) Comment: (1.75:1 - 12/21) |
| 67 |
23-1761526 |
SPACER SHIM, (.230) |
| 68 |
31-815480 |
BEARING, Thrust |
| 69 |
12-815481 |
THRUST WASHER |
| 70 |
828831A3 |
ADAPTOR ASSEMBLY, Bearing |
| 71 |
31-814653T |
BEARING ASSEMBLY, Needle Rollers |
| 72 |
12-18448 |
THRUST WASHER |
| 73 |
31-15842 |
BEARING, Thrust |
| 74 |
8182911 |
RACE, Thrust |
| 75 |
814605 |
KEEPER |
| 76 |
25-8M0214920 |
O-RING |
| 77 |
818290T8 |
CARRIER ASSEMBLY, Bearing |
| 78 |
31-30956T |
BEARING, Needle |
| 79 |
26-14077 |
SEAL, Oil (INSIDE) |
| 80 |
26-8M0204670 |
SEAL (OUTSIDE) |
| 81 |
14-18323 |
TAB WASHER |
| 82 |
8M2011027 |
RETAINER |
| 83 |
97-76214Q5 |
ANODE KIT |
| 84 |
10-8M0204686 |
SCREW, (.437-14 x 1.750) |
▶GEAR HOUSING(PROP SHAFT)(STANDARD ROTATION) (32 parts)
| Ref |
OEM Part # |
Part Name |
| - |
26-816575A4 |
SEAL KIT, Gear Housing |
| 1 |
1623-859399T18 |
GEAR HOUSING ASSEMBLY, Basic |
| 47 |
22-859403 |
PLUG |
| 48 |
8M0226861 |
SHIFT CRANK |
| 49 |
8M0235940 |
SPOOL ASSEMBLY |
| 50 |
NSS |
NOT SOLD SEPARATE, SHIFT POOL |
| 51 |
18-469501 |
COTTER PIN |
| 52 |
NSS |
NOT SOLD SEPARATE, SLEEVE |
| 53 |
43-859321A3 |
GEAR SET, Forward/Pinion (12/21) Comment: (1.75:1 - 12/21) |
| 54 |
15-44491A1 |
SHIM SET |
| 55 |
31-30894A1 |
BEARING SET, Cup And Cone |
| 56 |
NSS |
NOT SOLD SEPARATE, CUP |
| 57 |
53-856823 |
RING, Retaining |
| 58 |
31-30895T |
BEARING, Needle |
| 59 |
24-30893 |
SPRING |
| 60 |
52-859340T |
CLUTCH |
| 61 |
17-828356 |
PIN, Detent |
| 62 |
17-8M0100263 |
PIN, Cross |
| 63 |
44-8M0140440 |
PROPELLER SHAFT |
| 64 |
43-859322A1 |
GEAR, Reverse (12/21) Comment: (1.75:1 - 12/21) |
| 65 |
23-824108 |
SPACER |
| 66 |
681001 |
RING, Thrust |
| 67 |
30-88957T |
BEARING, Ball |
| 68 |
25-8M0214920 |
O-RING |
| 69 |
818763T11 |
CARRIER ASSEMBLY, Bearing |
| 70 |
31-30956T |
BEARING, Needle |
| 71 |
26-14077 |
SEAL, Oil (INSIDE) |
| 72 |
26-8M0204670 |
SEAL (OUTSIDE) |
| 73 |
14-18323 |
TAB WASHER |
| 74 |
8M2011027 |
RETAINER |
| 75 |
97-76214Q5 |
ANODE KIT |
| 76 |
10-8M0204686 |
SCREW, (.437-14 x 1.750) |
▶OIL INJECTION COMPONENTS (11 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
1200-8M0119508 |
TANK ASSEMBLY |
| 2 |
NSS |
NOT SOLD SEPARATE, DECAL, Reservoir |
| 3 |
10-58376 |
SCREW, (.164-18 x .375) |
| 4 |
12-72761 |
WASHER, (.203 x .562 x .060) Stainless Steel |
| 5 |
36-814449A3 |
CAP ASSEMBLY |
| 6 |
27-42999T |
GASKET |
| 7 |
87-856156T02 |
