Mercury 40 (4-STROKE)(4 CYL.) (0P094500 THRU 0P206999) Parts & Diagrams

OEM and aftermarket replacement parts for Mercury 40 (4-STROKE)(4 CYL.). Scroll down for exploded parts diagrams (31), specifications, and maintenance reference.

Sidebar

Категории

Бренд

Лошадиная сила

Show All

Двигатель

Show All

Доступность

Цена

$
to
$

Нужна помощь?

Images

Product

Price

Qty

Options

06211-ZY2-506 Maintenance Kit for Honda BF175A BF200A BF225A | JLM Marine
06211-ZY2-506 Maintenance Kit for Honda BF175A BF200A BF225A | JLM Marine
$83.50
$83.50
files/kit-23KH762-4N.pngDefault Title
$83.50
06211-ZY5-505 Maintenance Kit for Honda BF135A BF150A | JLM Marine
06211-ZY5-505 Maintenance Kit for Honda BF135A BF150A | JLM Marine
$82.50
$82.50
files/kit-23KH761-4N.pngDefault Title
$82.50
06211-ZW5-505 Maintenance Kit for Honda BF115A BF130A | JLM Marine
06211-ZW5-505 Maintenance Kit for Honda BF115A BF130A | JLM Marine
$82.50
$82.50
files/kit-23KH760-4N.pngDefault Title
$82.50
06211-ZW0-505 Maintenance Kit for Honda BF75A BF90A | JLM Marine
06211-ZW0-505 Maintenance Kit for Honda BF75A BF90A | JLM Marine
$71.50
$71.50
files/kit-23KH758-4N.pngDefault Title
$71.50
Water Pump Impeller – Fits Mercury/Mariner 40 - 60 HP 4 - Stroke Outboards (Replaces 47 - 19453T) - JLM Marine Boat Parts Limited
Крыльчатка водяного насоса для Mercury 40 / 50 / 60 PK (4 цилиндра) EFI 4-тактный 47-19453
$24.50
$24.50
files/17IM0041_c8c4c0af-7ce4-47a0-ad6c-3a82683ca82e.jpgDefault Title
$24.50

Mercury 40 (4-STROKE)(4 CYL.) (0P094500 THRU 0P206999) Parts & Diagrams

🔎 Mercury 40 (4-STROKE)(4 CYL.) Reference Library — Exploded parts diagrams (31 diagrams), specifications, common issues, and maintenance checklist.

The Mercury 40 (4-STROKE)(4 CYL.) is a 4-Stroke, Inline 4-Cylinder, EFI, SOHC outboard motor. Commonly used on jon boats, pontoons, and mid-size utility craft.

Quick Reference Specifications

Specification Value
Engine Type 4-Stroke, Inline 4-Cylinder, EFI, SOHC
Horsepower 40 HP
Displacement 995 cc
Bore x Stroke 65 mm x 75 mm
Spark Plug (Type & Gap) NGK IZFR6F-11
Engine Oil Capacity 3.0 L (3.17 quart)
Recommended Engine Oil SAE 25W-40 Mercury FourStroke Oil
Gear Case Oil Capacity 440 mL (14.9 fl oz)
Idle Speed (in gear) 700 ± 50 RPM (in gear)
Full Throttle RPM Range 5500-6000
Fuel Unleaded Gasoline, 87 Octane min.

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

Common Issues & Recommended Parts

Below are common maintenance scenarios for the Mercury 40 (4-STROKE)(4 CYL.):

  • Water Pump / Overheating: If the tell-tale stream is weak or absent, the water pump impeller likely needs replacement. Inspect annually or every 100 hours. → Recommended: Water Pump Impeller Kit
  • Engine Oil / Maintenance Light: 4-stroke engines require regular oil and filter changes. Use marine-grade oil rated for your engine. Change every 100 hours or annually. → Recommended: Oil Filter, Engine Oil
  • Fuel Injector Issues (EFI models): Rough idle or misfires may indicate clogged fuel injectors. Use fuel stabilizer and clean injectors periodically. → Recommended: Fuel Injector, Fuel Filter
  • Gear Case Oil Leak: Check lower unit seals if gear oil appears milky (water contamination). Replace seals and gaskets during lower unit service. → Recommended: Lower Unit Seal Kit, Drain Plug Gaskets
  • Anode Corrosion: Inspect sacrificial anodes regularly, especially in saltwater. Replace when 50% depleted to protect against galvanic corrosion. → Recommended: Zinc/Aluminum Anode Kit

Parts Diagrams & OEM Part Numbers

Expand the sections below to view detailed exploded parts diagrams and find the exact OEM replacement components for your Mercury 40 (4-STROKE)(4 CYL.).

