🔎 Mercury 4/5 (1 CYL. PRODUCT OF JAPAN) Reference Library — Exploded parts diagrams (15 diagrams), specifications, common issues, and maintenance checklist.
The Mercury 4/5 (1 CYL. PRODUCT OF JAPAN) is a 4-Stroke, 1-Cylinder outboard motor. Designed for dinghies, inflatable boats, and small tenders where lightweight portability is essential.
Quick Reference Specifications
| Specification |
Value |
| Engine Type |
4-Stroke, 1-Cylinder |
| Horsepower |
4 HP |
| Displacement |
123 cc |
| Bore x Stroke |
59 mm x 45 mm |
| Spark Plug (Type & Gap) |
NGK DPR6EA-9 |
| Engine Oil Capacity |
0.45 L (15 fl oz) |
| Recommended Engine Oil |
SAE 10W-30 Mercury 4-Stroke Outboard Oil |
| Gear Case Oil Capacity |
189 mL (6 fl oz) |
| Idle Speed (in gear) |
1100 RPM (in gear) |
| Full Throttle RPM Range |
4500-5500 |
| 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 4/5 (1 CYL. PRODUCT OF JAPAN):
-
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 4/5 (1 CYL. PRODUCT OF JAPAN).
▶ACCESSORIES (24 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
16837A2 |
ALTERNATOR KIT |
| 2 |
16074T |
ALTERNATOR |
| 3 |
10-16059 |
SCREW, ALTERNATOR |
| 4 |
54-16060 |
CLAMP, ALTERNATOR |
| 5 |
10-16821 |
SCREW, ALTERNATOR CLAMP |
| 6 |
16838A4 |
RECTIFIER KIT |
| 7 |
16076A1 |
RECTIFIER |
| 8 |
89-16077 |
FUSE |
| 9 |
10-16078 |
SCREW, RECTIFIER |
| 10 |
13-16079 |
LOCKWASHER, RECTIFIER SCREW |
| 11 |
12-8M0108373 |
WASHER, Stainless Steel, RECTIFIER SCREW |
| 12 |
54-813275 |
CLAMP, RECTIFIER Comment: (SAILPOWER) |
| 13 |
11-16081 |
NUT, Stainless Steel, RECTIFIER SCREW |
| 14 |
84-16822 |
HARNESS, Extension |
| 15 |
25-16823 |
GROMMET |
| 16 |
84-16082 |
CABLE, Battery |
| 17 |
16839A4 |
GUIDE KIT, Vertical Rope |
| 18 |
16839A4 |
BRACKET |
| 19 |
16113 |
PLATE, Seal |
| 20 |
10-16827 |
SCREW, VERTICAL STARTING DEVICE |
| 21 |
12-16826 |
WASHER, Stainless Steel |
| 22 |
16841Q02 |
FLUSHING ATTACHMENT |
| 23 |
84-17175A2 |
HARNESS KIT, Lighting |
| 24 |
84125T |
REGULATOR ASSEMBLY, Voltage |
▶CARBURETOR (48 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
3303-812648T |
CARBURETOR Comment: (5 H.P.) SN# USA-A838661/Belgium-9542671 & Up |
| 2 |
812650 |
MAIN NOZZLE Comment: (5 H.P.) SN# USA-A838661/Belgium-9542671 & Up |
| 3 |
78,16250 |
MAIN JET Comment: (5 H.P.) SN# USA-A838661/Belgium-9542671 & Up |
| 4 |
52,16251 |
JET, Pilot Comment: (5 H.P.) SN# USA-A838181/Belgium-9542671 & Up |
| 5 |
16252 |
CAP, SLOW JET |
| 6 |
16254 |
FLOAT VALVE |
| 7 |
54-16255 |
CLIP, FLOAT VALVE |
| 8 |
16253 |
FLOAT |
| 9 |
17-16256 |
PIN, FLOAT |
| 10 |
10-16257 |
SCREW, FLOAT |
| 11 |
16258 |
FLOAT BOWL |
| 12 |
25-16259 |
O-RING, FLOAT BOWL |
| 13 |
10-16260 |
SCREW, (M4 x 12), FLOAT BOWL |
| 14 |
10-16261 |
SCREW, Drain |
| 15 |
27-16262 |
GASKET, DRAIN SCREW |