SWITCH ASSEMBLY |
| 8 |
10-81893435 |
SCREW, (M8 x 35) |
| 9 |
12-4002318 |
WASHER |
| 10 |
25-855362001 |
GROMMET |
| 11 |
23-855364 |
BUSHING |
▶OILING SYSTEM (28 parts)
| Ref |
OEM Part # |
Part Name |
| - |
854198A01 |
POWERHEAD ASSEMBLY Comment: (200) |
| 1 |
32-8M0054152 |
TUBING, (36.00 Inches Bulk), Cut to 11-1/2 IN. |
| 2 |
32-8M0054152 |
TUBING, (36.00 Inches Bulk), Cut to 5 IN. |
| 3 |
35-8M0207786 |
FILTER |
| 4 |
32-8M0054152 |
TUBING, (36.00 Inches Bulk), Cut to 9 IN. |
| 5 |
22-8245021 |
CONNECTOR |
| 6 |
32-8M0108355 |
HOSE, (57.00 Inches Bulk), Cut to 7 IN. |
| 7 |
22-8M0207780 |
FITTING |
| 8 |
54-816311T |
TIE STRAP, (8.00 Inches) |
| 9 |
32-875289 |
HOSE |
| 10 |
22-858955 |
CONNECTOR |
| 11 |
54-816311T |
TIE STRAP, (8.00 Inches) |
| 12 |
32-875283 |
HOSE, (2.00 Inches) |
| 13 |
35-875284T01 |
FILTER, In Line |
| 14 |
21-858870 |
CHECK VALVE |
| 15 |
859230T |
RETAINER |
| 16 |
32-82381455 |
TUBING, (25.00 Inches Bulk), Cut to 22 IN. |
| 17 |
32-85583464 |
TUBING, (33.00 Inches Bulk), Cut to 33 Inches |
| 18 |
32-8M0054152 |
TUBING, (36.00 Inches Bulk), Cut to 19-1/2 IN. |
| 19 |
56762 |
TIE STRAP, (4.00 Inches) |
| 20 |
32-8M0054152 |
TUBING, (36.00 Inches Bulk), Cut to 11-1/2 IN. |
| 21 |
32-8M0054152 |
TUBING, (36.00 Inches Bulk), Cut to 6 IN. |
| 22 |
32-8M0054152 |
TUBING, (36.00 Inches Bulk), Cut to 4 IN. |
| 23 |
54-816311T |
TIE STRAP, (8.00 Inches) |
| 24 |
56762 |
TIE STRAP, (4.00 Inches) |
| 25 |
32-8M0054152 |
TUBING, (36.00 Inches Bulk), Cut to 20-1/2 IN. |
| 26 |
32-8M0054152 |
TUBING, (36.00 Inches Bulk), Cut to 15-1/2 IN. |
| 27 |
NSS |
NOT SOLD SEPARATE, PLUG |
▶PORT CENTER MAIN OILING SYSTEM (15 parts)
| Ref |
OEM Part # |
Part Name |
| - |
854198A01 |
POWERHEAD ASSEMBLY Comment: (200) |
| 1 |
22-887801 |
FITTING, Elbow 90 Degree (.0625-27) Comment: SN# 0T409000 & Up |
| 2 |
22-887801 |
FITTING, Elbow 90 Degree (.0625-27) |
| 3 |
32-8M0054152 |
TUBING, (36.00 Inches Bulk), Cut to 20-1/2 IN. |
| 4 |
32-8M0054152 |
TUBING, (36.00 Inches Bulk), Cut to 5 IN. |
| 5 |
21-8592352 |
CHECK VALVE, 90 Degree (.0625-27) |
| 6 |
32-8M0054152 |
TUBING, (36.00 Inches Bulk), Cut to 13 IN. |
| 7 |
21-8282182 |
CHECK VALVE |
| 8 |
21-8582362 |
CHECK VALVE |
| 9 |
54-23567 |
CLIP |
| 10 |
10-48408 |
SCREW, (#10-16 x .500) |
| 11 |
32-8M0054152 |
TUBING, (36.00 Inches Bulk), Cut to 4-3/4 IN. |
| 12 |
32-8M0054152 |
TUBING, (36.00 Inches Bulk), Cut to 11 IN. |