▶ACCESSORIES (1 parts) ACCESSORIES
Ref OEM Part # Part Name
- 12092A18 EXTENSION KIT, Driveshaft - 5 Inch Comment: (BIGFOOT)
▶ADAPTOR PLATE (25 parts) ADAPTOR PLATE
Ref OEM Part # Part Name
- 27-859352A01 GASKET SET
1 8M0162935 DIPSTICK
2 825989003 DIPSTICK TUBE
3 8560552 SEAL
4 8289151 HEAT SHIELD
5 17-23784 PIN, Dowel
6 22-629101 FITTING, Elbow - 90 Degree (.125-27)
7 54-816311T TIE STRAP, (8.00 Inches)
8 26-66301 SEAL, Oil
9 23-859594 BUSHING
10 22-384073 PLUG, Pipe (.500-14)
11 825228A17 ADAPTOR PLATE KIT
12 19-822464 PLUG
13 19-48323 PLUG
14 25-845746 O-RING
15 10-8M0204741 SCREW, (M6 x 20) Stainless Steel
16 8M0210772 BODY, Oil Pressure Relief Comment: (DESIGN II)
17 893765 PLATE, Oil Pickup-Top
18 32-854793 HOSE, Oil Pickup
19 893700 BAFFLE
20 54-855228 CLAMP
21 10-4007455 SCREW, (M6 x 50)
22 856592 DEFLECTOR, Oil Comment: (DESIGN I)
23 8M0210772 BODY ASSEMBLY, Oil Pressure Relief Comment: (DESIGN I)
24 27-8M0213113 GASKET
▶BOTTOM COWL (18 parts) BOTTOM COWL
Ref OEM Part # Part Name
1 4020-826277T1 BOTTOM COWL Comment: (LONG-PORT)
2 4020-826278T7 BOTTOM COWL Comment: (LONG-STBD.)
3 10-82684430 SCREW, (M6 x 30)
4 12-8M0204649 WASHER, (.281 x .500 x .060) Stainless Steel
5 825238002 SEAL
6 12-855576 WASHER
7 27-855627 GASKET
8 10-82684460 SCREW, (M6 x 60)
9 22-827948 FITTING
10 826273001 BOOT
11 54-816311T TIE STRAP, (8.00 Inches)
12 825782F1 LEVER, Cowl Latch
13 23-812707 BUSHING
14 13-12134 WASHER, Wave
15 893766 LATCH HOOK
16 10-1993716 SCREW, (M6 x 16)
17 25-19565002 GROMMET
18 87-8M0235191 SWITCH, Trim
▶CAMSHAFT (11 parts) CAMSHAFT
Ref OEM Part # Part Name
- 893505T01 CYLINDER HEAD ASSEMBLY
1 400-8M0183247 CAMSHAFT
2 857087T1 PUMP ASSEMBLY, Oil
3 25-857096 O-RING
4 NSS NOT SOLD SEPARATE
5 25-857094 O-RING
6 25-857093 O-RING
7 10-875206 SCREW, (M6 x 16)
8 10-4000333 SCREW, (M6 x 40)
9 17-878183 PIN, Dowel
10 17-826149 PIN
▶CARBURETOR (36 parts) CARBURETOR
Ref OEM Part # Part Name
- 8542561 REPAIR KIT, Carburetor Comment: (1 Per Carburetor)
1 3329-857102T4 CARBURETOR Comment: (BOTTOM)
2 10-854246 SCREW
3 854245 PLATE
4 27-8542572 GASKET
5 854254T3 ENRICHENER
6 NSS NOT SOLD SEPARATE
7 854255 PLATE
8 19-880814 CAP
9 10-880841 SCREW, Adjusting
10 25-880842 O-RING
11 24-880815 SPRING
12 803912 JET (SLOW)
13 25-880843 O-RING
14 19-880844 PLUG
15 98,803915 JET (MAIN)
16 8039142 MAIN NOZZLE
17 854247 VALVE, Float
18 8542531 FLOAT
19 17-8542581 PIN, Float
20 10-880845 SCREW
21 27-8542573 GASKET
22 8039171 FLOAT BOWL Comment: (CENTERS/BOTTOM)
23 10-8542463 SCREW
24 10-8542464 SCREW, Drain
25 12-8542591 WASHER
26 10-803925 SCREW, Synchronization Comment: (TOP/CENTERS)
27 24-880846 SPRING Comment: (TOP/CENTERS)
28 24-803923 SPRING Comment: (TOP/CENTERS)
29 10-803913 SCREW Comment: (BOTTOM)
30 24-854249 SPRING Comment: (BOTTOM)
31 24-880847 SPRING
32 8542511 PLUNGER
33 10-880848 SCREW
34 NSS NOT SOLD SEPARATE
35 880849 PLUNGER ROD
▶CRANKSHAFT (13 parts) CRANKSHAFT
Ref OEM Part # Part Name
- 27-859352A01 GASKET SET
1 413-857077T02 CRANKSHAFT
2 8M0151047 SEAL
3 8M0151048 SEAL
4 600-893530T01 CONNECTING ROD
5 10-8M0049884 BOLT
6 23-893630002 BEARING, Blue
7 700-893524T02 PISTON, w/o Rings Comment: (.50MM Oversized)(Bare Piston)
8 39-893525A03 RING, Piston (TOP) Comment: (.50MM Oversized)