| 16 |
27-16326 |
GASKET, PUMP BODY |
| 17 |
16325 |
DIAPHRAGM |
| 18 |
16268 |
BODY, Pump |
| 19 |
21-16269 |
CHECK VALVE |
| 20 |
10-16270 |
SCREW, CHECK VALVE TO BODY |
| 21 |
11-16271 |
NUT, CHECK VALVE SCREW |
| 22 |
16275 |
DIAPHRAGM |
| 23 |
27-16274 |
GASKET, PUMP COVER |
| 24 |
16272 |
COVER, Pump |
| 25 |
10-162606 |
SCREW, PUMP COVER |
| 26 |
10-812935 |
SCREW, Adjusting Comment: (5 H.P.) SN# USA-A838661/Belgium-9542671 & Up |
| 27 |
24-16266 |
SPRING, ADJUSTING SCREW |
| 28 |
10-16263 |
SCREW |
| 29 |
24-16264 |
SPRING, STOP SCREW |
| 30 |
10-16267 |
SCREW |
| 31 |
27-16327 |
GASKET, CARBURETOR |
| 32 |
8M0207654 |
BRACKET, BAFFLE PLATE |
| 33 |
10-855809003 |
BOLT, (M6 x 85), BRACKET |
| 34 |
13-16818 |
LOCKWASHER, BRACKET BOLT |
| 35 |
812936 |
PLATE, Baffle Comment: SN# USA-A838181/Belgium-9542671 & Up |
| 36 |
10-16334 |
SCREW, BAFFLE PLATE |
| 37 |
12-16335 |
WASHER, BAFFLE PLATE SCREW |
| 38 |
16331 |
ROD, Choke |
| 39 |
25-16332 |
GROMMET, CHOKE ROD |
| 40 |
16333 |
ROD, Snap |
| 41 |
22-8M0182334 |
CONNECTOR, Fuel - Brass Comment: 5 H.P FOR TANK/FUEL LINES SEE ACCESSORIES GUIDE |
| 42 |
10-4000333 |
SCREW, (M6 x 40) Comment: 5 H.P FOR TANK/FUEL LINES SEE ACCESSORIES GUIDE |
| 43 |
12-16826 |
WASHER, Stainless Steel Comment: 5 H.P FOR TANK/FUEL LINES SEE ACCESSORIES GUIDE |
| 44 |
32-17668 |
HOSE (6-1/2") Comment: 5 H.P FOR TANK/FUEL LINES SEE ACCESSORIES GUIDE |
| 45 |
35-8M0157133 |
FILTER, Fuel Comment: 5 H.P FOR TANK/FUEL LINES SEE ACCESSORIES GUIDE |
| 46 |
32-17669 |
HOSE (5-1/4") Comment: 5 H.P FOR TANK/FUEL LINES SEE ACCESSORIES GUIDE |
| 47 |
54-95395 |
CLIP, Stainless Steel Comment: 5 H.P FOR TANK/FUEL LINES SEE ACCESSORIES GUIDE |
| 48 |
54-8M0130961 |
CLAMP Comment: 5 H.P FOR TANK/FUEL LINES SEE ACCESSORIES GUIDE |
▶CLAMP AND SWIVEL BRACKETS (36 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
3406-9622T6 |
CLAMP BRACKET (STARBORAD) |
| 2 |
3406-96231 |
CLAMP BRACKET (PORT) |
| 3 |
10-898101337 |
BOLT, CLAMP BRACKET |
| 4 |
12-95375 |
WASHER, CLAMP BRACKET BOLT |
| 5 |
12-16192 |
WASHER, CLAMP BRACKET BOLT |
| 6 |
11-95374 |
NUT, CLAMP BRACKET BOLT |
| 7 |
16193 |
DISTANCE PLATE, CLAMP BRACKET |
| 8 |
10-16194 |
SCREW, DISTANCE PLATE |
| 9 |
24-161951 |
SPRING, CLAMP BRACKET |
| 10 |
10-16196 |
SCREW, CLAMP BRACKET SPRING |
| 11 |
12-16197 |
WASHER, CLAMP BRACKET SPRING SCREW |
| 12 |
16198004 |
THRUST ROD |
| 13 |
24-8150931 |
SPRING, THRUST ROD |
| 14 |
10-16200 |
CLAMP SCREW ASSEMBLY |
| 15 |
12-95379 |
PAD, CLAMP SCREW |
| 16 |
3407-813029T1 |
SWIVEL BRACKET Comment: SN# USA-A838180/Belgium-9542670 & Below |
| 17 |
10-16201 |
BOLT, SWIVEL BRACKET |
| 18 |
12-16826 |
WASHER, Stainless Steel, SWIVEL BRACKET BOLT |
| 19 |
23-8M0057473 |
BUSHING, SWIVEL BRACKET (UPPER) |
| 20 |