| 13 |
32-8M0054152 |
TUBING, (36.00 Inches Bulk), Cut to 9 IN. |
| 14 |
22-151333 |
FITTING Comment: SN# 0T408999 & Below |
▶POWER TRIM COMPONENTS(CAST PUMP HOUSING) (38 parts)
| Ref |
OEM Part # |
Part Name |
| - |
855998A11 |
POWER TRIM, Complete |
| 1 |
878265A4 |
TRIM MOTOR |
| 2 |
NSS |
NOT SOLD SEPARATE, ARMATURE |
| 3 |
NSS |
NOT SOLD SEPARATE, END FRAME |
| 4 |
10-82494830 |
SCREW, (M6 x 30) |
| 5 |
13-400256 |
LOCKWASHER, (M6) |
| 6 |
8782451 |
COUPLING |
| 7 |
878410A1 |
PO CHECK KIT |
| 8 |
893929A01 |
MANUAL RELEASE ASSEMBLY |
| 9 |
8M0142997 |
SHAFT KIT Comment: (Incls. Ref. #26) |
| 10 |
17-878267 |
PIN |
| 11 |
878235A03 |
TILT CYLINDER ASSEMBLY |
| 12 |
878239A02 |
GUIDE KIT Comment: (Incls. Ref. #26) |
| 13 |
8M0142999 |
O-RING KIT Comment: (Incls. Ref. #26) |
| 14 |
8M0168219 |
SHOCK ROD KIT Comment: (Incls. Ref. #26) |
| 15 |
8M0143000 |
PISTON ASSEMBLY, Memory |
| 16 |
878406A02 |
REPAIR KIT, Check Valve Comment: (Incls. Ref. #26) |
| 17 |
878414T01 |
PISTON ASSEMBLY |
| 18 |
878413A1 |
PISTON ASSEMBLY |
| 19 |
1100-8M0021648 |
GUIDE ASSEMBLY |
| 20 |
878264A1 |
RESERVOIR KIT |
| 21 |
19-811613 |
PLUG ASSEMBLY |
| 22 |
10-4000327 |
SCREW, (M6 x 14) |
| 23 |
12-4002315 |
WASHER |
| 24 |
892251A01 |
PUMP KIT |
| 25 |
878408A1 |
REPAIR KIT, Power Trim |
| 26 |
17-821539 |
PIN, Trilobe |
| 27 |
10-858771 |
SCREW, (M10 x 30) |
| 28 |
12-4002319 |
WASHER |
| 29 |
97-818298Q1 |
ANODE KIT |
| 30 |
10-8M0204707 |
SCREW, (M6 x 25) |
| 31 |
12-8M0204649 |
WASHER, (.281 x .500 x .060) Stainless Steel |
| 32 |
99625002 |
SHAFT |
| 33 |
8M0084613 |
C WASHER |
| 34 |
54-26550 |
CLAMP |
| 35 |
10-878609 |
SCREW, (#10-16 x .600) |
| 36 |
32-828547353 |
CONDUIT, (.350 Inside Diameter x 3.00 Feet Bulk) |
| 37 |
54-816311T |
TIE STRAP, (8.00 Inches) |
▶POWER TRIM COMPONENTS(REMOVABLE PUMP HOUSING) (38 parts)
| Ref |
OEM Part # |
Part Name |
| - |
855998A11 |
POWER TRIM ASSEMBLY, Complete |
| 1 |
811604F |
MANIFOLD ASSEMBLY |
| 2 |
22-878089 |
PLUG, Pipe (.0625-27) |
| 3 |
880952A03 |
CYLINDER ASSEMBLY, Tilt |
| 4 |
823553T |
ROD, Trim Piston |
| 5 |
878239A02 |
GUIDE KIT |
| 6 |
811607A1 |
REPAIR KIT |
| 7 |
811610A1 |
CHECK VALVE KIT |
| 8 |
1100-8M0021648 |
GUIDE ASSEMBLY |
| 9 |
878414T01 |
PISTON ASSEMBLY Comment: (STBD.) |
| 10 |
35-12184A1 |
TRIM FILTER ASSEMBLY |
| 11 |
893929A01 |
MANUAL RELEASE ASSEMBLY |
| 12 |
53-815949001 |
E RING |
| 13 |