9 NSS NOT SOLD SEPARATE, Piston (SECOND) Comment: (.50MM Oversized)
10 39-893950 RING, Oil
11 41-893863 PIN, Piston
12 40-825017 RETAINER
▶CYLINDER BLOCK AND CRANKCASE (28 parts) CYLINDER BLOCK AND CRANKCASE
Ref OEM Part # Part Name
- 27-859352A01 GASKET SET
1 800-893502T02 CYLINDER BLOCK
2 17-825010 PIN, Dowel
3 22-479452 PLUG
4 22-384073 PLUG, Pipe (1/2-14)
5 22-416223 PLUG, Pipe (.750-14)
6 23-893631002 BEARING, Blue
7 822625 NIPPLE, (M20)
8 10-82506182 SCREW, (M8 x 82)
9 10-8M0205943 SCREW, (M6 x 35)
10 27-8M0213112 GASKET
11 35-8M0162829 FILTER, Oil
12 27-8M0224375 GASKET
13 8M0188836 COVER, Exhaust
14 22-479452 PLUG
15 14586 THERMOSTAT
16 27-8M0204714 GASKET
17 27-8M0177107 GASKET
18 8M0188835 COVER
19 10-8M0205943 SCREW, (M6 x 35)
20 22-996642 FITTING, Elbow 90 Degree (.125-27 x .250) Nylon
21 54-816311T TIE STRAP, (8.00 Inches)
22 32-8M0108349 TUBING, (.312) (70.00 Inches Bulk) (Cut to 11 IN.)
23 8M0214984 SENSOR ASSEMBLY, Temperature
24 25-627021 O-RING, (.301 x .070)
25 893697 LIFTING EYE
26 10-857139 SCREW, (M8 x 35)
27 NSS NOT SOLD SEPARATE
▶CYLINDER HEAD (28 parts) CYLINDER HEAD
Ref OEM Part # Part Name
- 893505T01 CYLINDER HEAD ASSEMBLY
1 893505T06 CYLINDER HEAD ASSEMBLY
2 858266 GUIDE
3 10-4000325 SCREW, (M6 x 8)
4 12-859768 WASHER
5 26-893549 SEAL, Oil
6 22-875209 PIPE PLUG
7 25-8M0011870 SEAL
8 8M0174400 COVER
9 NSS NOT SOLD SEPARATE
10 858277 PLATE, Baffle
11 10-4005685 SCREW, (M4 x 10)
12 22-629101 FITTING, Elbow - 90 Degree (.125-27)
13 27-8M0118179 GASKET
14 10-8M0204741 SCREW, (M6 x 20) Stainless Steel
15 10-82503395 SCREW, (M9 x 95)
16 17-825010 PIN, Dowel
17 859578A1 PLUG ASSEMBLY, Oil
18 25-8M0204673 O-RING, (.921 x .139)
19 NSS NOT SOLD SEPARATE, Decal
20 NSS NOT SOLD SEPARATE, Decal
21 NSS NOT SOLD SEPARATE, POWERHEAD ID
22 826060 DIAPHRAGM
23 877844 DASHPOT Comment: (NON HANDLE)
24 10-40011126 SCREW, (M6 x 13) Stainless Steel
25 32-77653101 HOSE, (48.00 Inches Bulk) (Cut to 19 IN.)
26 54-816311T TIE STRAP, (8.00 Inches)
27 10-893745025 SCREW, (M6 x 25)
▶DRIVESHAFT HOUSING (26 parts) DRIVESHAFT HOUSING
Ref OEM Part # Part Name
1 1503-852421T07 HOUSING, Driveshaft
2 825220T06 PIPE, Exhaust
3 10-824459110 SCREW, (M8 x 110) Stainless Steel
4 10-88960845 SCREW, (M8 x 45)
5 8288181 PLUG, Drain
6 27-8M0204692 GASKET
7 826276 BUMPER
8 8M0151042 GROMMET
9 16-903501 STUD, (M10 x 100) Comment: (BIGFOOT)
10 12-8M0214963 WASHER, (.406 x .750 x .105) Stainless Steel
11 11-40140 NUT, (M10)
12 32-897971A01 TUBE, Water
13 54-828529 GUIDE
14 8M0043364 BUMPER Comment: (LONG)
15 42941001 SEAL, Water Tube
16 893770 PLATE
17 10-1993325 SCREW, (M10 x 25 MM)
18 22-85822A7 SPEEDOMETER PICK UP
19 22-85822T CONNECTOR, Straight
20 22-8M0181450 FITTING
21 23-813745 SPACER
22 43585 COUPLING
23 23-855623 BUSHING
24 12-45176 WASHER, (.453 x .812 x .105) Stainless Steel
25 11-40140 NUT, (M10)
26 54-816311T TIE STRAP, (8.00 Inches)
▶ELECTRICAL COMPONENTS (47 parts) ELECTRICAL COMPONENTS
Ref OEM Part # Part Name
- 61-893678T03 POWERHEAD ASSEMBLY
1 825096T01 RELAY
2 8M0010250 BRACKET
3 825074 SOLENOID PLATE
4 11-401386 NUT, (M6) Stainless Steel
5 84-88439A9 CABLE ASSEMBLY, Battery - Positive
6 85-880786 BOOT, Insulator - Red
7 84-93388A16 CABLE ASSEMBLY, (8.50 Inches)