23-16203 |
BUSHING, SWIVEL BRACKET (LOWER) |
| 21 |
16204 |
THRUST PLATE |
| 22 |
10-162061 |
SCREW, FRICTION PLATE |
| 23 |
24-953838 |
SPRING, FRICTION PLATE SCREW |
| 25 |
162051 |
FRICTION PLATE, SWIVEL BRACKET |
| 26 |
8M0045584 |
STOP ASSEMBLY, Tilt |
| 27 |
16208 |
GRIP, TILT STOP |
| 28 |
23-16209 |
BUSHING, TILT STOP |
| 29 |
16210002 |
SET PLATE, TILT STOP |
| 30 |
10-95396 |
BOLT, SET PLATE |
| 31 |
13-400256 |
LOCKWASHER, SET PLATE SCREW |
| 32 |
24-16212 |
SPRING, TILT STOP |
| 33 |
16213 |
ARM, Reverse Lock |
| 34 |
24-16215 |
SPRING, REVERSE LOCK ARM (RIGHT) |
| 35 |
24-16216 |
SPRING, REVERSE LOCK ARM (LEFT) |
| 36 |
10-16223 |
BOLT, REVERSE LOCK ARM |
| 37 |
12-16826 |
WASHER, Stainless Steel, REVERSE LOCK ARM BOLT |
▶COWLING (20 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
2189-9721 |
TOP COWL ASSEMBLY Comment: (5 H.P.) |
| 2 |
25-162282 |
GROMMET, TOP COWL |
| 3 |
2189-825984A2 |
BOTTOM COWL |
| 4 |
10-16832 |
BOLT, BOTTOM COWL |
| 5 |
12-16826 |
WASHER, Stainless Steel, BOTTOM COWL BOLT |
| 6 |
162181 |
HOOK LEVER |
| 7 |
26-16219 |
SEAL, HOOK LEVER |
| 8 |
23-16220 |
BUSHING, HOOK LEVER |
| 9 |
16222 |
COVER HOOK |
| 10 |
10-16223 |
BOLT, (M6 x 14), COVER HOOK |
| 11 |
13-400256 |
LOCKWASHER, COVER HOOK BOLT |
| 12 |
12-953921 |
WASHER, COVER HOOK BOLT |
| 13 |
13-16221 |
WAVE WASHER, COVER HOOK |
| 14 |
25-16231 |
GROMMET, STARTER LOCK ROD |
| 15 |
25-16225 |
GROMMET, THROTTLE LEVER |
| 16 |
25-16226 |
GROMMET, CARBURETOR DRAIN |
| 17 |
37-16227 |
DECAL, Fuel Cock |
| 18 |
91-16229 |
TOOL KIT |
| 19 |
50-16230 |
SAFETY ROPE |
| 20 |
19-18670 |
PLUG Comment: (5 H.P.) |
▶CYLINDER BLOCK/CRANKSHAFT/PISTON (39 parts)
| Ref |
OEM Part # |
Part Name |
| - |
813025 |
POWERHEAD ASSEMBLY, COMPLETE Comment: (5 H.P.) SN# USA-A838181/Belgium-9542671 & Up |
| 1 |
878-812938 |
CYLINDER BLOCK Comment: SN# USA-A838181/Belgium-9542671 & Up |
| 2 |
17-95218 |
PIN, Dowel |
| 3 |
10-16695 |
BOLT, CYLINDER BLOCK |
| 4 |
10-16696 |
BOLT, CYLINDER BLOCK |
| 5 |
13-16818 |
LOCKWASHER, CYLINDER BLOCK BOLTS |
| 6 |
979-96301 |
CYLINDER HEAD |
| 7 |
27-812939015 |
GASKET, CYLINDER HEAD Comment: SN# USA-A838181/Belgium-9542671 & Up |
| 8 |
10-16126 |
BOLT, CYLINDER HEAD |
| 9 |
12-4002217 |
WASHER, CYLINDER HEAD BOLT |
| 10 |
33-8M0114744 |
SPARK PLUG, (NGK#BP7HS-10) |
| 11 |
21-16700 |
CHECK VALVE |
| 12 |
24-16701 |
SPRING, CHECK VALVE |
| 13 |
34-16706 |
REED VALVE |
| 14 |
34-17666 |
STOP, REED VALVE Comment: (5 H.P.) |
| 15 |
10-16820 |
SCREW, REED STOP |
| 16 |
8150162 |
HEAD, CYLINDER BLOCK |
| 17 |
26-8M0101649 |
SEAL, Oil, HEAD |
| 18 |
27-8M0152378 |
GASKET, HEAD |
| 19 |
10-16705 |
BOLT, HEAD |
| 20 |
13-400256 |
LOCKWASHER, HEAD BOLT |
| 21 |
53-16057 |
CLIP, PISTON PIN |
| 22 |
28-16053 |
KEY, CRANKSHAFT |
| 23 |