811612A3 |
O-RING KIT |
| 14 |
811617T1 |
PUMP |
| 15 |
19-811613 |
PLUG ASSEMBLY |
| 16 |
10-4000327 |
SCREW, (M6 x 14) |
| 17 |
12-4002315 |
WASHER |
| 18 |
811611 |
COVER |
| 19 |
828710 |
DRIVE JOINT |
| 20 |
878265A4 |
TRIM MOTOR Comment: (BREAKDOWN ON POWER TRIM MOTOR) |
| 21 |
10-811616 |
SCREW (SHORT) |
| 22 |
8M0142997 |
SHAFT ASSEMBLY |
| 23 |
22-878089 |
PLUG, Pipe (.0625-27) |
| 24 |
17-878267 |
PIN, Groove |
| 25 |
17-821539 |
PIN, Trilobe |
| 26 |
99625002 |
SHAFT |
| 27 |
97-818298Q1 |
ANODE KIT |
| 28 |
10-8M0204707 |
SCREW, (M6 x 25) |
| 29 |
12-8M0204649 |
WASHER, (.281 x .500 x .060) Stainless Steel |
| 30 |
10-4000377 |
SCREW, (M10 x 30) |
| 31 |
12-4002319 |
WASHER |
| 32 |
54-26550 |
CLAMP |
| 33 |
10-878609 |
SCREW, (#10-16 x .600) |
| 34 |
8M0084613 |
C WASHER |
| 35 |
37-435301 |
DECAL, Caution-Power Trim |
| 36 |
32-828547353 |
CONDUIT, (.350 Inside Diameter x 3.00 Feet Bulk) |
| 37 |
54-816311T |
TIE STRAP, (8.00 Inches) |
▶POWER TRIM MOTOR(REMOVABLE PUMP HOUSING) (4 parts)
| Ref |
OEM Part # |
Part Name |
| - |
878265A4 |
TRIM MOTOR |
| 1 |
828714A1 |
BRUSH AND SEAL KIT |
| 2 |
828713T1 |
ARMATURE KIT |
| 3 |
828715A1 |
END FRAME (COMPLETE) |
▶SERVICE/SUPPORT MATERIAL (1 parts)
| Ref |
OEM Part # |
Part Name |
| 0 |
37-804658A02 |
DECAL, EPA Label Information Comment: (2002)(SEE NOTE 1) |
▶SOLENOID PLATE (53 parts)
| Ref |
OEM Part # |
Part Name |
| - |
13540 |
CAP, Female Comment: (TRACKER) |
| 1 |
858366T2 |
PLATE |
| 2 |
89-817109A2 |
SOLENOID ASSEMBLY, (#10-32 / .3125-18 Terminals) |
| 3 |
25-822179 |
GROMMET |
| 4 |
10-82129125 |
SCREW, (M6 x 25) |
| 5 |
23-8M0214955 |
BUSHING |
| 6 |
8M0207773 |
RELAY ASSEMBLY |
| 7 |
NSS |
NOT SOLD SEPARATE, DECAL |
| 8 |
828102 |
BRACKET |
| 9 |
23-8M0214955 |
BUSHING |
| 10 |
25-818967 |
GROMMET |
| 11 |
84-878082T4 |
HARNESS ASSEMBLY, Engine Wiring |
| 12 |
88-832969T15 |
FUSE, Mini - Blue - 15 Ampere |
| 13 |
858754 |
COVER, Fuse |
| 14 |
879346A49 |
HARNESS ASSEMBLY (DIRECT INJECTOR) |
| 15 |
879346A50 |
HARNESS ASSEMBLY (FUEL INJECTOR) |
| 16 |
879346A50 |
HARNESS ASSEMBLY (TPS) |
| 17 |
10-82130012 |
SCREW, (M6 x 12) |
| 18 |
84-819514T16 |
HARNESS ASSEMBLY, Trim |
| 19 |
85-8500671 |
BOOT, Insulator - Red |
| 20 |
84-882829A1 |
CABLE ASSEMBLY, Starter Comment: SN# 0T409000 & Up |
| 21 |
12-8M0204649 |
WASHER, (.281 x .500 x .060) Stainless Steel |
| 22 |
10-32,11-813938 |
CAP NUT, |
| 23 |