8 84-88439A4 CABLE ASSEMBLY, Battery - Negative
9 50-893888T STARTER MOTOR ASSEMBLY (SEE BREAKDOWN ON STARTER MOTOR)
10 10-40011153 SCREW, (M8 x 45) Stainless Steel
11 87-8M0098207 PRESSURE SWITCH
12 8M0082988 SENSOR
13 10-40011107 SCREW, (M5 x 16) Stainless Steel
14 10-82130025 SCREW, (M6 x 25)
15 12-8M0214930 WASHER
16 859224 PLATE
17 856836001 RETAINER
18 856040 BRACKET
19 10-82129114 SCREW, (M6 x 14)
20 92753 RETAINER
21 23-856954 BUSHING
22 25-8M0190980 GROMMET
23 87843303S ECM, Engine Control Module
24 23-8539201 BUSHING
25 10-82129140 SCREW, (M6 x 40)
26 33-827858Q SPARK PLUG, NGK-DPR6EA-9
27 339-859738T1 COIL ASSEMBLY, Ignition
28 NSS NOT SOLD SEPARATE, Decal Comment: (COIL ID #1)
29 NSS NOT SOLD SEPARATE, Decal Comment: (COIL ID #2)
30 NSS NOT SOLD SEPARATE, Decal Comment: (COIL ID #3)
31 NSS NOT SOLD SEPARATE, Decal Comment: (COIL ID #4)
32 10-82684430 SCREW, (M6 x 30)
33 84-857111T2 HARNESS ASSEMBLY, Engine Wiring
34 88-812619 FUSE, Yellow - 20 Ampere (SFE)
35 828054 COVER, Fuse
36 84-852375A6 HARNESS ASSEMBLY, Extension Comment: (HANDLE)
37 54-816311T TIE STRAP, (8.00 Inches)
38 883071T1 REGULATOR, Voltage
39 893771 BRACKET
40 8308971 FOAM PAD
41 10-8248329 SCREW, (M6 x 40)
42 10-82129110 SCREW, (M6 x 10)
43 10-8248324 SCREW, (M6 x 16)
44 13541 PLUG, Male
45 10-40011149 SCREW, (M8 x 25) Stainless Steel
46 11-94330 NUT, (.250-20) Brass
▶FLYWHEEL (21 parts) FLYWHEEL
Ref OEM Part # Part Name
- 893505T01 CYLINDER HEAD ASSEMBLY
1 859284T2 FLYWHEEL COVER
2 10-8248326 SCREW, (M6 x 25 MM)
3 37-804655A01 DECAL, EPA Label Information Comment: (SEE NOTE)
4 284-832010T32 FLYWHEEL
5 8331045 GEAR, Driven
6 NSS NOT SOLD SEPARATE, Decal
7 NSS NOT SOLD SEPARATE, Decal
8 NSS NOT SOLD SEPARATE, Decal
9 11-893789 NUT
10 12-893762 WASHER
11 10-4013930 SCREW, (M5 x 30)
12 398-852387T7 STATOR
13 834838 LOAD RING
14 833102T GEAR, Drive
15 10-82761140 SCREW, (M10 x 40)
16 12-4002320 WASHER
17 28-91800 KEY, Woodruff
18 28-893761 KEY
19 8M0151040 BELT
20 54-816311T TIE STRAP, (8.00 Inches)
▶FUEL LINES (19 parts) FUEL LINES
Ref OEM Part # Part Name
1 22-822771 CONNECTOR
2 22-878404 FITTING, 45 Degree
3 22-878593 Y-CONNECTOR
4 54-878425 CLIP
5 32-878181 HOSE
6 32-85682239 TUBING, (17.00 Inches Bulk) (Cut to 3-1/2 IN)
7 32-82381310 HOSE
8 8566101 LINKAGE
9 23-803896 BUSHING
10 18-880850 COTTER PIN
11 12-8542592 WASHER
12 32-856607 HOSE
13 32-856609 HOSE
14 32-856611 HOSE and SLEEVE
15 32-880773 HOSE
16 32-856613 HOSE
17 32-880772 HOSE
18 54-816311T TIE STRAP, (8.00 Inches)
19 56762 TIE STRAP, (4.00 Inches)
▶FUEL PUMP (24 parts) FUEL PUMP
Ref OEM Part # Part Name
- 27-859352A01 GASKET SET
1 35-877565T1 FILTER, Fuel
2 54-816311T TIE STRAP, (8.00 Inches)
3 32-8M0108355 HOSE, (57.00 Inches Bulk) (Cut to 14 IN.)
4 32-8M0108355 HOSE, (57.00 Inches Bulk) (Cut to 19 IN.)
5 22-8M0148585 CONNECTOR ASSEMBLY, Fuel
6 826398T3 PUMP, Fuel
7 10-809564 SCREW, (M5 x 35)
8 809565 COVER
9 8095611 DIAPHRAGM
10 10-41889M SCREW, (M3 x 5)
11 11-82537M NUT
12 21-41888M CHECK VALVE
13 8095612 DIAPHRAGM
14 17-8095661 PIN
15 24-809562 SPRING
16 11-82388M NUT, (M5)
17 24-8095621 SPRING
18 8095631 PLUNGER
19 25-8M0052669 O-RING
20 10-82684430 SCREW, (M6 x 30)
21 19-854310 PLUG