30-16049 |
BEARING, Ball, CRANKSHAFT |
| 24 |
8537122 |
THRUST PLATE |
| 25 |
26-16051 |
SEAL, Oil, CRANKSHAFT |
| 26 |
31-16052 |
BEARING, Roller, CONNECTING ROD |
| 27 |
779-9616T |
PISTON Comment: (.5MM OVERSIZE) |
| 28 |
39-8M0080356 |
RING, Piston Comment: (.5MM OVERSIZE) |
| 29 |
41-898101918 |
PIN, Piston |
| 30 |
32-8M0057112 |
HOSE, (160 mm) Comment: SN# USA-A838181/Belgium-9542671 & Up |
| 31 |
21-42657A3 |
CHECK VALVE Comment: SN# USA-A838181/Belgium-9542671 & Up |
| 32 |
54-95224 |
CLIP Comment: SN# USA-A838181/Belgium-9542671 & Up |
| 33 |
474-879147T15 |
CRANKSHAFT ASSEMBLY |
| 34 |
463-813044 |
CRANKSHAFT |
| 35 |
463-813045 |
CRANKSHAFT |
| 36 |
813046 |
PIN, Crank |
| 37 |
629-813047 |
CONNECTING ROD |
| 38 |
31-813048 |
BEARING |
▶DRIVESHAFT HOUSING/GEAR HOUSING (32 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
1500-8M0089106 |
HOUSING, Driveshaft Comment: (LONG) SN# USA-A838180/Belgium-9542670 & Below |
| 2 |
23-16114 |
BUSHING, SHIFT LEVER |
| 3 |
10-16830 |
BOLT, DRIVESHAFT HOUSING |
| 4 |
12-16826 |
WASHER, Stainless Steel, DRIVESHAFT HOUSING BOLT |
| 5 |
19-879194296 |
PLUG, Water |
| 6 |
27-95220 |
GASKET, WATER PLUG |
| 7 |
27-812947001 |
GASKET, DRIVESHAFTG HOUSING |
| 8 |
17-16119 |
PIN, Dowel, DRIVESHAFT HOUSING |
| 9 |
25-161181 |
GROMMET, CAM ROD |
| 10 |
25-16117 |
GROMMET, DRIVESHAFT HOUSING |
| 11 |
827663A1 |
BUSHING, DRIVESHAFT Comment: (LONG) |
| 12 |
16121 |
RETAINER, DRIVESHAFT BUSHING |
| 13 |
10-16123 |
SCREW, (25 mm) Comment: (LONG) |
| 14 |
1668-9621T6 |
GEAR HOUSING ASSEMBLY Comment: (SAIL POWER) |
| 15 |
23-16124 |
BUSHING, GEAR HOUSING |
| 16 |
97-823912 |
ANODE |
| 17 |
10-16832 |
BOLT, (M6 x 16), ANODE |
| 18 |
22-8M0229353 |
PLUG, OIL |
| 19 |
27-95220 |
GASKET, OIL PLUG |
| 20 |
10-16125 |
BOLT, GEAR HOUSING (FRONT) |
| 21 |
12-16826 |
WASHER, Stainless Steel, GEAR HOUSING BOLT |
| 22 |
10-16126 |
BOLT, GEAR HOUSING (REAR) |
| 23 |
12-16192 |
WASHER, REAR GEAR HOUSING BOLT |
| 24 |
16133 |
STRAINER, Water |
| 25 |
10-16134 |
SCREW, WATER STRAINER |
| 26 |
30-16128 |
BEARING, Ball, BEVEL GEAR |
| 27 |
30-16132 |
BEARING, Ball, PROPELLER SHAFT |
| 28 |
26-16130 |
SEAL, Oil, PROPELLER SHAFT |
| 29 |
25-16131 |
O-RING, PROPELLER SHAFT HOUSING |
| 30 |
825118T |
HOUSING, PROPELLER SHAFT |
| 31 |
10-16832 |
BOLT, PROPELLER SHAFT |
| 32 |
12-16826 |
WASHER, Stainless Steel, PROPELLER SHAFT BOLT |
▶FUEL TANK(4 HORSEPOWER) (26 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
1258-824964A03 |
TANK, Fuel Comment: SN# USA-A838180/Belgium-9542670 & Below |
| 2 |
36-812952 |
CAP, FUEL TANK Comment: SN# USA-A838181/Belgium-9542671 & Up |
| 3 |
27-8M0065762 |
GASKET, CAP Comment: SN# USA-A838181/Belgium-9542671 & Up |
| 4 |
36-812952 |
CAP, FUEL TANK Comment: SN# USA-A838180/Belgium-9542670 & Below |