11-8M0204668 |
NUT, (.312-18) |
| 24 |
10-32,11-45076 |
NUT, Brass |
| 25 |
13-53166 |
LOCKWASHER, (.312) |
| 26 |
54-858755 |
CLIP, (1.00) |
| 27 |
54-828991T |
CLIP |
| 28 |
8M0086583 |
ECM, Engine Control Module Comment: (225 SALTWATER) |
| 29 |
10-82130025 |
SCREW, (M6 x 25) |
| 30 |
23-856954 |
BUSHING |
| 31 |
25-8M0190980 |
GROMMET |
| 32 |
12-65567 |
WASHER, (.265 x .750 x .048) Stainless Steel |
| 33 |
8590881 |
CLIP |
| 34 |
10-82129114 |
SCREW, (M6 x 14) |
| 35 |
881879T11 |
SENSOR, (0 - 100 PSI) |
| 36 |
22-8M0207782 |
FITTING |
| 37 |
54-858954 |
CLIP, (.625) Comment: (USE W/ SENSOR STAMPED 859210) |
| 38 |
859313 |
BRACKET |
| 39 |
25-818967 |
GROMMET |
| 40 |
23-8M0214955 |
BUSHING |
| 41 |
10-82130025 |
SCREW, (M6 x 25) |
| 42 |
54-859376 |
CLIP |
| 43 |
54-816311T |
TIE STRAP, (8.00 Inches) |
| 44 |
84-88807A16 |
CABLE ASSEMBLY, (4.00 Inches) Black |
| 45 |
10-81893420 |
SCREW, (M8 x 20) |
| 46 |
84-88439A26 |
CABLE ASSEMBLY, Battery - Negative |
| 47 |
858953 |
BRACKET |
| 48 |
881065A1 |
CONNECTOR, 6 Pin Plug Comment: (TRACKER) |
| 49 |
13541 |
PLUG, Male |
| 50 |
832948A1 |
CONNECTOR ASSEMBLY Comment: (TRACKER) |
| 51 |
84-880771T1 |
CABLE ASSEMBLY, (24.00 Inches) Red Comment: (Use where Applicable) |
| 52 |
85-8500673 |
BOOT, Insulator - Yellow Comment: (Use where Applicable) |
▶SPEEDO/BLOCK PRESSURE SYSTEM(S/N-0T408999 & BELOW) (10 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
22-881866 |
FITTING |
| 2 |
32-85978571 |
TUBING, (44.00 Inches Bulk) (GRAY) |
| 3 |
22-8M0214971 |
COUPLER |
| 4 |
22-859732 |
PLUG |
| 5 |
22-8M0214970 |
FITTING, Adapter |
| 6 |
32-85944975 |
TUBING, (72.00 Inches Bulk) (BLACK) Comment: Cut to 52 IN. |
| 7 |
22-859448T |
FITTING |
| 8 |
25-8M0153609 |
GROMMET |
| 9 |
54-850181 |
TIE STRAP, (11.750 Inches) |
| 10 |
32-85944975 |
TUBING, (72.00 Inches Bulk) (BLACK) Comment: Cut to 34 IN. |
▶SPEEDO/BLOCK PRESSURE SYSTEM(S/N-0T409000 & UP) (11 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
22-881866 |
FITTING |
| 2 |
32-85978571 |
TUBING, (44.00 Inches Bulk), Cut to 44 IN. |
| 3 |
22-8M0214971 |
COUPLER |
| 4 |
22-859732 |
PLUG |
| 5 |
22-8M0214970 |
FITTING, Adapter |
| 6 |
32-85978571 |
TUBING, (44.00 Inches Bulk), Cut to 5 IN. |
| 7 |
22-875207 |
TEE, Fitting |
| 8 |
22-859448T |
FITTING |
| 9 |
25-8M0153609 |
GROMMET |
| 10 |
54-850181 |
TIE STRAP, (11.750 Inches), Cut to 11-1/2 IN. |
| 11 |
32-85944975 |