22 54-8M0024808 J CLIP
23 8M0007776 DEFLECTOR, Cowl
▶GEAR HOUSING(DRIVESHAFT)(1.83:1 GEAR RATIO) (37 parts) GEAR HOUSING(DRIVESHAFT)(1.83:1 GEAR RATIO)
Ref OEM Part # Part Name
- 46-812966A12 REPAIR KIT, Water Pump
1 1671-9760T42 GEAR HOUSING ASSEMBLY, Basic
2 10-79953Q04 SCREW KIT, (.375-16 x .250) Drain
3 10-79953Q04 SCREW KIT, (.375-16 x .250) Drain
4 12-191833 WASHER
5 17-8M0084244 PIN, Dowel - With Hole (.375 x .625)
6 17-43044 PIN, Dowel - Without Hole (.375 x .625)
7 22-878089 PLUG, Pipe (.0625-27)
8 31-812768 BEARING, Roller
9 818226A1 SEAL/PLATE KIT
10 NSS NOT SOLD SEPARATE
11 43-859103T GEAR, Pinion - 12 Teeth
12 11-55910 NUT, (.437-20)
13 859607A1 SHIFT SHAFT ASSEMBLY
14 53-29641 E RING
15 23-813696A2 BUSHING ASSEMBLY
16 25-45258 O-RING, (.987 x .103)
17 26-8M0204708 SEAL, Oil
18 45-859102 DRIVESHAFT, Long
19 15-812770A1 SHIM SET
20 31-8M0166756 BEARING ASSEMBLY, Roller
21 NSS NOT SOLD SEPARATE
22 11-8128201 NUT
23 46-812966A7 BASE ASSEMBLY, Water Pump
24 25-8M0204651 O-RING, (1.859 x .139)
25 26-814669 SEAL, Oil
26 26-814670 SEAL, Oil
27 47-19453T IMPELLER
28 28-8M0032831 KEY
29 12-8M0204720 WASHER
30 46-812966A12 PUMP ASSEMBLY, Water
31 27-8M0224241 GASKET (LOWER)
32 27-822189 GASKET, Upper Water Pump
33 19700A2 FACE PLATE
34 10-8248324 SCREW, (M6 x 16)
35 760394 CAM, Shift Control
36 8M0151045 COUPLER
▶GEAR HOUSING(DRIVESHAFT)(2.31:1 GEAR RATIO) (43 parts) GEAR HOUSING(DRIVESHAFT)(2.31:1 GEAR RATIO)
Ref OEM Part # Part Name
- 47-8M0100526 REPAIR KIT, Water Pump Impeller
1 1667-9011G59 GEAR HOUSING ASSEMBLY, Basic Comment: (BASIC)
2 17-8M0084244 PIN, Dowel - With Hole (.375 x .625) (FRONT)
3 43046 TUBE, Oiler
4 10-79953Q04 SCREW KIT, (.375-16 x .250) Drain
5 12-191833 WASHER
6 17-43044 PIN, Dowel - Without Hole (.375 x .625) (REAR)
7 31640T07 TRIM TAB
8 10-825427 SCREW, (.437-14 x 1.250) Stainless Steel
9 12-451761 WASHER, (.453 x .812 x .105) Black Oxide
10 43040T1 CARRIER ASSEMBLY
11 NSS NOT SOLD SEPARATE
12 97-826134Q ANODE
13 11-401386 NUT, (M6) Stainless Steel
14 10-4000333 SCREW, (M6 x 40)
15 43-44484T GEAR, Pinion (13 Teeth)
16 11-35921 NUT, (.625-18)
17 850307 CAM, Shift Control
18 31-42677A1 BEARING ASSEMBLY, Tapered Roller
19 15-44492A1 SHIM SET
20 45-859105A1 DRIVESHAFT ASSEMBLY
21 42461A1 SLEEVE/RING KIT
22 NSS NOT SOLD SEPARATE
23 43055A4 COVER ASSEMBLY, Water Pump
24 27-430331 GASKET
25 27-8M0214931 GASKET
26 26-43036 SEAL, Oil (LOWER)
27 26-43035 SEAL, Oil (UPPER)
28 27-8172771 GASKET
29 817275A2 HOUSING KIT, Upper Water Pump
30 8M0204709 FACEPLATE
31 10-8M0214957 SCREW, (M6 x 30)
32 8M0204658 SEAL
33 28-8M0204723 KEY
34 47-43026T2 IMPELLER
35 10-8248326 SCREW, (M6 x 25 MM)
36 853906A1 SHIFT SHAFT ASSEMBLY
37 53-29641 E RING
38 23-43052A4 BUSHING ASSEMBLY
39 25-8M0204681 O-RING, (1.424 x .103)
40 26-8M0204708 SEAL, Oil
41 10-8248326 SCREW, (M6 x 25 MM)
42 26-861415 FACE SEAL
▶GEAR HOUSING(PROP SHAFT)(1.83:1 GEAR RATIO) (33 parts) GEAR HOUSING(PROP SHAFT)(1.83:1 GEAR RATIO)
Ref OEM Part # Part Name
- 26-814669A2 SEAL KIT, Gear Housing
1 1671-9760T42 GEAR HOUSING ASSEMBLY, Basic
37 15-812769A1 SHIM SET
38 31-8M0103476 BEARING ASSEMBLY, Tapered Roller
39 NSS NOT SOLD SEPARATE
40 43-859101T2 GEAR, Forward - 22 Teeth
41 31-21739 BEARING, Roller