| 5 |
27-16233 |
GASKET, FUEL TANK CAP Comment: SN# USA-A838180/Belgium-9542670 & Below |
| 6 |
50-16831 |
ROPE, FUEL TANK CAP Comment: SN# USA-A838180/Belgium-9542670 & Below |
| 7 |
16234 |
STRAINER, TANK CAP Comment: SN# USA-A838180/Belgium-9542670 & Below |
| 8 |
13-400256 |
LOCKWASHER, MOUNT |
| 9 |
12-898101937 |
WASHER, MOUNT |
| 10 |
11-400212 |
NUT, MOUNT |
| 11 |
8M0046049 |
BRACKET, FUEL TANK |
| 12 |
10-16832 |
BOLT, FUEL TANK BRACKET |
| 13 |
13-400256 |
LOCKWASHER, FUEL TANK BRACKET BOLT |
| 14 |
22-16240 |
FUEL COCK ASSEMBLY |
| 15 |
54-95395 |
CLIP, Stainless Steel, FUEL HOSE |
| 16 |
32-16246 |
HOSE, FUEL |
| 17 |
32-16242001 |
TUBE, FUEL COCK ROD |
| 18 |
16241 |
ROD, FUEL COCK |
| 19 |
16244 |
RUBBER, FUEL COCK ROD |
| 20 |
16243 |
KNOB, FUEL COCK ROD |
| 21 |
10-16245 |
SCREW, KNOB |
| 22 |
32-16247 |
HOSE, (117 mm), FUEL |
| 23 |
35-8M0157133 |
FILTER, Fuel |
| 24 |
26-8M0099393 |
SEAL, FUEL TANK |
| 25 |
16236 |
MOUNT, FUEL TANK |
| 26 |
12-953921 |
WASHER, MOUNT |
▶GEAR HOUSING COMPONENTS (39 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
45-8M0076368 |
DRIVESHAFT Comment: (LONG) |
| 2 |
30-95347 |
BEARING, DRIVSHAFT |
| 3 |
28-16155 |
KEY, DRIVESHAFT |
| 4 |
43-16138 |
GEAR, DRIVESHAFT |
| 5 |
27-16164003 |
GASKET, LOWER WATER PUMP HOUSING |
| 6 |
15-8132761 |
SHIM, LOWER WATER PUMP HOUSING (0.15) |
| 7 |
26-16162 |
SEAL, Oil, LOWER WATER PUMP HOUSING |
| 8 |
46-16161 |
HOUSING, WATER PUMP (LOWER) |
| 9 |
16165 |
RETAINER, CAM ROD BUSHING |
| 10 |
10-8M0204707 |
BOLT, Stainless Steel, BUSHING RETAINER |
| 11 |
12-16826 |
WASHER, Stainless Steel, RETAINER BOLT |
| 12 |
27-16160004 |
GASKET, WATER PUMP HOUSING PLATE |
| 13 |
16159 |
PLATE, WATER PUMP HOUSING |
| 14 |
27-8M0155369 |
GASKET, WATER PUMP HOUSING |
| 15 |
47-8M0204676 |
IMPELLER |
| 16 |
16157 |
LINER, UPPER WATER PUMP HOUSING |
| 17 |
46-16156 |
HOUSING, Upper Water Pump |
| 18 |
10-16125 |
BOLT, UPPER WATER PUMP HOUSING |
| 19 |
12-16826 |
WASHER, Stainless Steel, UPPER WATER PUMP HOUSING BOLT |
| 20 |
26-16168 |
SEAL, WATER PUMP HOSE |
| 21 |
32-16167 |
HOSE, WATER PUMP |
| 22 |
26-16171 |
SEAL, LOWER WATER TUBE |
| 23 |
32-16170 |
TUBE, Water Comment: (LONG) |
| 24 |
15-813277 |
SHIM, (0.15), PROPELLER SHAFT GEAR |
| 25 |
43-812944 |
GEAR, PROPELLER SHAFT Comment: SN# USA-A838180/Belgium-9542670 & Below |
| 26 |
16152 |
FOLLOWER, Cam, CLUTCH |
| 27 |
16153 |
RETAINER, CLUTCH SPRING |
| 28 |
52-16149 |
CLUTCH Comment: SN# USA-A838180/Belgium-9542670 & Below |
| 29 |
17-16150 |
PIN, Clutch |
| 30 |
24-17667 |
SPRING, CLUTCH |
| 31 |
44-195133 |
PROPELLER SHAFT Comment: SN# USA-A828330/Belgium-9523183 & Below |
| 32 |
12-16140 |
WASHER, PROPELLER SHAFT GEAR |
| 33 |
43-8129451 |