TUBING, (72.00 Inches Bulk), Cut to 46 IN. |
▶STARBOARD CENTER MAIN OILING SYSTEM (9 parts)
| Ref |
OEM Part # |
Part Name |
| - |
854198A01 |
POWERHEAD ASSEMBLY Comment: (200) |
| 1 |
32-8M0054152 |
TUBING, (36.00 Inches Bulk), Cut to 15-1/2 IN. |
| 2 |
21-8592352 |
CHECK VALVE, 90 Degree (.0625-27) |
| 3 |
32-8M0054152 |
TUBING, (36.00 Inches Bulk), Cut to 16-1/2 IN. |
| 4 |
32-8M0054152 |
TUBING, (36.00 Inches Bulk), Cut to 15 IN. |
| 5 |
54-23567 |
CLIP |
| 6 |
10-48408 |
SCREW, (#10-16 x .500) |
| 7 |
22-887801 |
FITTING, Elbow 90 Degree (.0625-27) Comment: SN# 0T409000 & Up |
| 8 |
22-151333 |
FITTING Comment: SN# 0T408999 & Below |
▶STARTER MOTOR (15 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
50-892339T01 |
STARTER MOTOR ASSEMBLY |
| 2 |
10-803005 |
THRU BOLT |
| 3 |
43-880805A1 |
GEAR KIT |
| 4 |
809463A1 |
SOLENOID KIT |
| 5 |
84-88439A25 |
CABLE ASSEMBLY, Battery - Positive |
| 6 |
85-8500671 |
BOOT, Insulator - Red Comment: (Use where Applicable) |
| 7 |
37-8272822 |
DECAL, Warning, High Voltage |
| 8 |
13-400255 |
LOCKWASHER, (M5) |
| 9 |
11-400211 |
NUT, (M5) Stainless Steel |
| 10 |
13-8M0204647 |
LOCKWASHER, (.312) |
| 11 |
11-400213 |
NUT, (M8) Stainless Steel |
| 12 |
23-8M0034918 |
COLLAR |
| 13 |
8M0043276 |
STOP |
| 14 |
10-69035 |
SCREW AND LOCKWASHER, (.250-20 x .625) Stainless Steel |
| 15 |
84-93388A1 |
CABLE ASSEMBLY, (6.00 Inches) Black |
▶SWIVEL BRACKET AND STEERING ARM (32 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
1499-8M0102865 |
SWIVEL BRACKET ASSEMBLY, Black |
| 2 |
25-8M0214926 |
O-RING |
| 3 |
23-818764 |
BUSHING |
| 4 |
23-816039 |
SPACER |
| 5 |
26-87735 |
SEAL, Oil (LOWER) |
| 6 |
22-8M0169589 |
FITTING, Grease |
| 7 |
23-821207 |
BUSHING |
| 8 |
12-816432 |
THRUST WASHER |
| 9 |
826364T |
YOKE, Bottom Comment: (XL-STAINLESS STEEL) |
| 10 |
53-67684 |
RING, Retaining |
| 11 |
8M0045383 |
STRIKER PLATE |
| 12 |
13-58643 |
LOCKWASHER, (.375) |
| 13 |
11-46335 |
NUT, (.375-24) |
| 14 |
10-64014 |
SCREW, (.250-28 x .500) |
| 15 |
NSS |
NOT SOLD SEPARATE, DECAL, Serial Overlaminate |
| 16 |
8M0074846 |
SENDER ASSEMBLY, Trim Comment: (TRACKER) |
| 17 |
10-852368 |
SCREW, (#10-24 x .750) |
| 18 |
10,13-26996 |
LOCKWASHER, Stainless Steel |
| 19 |
12-89302 |
WASHER, (.203 x .406 x .040) |
| 20 |
17-8M0132731 |
SWIVEL PIN ASSEMBLY, Steering Arm - Stainless Steel Comment: (XL-STAINLESS STEEL) |
| 21 |
10-8M0141069 |