42 8129291 FOLLOWER, Cam
43 20843 SLIDE
44 24-38114 SPRING
45 52-813697T CLUTCH
46 17-8M0020942 PIN, Cross
47 24-815418 SPRING
48 44-14493 PROPELLER SHAFT
49 43-859104T GEAR, Reverse - 22 Teeth
50 30-20839T BEARING, Ball
51 8M0168900 CARRIER ASSEMBLY, Bearing
52 25-815460 O-RING
53 31-21700 BEARING, Needle
54 26-8M0205511 SEAL, Oil
55 26-8M0203757 SEAL, Oil
56 10-85594030 SCREW, (M8 x 30)
57 12-855941 WASHER, (.323 x .590 x .112) Stainless Steel
58 8227731 INSERT, Threaded
59 NSS NOT SOLD SEPARATE
60 17264T2 TRIM TAB, Zinc
61 10-4000377 SCREW, (M10 x 30)
62 12-8M0214963 WASHER, (.406 x .750 x .105) Stainless Steel
63 73345A1 THRUST HUB
64 11-69578Q1 PROP NUT KIT
65 14-8M0214942 TAB WASHER
66 12-8M0214963 WASHER, (.406 x .750 x .105) Stainless Steel
67 10-4000380 SCREW, (M10 x 45)
▶GEAR HOUSING(PROP SHAFT)(2.31:1 GEAR RATIO) (36 parts) GEAR HOUSING(PROP SHAFT)(2.31:1 GEAR RATIO)
Ref OEM Part # Part Name
- 26-43035A4 SEAL KIT, Gear Housing
1 1667-9011G59 GEAR HOUSING ASSEMBLY, Basic
2 31-30894A1 BEARING SET, Cup And Cone
3 NSS NOT SOLD SEPARATE
4 43-859472A3 GEAR ASSEMBLY, Forward - 30 Teeth
5 31-30895T BEARING, Needle
6 53-856823 RING, Retaining
7 850315A1 FOLLOWER KIT, Cam
8 30-44530 BALL
9 NSS NOT SOLD SEPARATE
10 24-850327 SPRING
11 52-850048T CLUTCH
12 17-8M0100263 PIN, Cross
13 24-30893 SPRING
14 44-8M0140445 PROPELLER SHAFT
15 43-850034T GEAR, Reverse (30 Teeth)
16 8M0168901 CARRIER ASSEMBLY, Bearing
17 25-8M0214974 O-RING, (3.609 x .139)
18 31-30956T BEARING, Needle
19 26-8M0205728 SEAL, Oil (INNER)
20 26-8M0205729 SEAL, Oil (OUTER)
21 31-12578T BEARING, Roller
22 12-12577 THRUST WASHER
23 31-12576 BEARING, Thrust
24 16-8M0034456 STUD, (M8 x 48)
25 12-855941 WASHER, (.323 x .590 x .112) Stainless Steel
26 11-401378 NUT, (M8)
27 15-44491A1 SHIM SET
28 8227731 INSERT, Threaded
29 NSS NOT SOLD SEPARATE, Decal
30 NSS NOT SOLD SEPARATE, Decal
31 13191Q01 THRUST WASHER
32 11-52707Q1 PROP NUT KIT, (.750-16)
33 14-816629Q TAB WASHER
34 10-4000380 SCREW, (M10 x 45)
35 12-8M0214963 WASHER, (.406 x .750 x .105) Stainless Steel
▶INTAKE (19 parts) INTAKE
Ref OEM Part # Part Name
- 27-859352A01 GASKET SET
1 10-82615890 SCREW, (M6 x 90)
2 857105T INTAKE, Air
3 25-8250572 O-RING
4 857103T PLATE
5 857104T1 ISOLATOR Comment: (40/50 HP)
6 19-827633 PLUG
7 857106A1 ATTENUATOR KIT, Sound Comment: (USE W/TAPERED BUSHING)
8 23-856954 BUSHING Comment: (TAPERED)
9 10-8M0204741 SCREW, (M6 x 20) Stainless Steel
10 54-850181 TIE STRAP, (11.750 Inches)
11 26-856128001 SEAL
12 25-8250572 O-RING
13 25-856525 O-RING
14 17-23784 PIN, Dowel
15 10-8248326 SCREW, (M6 x 25 MM)
16 32-8M0182223 BREATHER HOSE
17 54-816311T TIE STRAP, (8.00 Inches)
18 37-881865 DECAL, Caution, Start In Gear
▶INTAKE/EXHAUST VALVE (19 parts) INTAKE/EXHAUST VALVE
Ref OEM Part # Part Name
- 893505T01 CYLINDER HEAD ASSEMBLY
1 8M0065029 VALVE, Exhaust
2 832990T3 VALVE, Intake
3 26-858271 SEAL
4 24-893552 SPRING, Valve - Outer
5 822650 RETAINER
6 28-893554 KEY
7 898821A01 ROCKER ARM
8 10-825046 SCREW
9 11-826150 NUT
10 8570851 SHAFT, Rocker
11 NSS NOT SOLD SEPARATE
12 893560 BRACKET
13 893561 BRACKET
14 24-893562 SPRING
15 10-875218 SCREW, (M8 x 23)
16 27-893645 GASKET
17 17-859575 PIN
18 24-893563 SPRING, Overload