GEAR, PROPELLER SHAFT Comment: SN# USA-A838180/Belgium-9542670 & Below |
| 34 |
16145Q01 |
THRUST HOLDER, PROPELLER |
| 35 |
48-812951A02 |
PROPELLER (6"PITCH-HI-REVERSETHURST) Comment: (SAILPOWER) USA SN# A829010 AND BELOW , Belgium SN# 9523183 AND BELOW |
| 36 |
12-16146 |
WASHER, PROPELLER NUT |
| 37 |
11-16147 |
PROP NUT |
| 38 |
18-815026 |
COTTER PIN, PROPELLER NUT |
| 39 |
25-18876 |
GROMMET, WATER TUBE |
▶MAGNETO AND IGNITION COMPONENTS (32 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
200-8M0110989 |
FLYWHEEL Comment: SN# USA-834681/Belgium-9542671 & Up |
| 2 |
16058T |
COIL, Exciter |
| 3 |
10-16059 |
SCREW, EXITER COIL |
| 4 |
54-16060 |
CLAMP, EXCITER COIL WIRE |
| 5 |
10-16821 |
SCREW, CLAMP |
| 6 |
11-16071 |
NUT, FLYWHEEL |
| 7 |
12-16072 |
WASHER, FLYWHEEL |
| 8 |
160661 |
COIL, Pulser |
| 9 |
10-16067 |
SCREW, PULSER COIL |
| 10 |
815113T02 |
COIL, Ignition |
| 11 |
10-16065 |
BOLT, IGNITION COIL |
| 12 |
13-16818 |
LOCKWASHER, IGNITION COIL BOLT |
| 13 |
25-16068 |
GROMMET, PULSER COIL |
| 14 |
16061T04 |
CD UNIT |
| 15 |
878061 |
DAMPER, C.D. UNIT (FRONT) |
| 16 |
878062 |
DAMPER, C.D. UNIT (REAR) |
| 17 |
18-815026 |
COTTER PIN, C.D. UNIT |
| 18 |
87-823037A04 |
SWITCH ASSEMBLY, Stop |
| 20 |
16074T |
ALTERNATOR Comment: SAIL POWER |
| 21 |
10-16059 |
SCREW, ALTERNATOR Comment: SAIL POWER |
| 22 |
54-16060 |
CLAMP, ALTERNATOR Comment: SAIL POWER |
| 23 |
10-16821 |
SCREW, ALTERNATOR CLAMP Comment: SAIL POWER |
| 24 |
16076A1 |
RECTIFIER Comment: SAIL POWER |
| 25 |
89-16077 |
FUSE Comment: SAIL POWER |
| 26 |
10-16078 |
SCREW, RECTIFIER Comment: SAIL POWER |
| 27 |
13-16079 |
LOCKWASHER, RECTIFIER SCREW Comment: SAIL POWER |
| 28 |
12-8M0108373 |
WASHER, Stainless Steel, RECTIFIER SCREW Comment: SAIL POWER |
| 29 |
54-8M0130961 |
CLAMP, RECTIFIER Comment: SAIL POWER |
| 30 |
11-16081 |
NUT, Stainless Steel, RECTIFIER SCREW Comment: SAIL POWER |
| 31 |
84-16822 |
HARNESS, Extension Comment: SAIL POWER |
| 32 |
25-16823 |
GROMMET Comment: SAIL POWER |
| 33 |
84-16082 |
CABLE, Battery Comment: SAIL POWER |
▶MISCELLANEOUS PARTS/ACCESSORIES (1 parts)
| Ref |
OEM Part # |
Part Name |
| - |
90-15794890 |
OWNERS GUIDE |
▶RECOIL STARTER, S#USA-A834680/Belgium-9542670 and Below (31 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
16092 |
HOUSING, Starter |
| 2 |
16095 |
SHEAVE, Starter |
| 3 |
16096 |
PAWL, STARTER SHEAVE |
| 4 |
53-16097 |
E RING, PAWL |
| 5 |
24-16098 |
SPRING, Guide, PAWL |
| 6 |
24-16099 |
SPRING, PAWL |
| 7 |
16100 |
GUIDE PLATE, SPRING |
| 8 |
16101 |
HOUSING, STARTER SPRING |
| 9 |
24-812645T |
SPRING, Starter |
| 10 |
16103 |
PLATE, STARTER SPRING |
| 11 |
16104 |
SHAFT, Starter |
| 12 |
10-16105 |
BOLT, STARTER SHAFT |
| 13 |
12-16106 |
WASHER, STARTER SHAFT BOLT |
| 14 |
11-400212 |
NUT, STARTER SHAFT BOLT |