SCREW, (M12 x 190) |
| 22 |
824998001 |
BUMPER |
| 23 |
8163851 |
MOUNT, Upper |
| 24 |
12-8154371 |
WASHER |
| 25 |
12-815436 |
WASHER |
| 26 |
11-896963 |
NUT, (M12) |
| 27 |
8M0036783 |
CLAMP |
| 28 |
10-81893435 |
SCREW, (M8 x 35) |
| 29 |
92876A12 |
LINK ROD ASSEMBLY |
| 30 |
10-849838 |
SCREW, (.375-24 x 1.250) |
| 31 |
11-8M0204726 |
NUT, (.375-24) Stainless Steel |
| 32 |
12-37828 |
WASHER, (.390 x .625 x .062) Stainless Steel |
▶THROTTLE LINKAGE (25 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
8M0040987 |
LEVER, Throttle Control |
| 2 |
10-81893435 |
SCREW, (M8 x 35) |
| 3 |
12-36042 |
WASHER |
| 4 |
23-821113 |
BUSHING |
| 5 |
10-40124 |
SCREW, (M6 x 55) |
| 6 |
11-400212 |
NUT, (M6) Stainless Steel |
| 7 |
42942 |
CAP |
| 8 |
42927 |
INSERT |
| 9 |
11-401386 |
NUT, (M6) Stainless Steel |
| 10 |
23-8M0215006 |
BUSHING |
| 11 |
8583541 |
LINK |
| 12 |
824010T05 |
BRACKET |
| 13 |
824016 |
LATCH |
| 14 |
10-42975 |
DRIVE SCREW |
| 15 |
824015 |
CUP, Barrel Retainer |
| 16 |
10-82155025 |
SCREW, (M8 x 25) Stainless Steel |
| 17 |
54-859172 |
CLAMP |
| 18 |
10-82155025 |
SCREW, (M8 x 25) Stainless Steel |
| 19 |
8M0039052 |
GUIDE, Roller |
| 20 |
87-8M0052931 |
SWITCH |
| 21 |
54-816311T |
TIE STRAP, (8.00 Inches) |
| 22 |
10-82470620 |
SCREW, (M3.5 x 20) |
| 23 |
12-43430 |
WASHER |
| 24 |
12-35459 |
WASHER |
| 25 |
12-36001 |
WASHER |
▶TOOLS-SPECIAL (1 parts)
| Ref |
OEM Part # |
Part Name |
| 0 |
84-875233A2 |
HARNESS ASSEMBLY, Test |
▶TOP COWL (24 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
112-850299T2 |
TOP COWL ASSEMBLY, Silver |
| 2 |
850300F1 |
CAP |
| 3 |
10-82130016 |
SCREW, (M6 x 16) |
| 4 |
854371A1 |
SOUND BLANKET, Top |
| 5 |
NSS |
NOT SOLD SEPARATE, SOUND BLANKET, Side |
| 6 |
13-93702 |
WASHER, (.250 External Star) |
| 7 |
19-823865 |
CAP PLUG |
| 8 |
850682T4 |
HOOK ASSEMBLY, Rear Latch |
| 9 |
53-8237951 |
RING, Retaining |
| 10 |
8M0207770 |
ROLLER |
| 11 |
25-850685T02 |
GROMMET |
| 12 |
8M0036792 |
BRACKET, Front |
| 13 |
10-82130016 |
SCREW, (M6 x 16) |
| 14 |
815477 |
BUMPER, Latch |
| 15 |
8155381 |
PIN, Roll |
| 16 |
11-401366 |
NUT, (M6) Stainless Steel |
| 17 |
12-8M0204649 |
WASHER, (.281 x .500 x .060) Stainless Steel |
| 18 |
53-8237951 |
RING, Retaining |
| 19 |
8M0207770 |
ROLLER |
| 20 |
826639T |
COVER |
| 21 |
10-82130020 |
SCREW, (M6 x 20) |
| 22 |
12-87161 |
WASHER |
| 23 |
NSS |