▶LINKAGE(HANDLE) (32 parts) LINKAGE(HANDLE)
Ref OEM Part # Part Name
1 10-40011158 SCREW, (M8 x 70) Stainless Steel
2 10-8147763 SCREW, (M6 x 60)
3 11-401196 NUT, (M6)
4 42942 CAP
5 822682A4 LEVER ASSEMBLY, Throttle
6 23-825078 BUSHING
7 10-8248326 SCREW, (M6 x 25 MM)
8 858245 SHIFT GUIDE
9 10-82239312 SCREW, (M5 x 12)
10 858246 SHIFT SLIDE
11 12016A2 DETENT/SPRING KIT
12 NSS NOT SOLD SEPARATE
13 858247 SHIFT ROD
14 18-210711 COTTER PIN
15 11-401386 NUT, (M6) Stainless Steel
16 12-8M0204649 WASHER, (.281 x .500 x .060) Stainless Steel
17 858248 SHIFT LINK
18 23-48475 BUSHING
19 850166T2 LEVER ASSEMBLY, Shift Shaft
20 23-850165 BUSHING
21 8535853 CAM, Throttle
22 23-309772 SPACER
23 12-4002314 WASHER
24 10-40056107 SCREW, (M5 x 16)
25 87-8M0052927 SWITCH
26 824923 PLATE
27 10-88075020 SCREW, (M3.5 x 20) Stainless Steel
28 830294T1 BRACKET Comment: (HANDLE)
29 877844 DASHPOT Comment: (NON-HANDLE)
30 10-40011126 SCREW, (M6 x 13) Stainless Steel
31 822682A4 LEVER, Throttle
32 826587 RETAINER
▶LINKAGE(REMOTE) (29 parts) LINKAGE(REMOTE)
Ref OEM Part # Part Name
1 10-40011158 SCREW, (M8 x 70) Stainless Steel
2 10-8147763 SCREW, (M6 x 60)
3 11-401196 NUT, (M6)
4 42942 CAP Comment: (50/60)
5 822682A4 LEVER ASSEMBLY, Throttle
6 883160 RETAINER
7 23-825078 BUSHING
8 822459 RETAINER
9 8259571 LEVER, Shift
10 827706A4 BRACKET
11 98889 LATCH
12 10-8248324 SCREW, (M6 x 16)
13 23-15885 SLEEVE
14 893777 SHIFT ROD
15 8501631 GUIDE, Shift Rod
16 893769A01 SHIFT LINK
17 23-48475 BUSHING
18 12-8M0204649 WASHER, (.281 x .500 x .060) Stainless Steel
19 11-401386 NUT, (M6) Stainless Steel
20 18-210711 COTTER PIN
21 850166T2 LEVER ASSEMBLY, Shift Shaft
22 23-850165 BUSHING
23 8535853 CAM, Throttle
24 23-309772 SPACER
25 12-4002314 WASHER
26 10-40056107 SCREW, (M5 x 16)
27 881283F SPACER, Throttle Stop Comment: (40)
28 822682A4 LEVER, Throttle
29 826587 RETAINER
▶POWER TRIM (27 parts) POWER TRIM
Ref OEM Part # Part Name
- 84-826802T18 HARNESS/RELAY ASSEMBLY, Trim
1 893943A01 SHOCK ROD KIT
2 8M0171822 PISTON ASSEMBLY, Memory
3 25-8M0171819 O-RING KIT, Rebuild
4 NSS NOT SOLD SEPARATE
5 893904T01 CYLINDER ASSEMBLY
6 893944A01 VALVE KIT, Trim Limit Comment: (BIGFOOT)
7 893906A02 PUMP ASSEMBLY
8 893907A02 MOTOR KIT
9 22-8134351 PLUG
10 893929A01 MANUAL RELEASE ASSEMBLY
11 893909A02 MANIFOLD KIT
12 10-809876A1 SCREW KIT (MOTOR)
13 809877A1 DRIVESHAFT/SEAL KIT
14 35-893912A02 FILTER KIT
15 893913A02 POPPET KIT
16 88238A18 CABLE ASSEMBLY
17 17-821539 PIN, Trilobe
18 17-19607 PIN
19 17-822869001 PIN
20 84-826802T17 HARNESS ASSEMBLY, Trim
21 8M0207773 RELAY ASSEMBLY
22 828102 BRACKET
23 25-818967 GROMMET
24 23-8M0214955 BUSHING
25 NSS NOT SOLD SEPARATE
26 10-82684430 SCREW, (M6 x 30)
▶SERVICE/SUPPORT MATERIAL (1 parts) SERVICE/SUPPORT MATERIAL
Ref OEM Part # Part Name
- 37-804655A02 DECAL, EPA Label Information Comment: (SEE NOTE)
▶STARTER MOTOR (11 parts) STARTER MOTOR
Ref OEM Part # Part Name
1 50-893888T STARTER MOTOR ASSEMBLY
2 15384 THRU BOLT
3 891752 DRIVE KIT
4 8236386 ARMATURE
5 68575T2 PINION
6 8236392 DRIVE CAP
7 8119013 CAP, Commutator
8 898265016 BRUSH/SPRING KIT
9 898265014 HOLDER
10 F15158 SCREW
11 37-8272822 DECAL, Warning, High Voltage
▶STEERING ARM (30 parts) STEERING ARM
Ref OEM Part # Part Name