| 15 |
19-16111 |
PLUG, STARTER SHEAVE |
| 16 |
10-8M0204707 |
BOLT, Stainless Steel, STARTER HOUSING |
| 17 |
13-400256 |
LOCKWASHER, STARTER HOUSING BOLT |
| 18 |
161101 |
PLATE, STARTER |
| 19 |
50-16108 |
ROPE, Starter |
| 20 |
95249 |
HANDLE, Starter |
| 21 |
25-16109 |
O-RING, STARTER ROPE |
| 22 |
17634 |
LOCK, Starter |
| 23 |
10-17635 |
SCREW, STARTER LOCK |
| 24 |
12-16335 |
WASHER, STARTER LOCK SCREW |
| 25 |
23-895130 |
COLLAR, STARTER LOCK |
| 26 |
24-812645007 |
SPRING, STARTER LOCK |
| 27 |
812643 |
CAM, STARTER LOCK |
| 28 |
10-17640 |
SHOULDER SCREW, CAM |
| 29 |
13-17641 |
WAVE WASHER, SHOULDER SCREW |
| 30 |
17642001 |
ROD, STARTER LOCK |
| 31 |
8M0169412 |
SNAP, Link Rod |
▶RECOIL STARTER, S#USA-A834681/Belgium-9542671 and Up (25 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
8M0227442 |
HOUSING, Starter |
| 2 |
24-812645T |
SPRING SET |
| 3 |
812633 |
SHEEVE, Starter |
| 4 |
24-812634 |
SPRING, Return |
| 5 |
8M0060217 |
RATCHET |
| 6 |
24-812636 |
SPRING, Friction |
| 7 |
10-8M0060218 |
BOLT, STARTER SHAFT |
| 8 |
812638 |
FRICTION PLATE |
| 9 |
812642 |
PULLEY, Starter |
| 10 |
10-16828 |
BOLT |
| 11 |
13-16818 |
LOCKWASHER |
| 12 |
200-8M0110989 |
FLYWHEEL |
| 13 |
161101 |
PLATE, STARTER |
| 14 |
50-12066Q10 |
ROPE, Starter |
| 15 |
812640 |
HANDLE, Starter Rope |
| 16 |
812641 |
RETAINER |
| 17 |
17634 |
LOCK, Starter |
| 18 |
23-895130 |
COLLAR, STARTER LOCK |
| 19 |
24-812645007 |
SPRING, STARTER LOCK |
| 20 |
12-16335 |
WASHER, STARTER LOCK SCREW |
| 21 |
10-17635 |
SCREW, STARTER LOCK |
| 22 |
812643 |
CAM, STARTER LOCK |
| 23 |
8M0169412 |
SNAP, Link Rod |
| 24 |
13-17641 |
WAVE WASHER, SHOULDER SCREW |
| 25 |
10-17640 |
SHOULDER SCREW, CAM |
▶REMOTE CONTROL ATTACHING KIT (36 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
16840A2 |
ATTACHING KIT, Remote Control |
| 2 |
16848 |
LEVER, THROTTLE WIRE |
| 3 |
17034 |
WIRE, Throttle |
| 4 |
10-16223 |
BOLT, (M6 x 14), THROTTLE WIRE LEVER |
| 5 |
13-400256 |
LOCKWASHER, THROTTLE WIRE LEVER BOLT |
| 6 |
12-953921 |
WASHER, THROTTLE WIRE LEVER BOLT |
| 7 |
23-16849 |
COLLAR, THROTTLE WIRE LEVER |
| 8 |
84-17035 |
HARNESS ASSEMBLY (DUEL STOP SWITCH) |
| 9 |
17-17031 |
PIN, Lock |
| 10 |
17-17033 |
PIN, LOCK PIN |
| 11 |
24-17032 |
SPRING, LOCK PIN |
| 12 |
17030 |
SLEEVE |
| 13 |
12-17029 |
WASHER, CAP SPRING |
| 14 |
16847 |
LEVER, Throttle |
| 15 |
17026 |
BRACKET |
| 16 |
17027 |
CAP, BRACKET |
| 17 |
24-17028 |
SPRING, BRACKET CAP |
| 18 |
13-16221 |
WAVE WASHER, THROTTLE LEVER |
| 19 |
26-16219 |
SEAL, THROTTLE LEVER |
| 20 |
23-16220 |
BUSHING, THROTTLE LEVER |
| 21 |
17023 |
BRACKET |
| 22 |
10-16832 |
BOLT, (M6 x 16), BRACKET |
| 23 |
13-400256 |
LOCKWASHER, BRACKET BOLT |
| 24 |
11-400212 |
NUT, BRACKET BOLT |
| 25 |
17024 |