NOT SOLD SEPARATE, DECAL, Counter Rotation Comment: (Right Hand) |
| 24 |
NSS |
NOT SOLD SEPARATE, DECAL, Break-in |
▶TRANSOM BRACKETS (19 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
3426-828334T03 |
BRACKET ASSEMBLY, Transom-Starboard |
| 2 |
3425-828333T08 |
BRACKET ASSEMBLY, Transom-Port |
| 3 |
22-8M0169588 |
FITTING, Grease (PORT) |
| 4 |
826125A1 |
TILT TUBE |
| 5 |
11-826135 |
NUT, (1.00-14) Brass/Nickel Plate |
| 6 |
25-45711 |
O-RING, (.612 x .103) |
| 7 |
13-88750 |
WASHER |
| 8 |
11-826164 |
NUT, (.875-14) |
| 9 |
10-8M0149747 |
SCREW, (.500-20 x 4.500) |
| 10 |
12-8M0204665 |
WASHER, (.530 x .870 x .105) Stainless Steel |
| 11 |
12-8M0204648 |
WASHER, (1.5 x 3.05 x 0.13) Stainless Steel |
| 12 |
11-82671117 |
NUT, (.500-20) |
| 13 |
8M0115104 |
LEVER ASSEMBLY, Tilt Lock |
| 14 |
24-830899 |
SPRING, Tension |
| 15 |
23-65830 |
NYLINER |
| 16 |
24-830900 |
SPRING, Compression |
| 17 |
99633 |
KNOB |
| 18 |
17-99615 |
PIN, Groove |
| 19 |
17-893709 |
PIN |
▶VAPOR SEPARATOR COMPONENTS (19 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
855432A2 |
COVER KIT |
| 2 |
22-8568431 |
FITTING, Straight |
| 3 |
26-803878 |
SEAL |
| 4 |
22-855437A2 |
FITTING KIT, Pump Outlet |
| 5 |
NSS |
NOT SOLD SEPARATE, O-RING |
| 6 |
1395-808612 |
SCREW AND WASHER, (#8-32 x .750) |
| 7 |
27-855528 |
GASKET |
| 8 |
8M6004920 |
FLOAT KIT |
| 9 |
F10064 |
SHAFT |
| 10 |
8M6004917 |
VALVE, Needle |
| 11 |
1395-5902 |
SCREW, (#6-32 x .187) |
| 12 |
855427A1 |
PUMP KIT |
| 13 |
8M6000589 |
SLEEVE |
| 14 |
855434A2 |
BOWL KIT |
| 15 |
26-8554331 |
SEAL |
| 16 |
19-855435A1 |
PLUG KIT |
| 17 |
22-8568421 |
ELBOW |
| 18 |
35-18458Q4 |
FILTER KIT |
| 19 |
8M0204710 |
PROBE |
▶WATER HOSES (13 parts)
| Ref |
OEM Part # |
Part Name |
| - |
854198A01 |
POWERHEAD ASSEMBLY Comment: (200) |
| 1 |
22-8M0214961 |
FITTING |
| 2 |
54-816311T |
TIE STRAP, (8.00 Inches) |
| 3 |
32-859090001 |
HOSE, Dump, STARBOARD |
| 4 |
32-859089001 |
HOSE, Dump, PORT |
| 5 |
32-856839 |
TUBING |
| 6 |
54-816311T |
TIE STRAP, (8.00 Inches) |
| 7 |
32-858807 |
HOSE |
| 8 |
54-816311T |
TIE STRAP, (8.00 Inches) |
| 9 |
32-858865 |
HOSE |
| 10 |
54-816311T |
TIE STRAP, (8.00 Inches) |
| 11 |
22-291112 |
FITTING |
| 12 |
22-996642 |
FITTING, Elbow 90 Degree (.125-27 x .250) Nylon |
100-Hour / Annual Service Checklist
Regular maintenance keeps your Mercury 200 (DFI) 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.