PLATE, Steering Hook |
| 26 |
10-4000354 |
BOLT, PLATE |
| 27 |
12-16192 |
WASHER, PLATE BOLT |
| 28 |
13-17025 |
LOCKWASHER, PLATE BOLT |
| 29 |
11-400213 |
NUT, PLATE BOLT |
| 30 |
87-823037A2 |
SWITCH ASSEMBLY, Stop |
| 31 |
84-17162 |
HARNESS ASSEMBLY (5.9M) |
| 32 |
25-16226 |
GROMMET, STOP SWITCH HOLE |
| 33 |
10-17174 |
BOLT, STOP SWITCH CLAMP |
| 34 |
12-8M0108373 |
WASHER, Stainless Steel, STOP SWITCH CLAMP BOLT |
| 35 |
54-17169 |
CLAMP, STOP SWITCH |
| 36 |
11-16081 |
NUT, Stainless Steel, STOP SWITCH CLAMP BOLT |
▶SHIFT COMPONENTS (20 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
8130275 |
LEVER, Shift Comment: SN# USA-A838180/Belgium-9542670 & Below |
| 2 |
30-812937 |
STOPPER, SHIFT LEVER Comment: SN# USA-A830690/Belgium-9542670 & Below |
| 3 |
24-813028 |
SPRING, SHIFT LEVER STOPPER Comment: SN# USA-A830690/Belgium-9542670 & Below |
| 4 |
16184 |
LEVER, SHIFT ROD |
| 5 |
10-16185 |
BOLT, SHIFT ROD LEVER |
| 6 |
17-16188 |
PIN, SHIFT LEVER |
| 7 |
18-16189 |
COTTER PIN, SHIFT ROD LEVER PIN |
| 8 |
25-16181 |
O-RING, SHIFT LEVER |
| 9 |
16187 |
SHIFT ROD Comment: (LONG) |
| 10 |
12-16826 |
WASHER, Stainless Steel, SHIFT ROD |
| 11 |
16190 |
JOINT, SHIFT ROD |
| 12 |
10-16832 |
BOLT, (M6 x 16), SHIFT ROD JOINT |
| 13 |
12-16826 |
WASHER, Stainless Steel, SHIFT ROD JOINT BOLT |
| 14 |
8M0058365 |
CAM ROD Comment: (LONG) |
| 15 |
17-16179 |
PIN, CAM ROD |
| 16 |
25-161771 |
O-RING, UPPER CAM ROD |
| 17 |
23-16176 |
BUSHING, CAM ROD |
| 18 |
25-16178 |
O-RING, LOWER CAM ROD |
| 19 |
8M0090459 |
CAM |
| 20 |
17-16175 |
PIN, CLUTCH CAM |
▶THROTTLE COMPONENTS (23 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
16075T4 |
HANDLE, Throttle |
| 2 |
37-8M0097201 |
DECAL, THROTTLE |
| 3 |
16088 |
WIRE, Throttle |
| 4 |
16093 |
SHAFT, Throttle |
| 5 |
23-16336 |
BUSHING, THROTTLE SHAFT |
| 6 |
23-16191 |
SPACER, THROTTLE SHAFT |
| 7 |
813026 |
FRICTION PIECE Comment: SN# USA-A838180/Belgium-9542670 & Below |
| 8 |
10-16087 |
SCREW, Adjusting, FRICTION PIECE |
| 9 |
12-16826 |
WASHER, Stainless Steel, FRICTION PIECE SCREW |
| 10 |
11-400212 |
NUT, FRICTION PIECE SCREW |
| 11 |
16086 |
GRIP |
| 12 |
10-16094 |
SCREW, GRIP |
| 13 |
16338 |
BRACKET, THROTTLE SHAFT |
| 14 |
10-16827 |
SCREW, BRACKET |
| 15 |
12-16826 |
WASHER, Stainless Steel, BRACKET SCREW |
| 16 |
23-16083005 |
BUSHING, HANDLE |
| 17 |
17-16085 |
PIN, HANDLE RETAINER |
| 18 |
8M0207656 |
RETAINER, HANDLE |
| 19 |
10-16832 |
BOLT |
| 20 |
13-400256 |
LOCKWASHER |
| 21 |
16089 |
BRACKET, THROTTLE WIRE |
| 22 |
10-16828 |
BOLT, THROTTLE WIRE BRACKET |
| 23 |
13-16818 |
LOCKWASHER, BRACKET BOLT |
100-Hour / Annual Service Checklist
Regular maintenance keeps your Mercury 4/5 (1 CYL. PRODUCT OF JAPAN) 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.