1 11-896963 NUT, (M12)
2 893773002 STRAP Comment: (DESIGN III)(THICK STRAP)
3 8M0224385 MOUNT
4 10-8M0204741 SCREW, (M6 x 20) Stainless Steel
5 8M0156878 BUMPER
6 53-89531 RING, Retaining
7 8M0118183 ARM, Steering
8 816667F1 BRACKET Comment: (NON-HANDLE)
9 14-8M0009820 TAB WASHER Comment: (NON-HANDLE)
10 10-4000377 SCREW, (M10 x 30) Comment: (NON-HANDLE)
11 10-898835001 BOLT, (M12 x 154)
12 23-8279971 SPACER
13 8M0219909 SWIVEL TUBE
14 84-88238T01 CABLE ASSEMBLY
15 8M0207768 CABLE ASSEMBLY, Ground
16 10-823567105 SCREW, (M10 x 105) Hex Flange - Stainless Steel
17 893703 BRACKET
18 10-878607 SCREW, (#10-16 x .375) Comment: (SELF-TAPPING)
19 11-8M0204726 NUT, (.375-24) Stainless Steel Comment: (HANDLE)
20 823792 LEVER Comment: (HANDLE)
21 12-29330 WASHER Comment: (HANDLE)
22 821961 ROD (THREADED) Comment: (HANDLE)
23 821957 BRAKE PLATE Comment: (HANDLE)
24 8165621 DISC Comment: (HANDLE)
25 8M0007471 PLATE Comment: (HANDLE)
26 8165621 DISC Comment: (HANDLE)
27 10-768042 SHOULDER SCREW, Hex Comment: (HANDLE)
28 12-4002321 WASHER, (12.80 mm x 24.0 mm x 2.4 mm) Stainless Steel Comment: (DESIGN I)
29 893773002 STRAP Comment: (Qty. of 1 used on DESIGN I)
30 12-20959 WASHER Comment: (DESIGN II)
▶SWIVEL BRACKET (16 parts) SWIVEL BRACKET
Ref OEM Part # Part Name
1 19608A14 ATTACHING KIT, Engine Steering Comment: (ELECTRIC NON HANDLE)
2 10-823919 SCREW, (.375-24 x 1.500) Comment: (ELECTRIC NON HANDLE)
3 12-8M0109680 WASHER, (.390 x .546 x .12) Comment: (ELECTRIC NON HANDLE)
4 12-37828 WASHER, (.390 x .625 x .062) Stainless Steel Comment: (ELECTRIC NON HANDLE)
5 11-8M0204726 NUT, (.375-24) Stainless Steel Comment: (ELECTRIC NON HANDLE)
6 822397 PUCK Comment: (ELECTRIC NON HANDLE)
7 23-8217711 BUSHING
8 1401-850066T01 SWIVEL BRACKET
9 23-19606 BEARING
10 22-8M0169589 FITTING, Grease Comment: (QTY. OF 3 REQUIRED ON HANDLE VERSIONS)
11 37-8237011 DECAL, Co-Pilot Comment: (HANDLE)
12 NSS NOT SOLD SEPARATE, Decal
13 23-821777 BUSHING (LOWER)
14 26-8M0205512 SEAL
15 10-40011149 SCREW, (M8 x 25) Stainless Steel Comment: (NON-HANDLE)
16 8282451 SEAL Comment: (NON-HANDLE)
▶TILLER HANDLE (38 parts) TILLER HANDLE
Ref OEM Part # Part Name
1 822148T06 COVER KIT
2 822150 PULLEY
3 NSS NOT SOLD SEPARATE
4 10-878608 SCREW, (#10-16 x .500) Comment: (SELF TAPPING)
5 4324210 CABLE ASSEMBLY, Throttle (30.50 Inches)
6 4324211 CABLE ASSEMBLY, Throttle (41.50 Inches)
7 85-960099 SLEEVE, (12.00 Inches)
8 10-82526225 SCREW, (M8 x 25 MM)
9 8M0072298 COVER
10 23-821477 BUSHING
11 828813T1 ARM, Steering Handle
12 822441 RETAINER
13 10-40011107 SCREW, (M5 x 16) Stainless Steel
14 10-8M0204707 SCREW, (M6 x 25)
15 892995 LOCK, Throttle
16 24-96203 SPRING
17 821972T KNOB, Throttle
18 8M0138696 TILLER TUBE
19 37-8242004 DECAL
20 821465 HANDLE, Throttle
21 8M0221732 GRIP
22 87-8M0104614 SWITCH, Stop
23 823687 CLIP
24 87-11083A31 SWITCH, Stop
25 8M0032846 RETAINER, Brass
26 821455A4 BRACKET, Tiller
27 13-826792 WAVE WASHER
28 23-821477 BUSHING
29 12-827314 WASHER
30 32-828547633 CONDUIT, (.620 Inside Diameter x 3.00 Feet Bulk)
31 54-816311T TIE STRAP, (8.00 Inches)
32 37-82409316 DECAL, F-N-R Shift
33 15920Q54 LANYARD ASSEMBLY
34 10-40011151 SCREW, (M8 x 35) Stainless Steel
35 830180A01 HANDLE
36 23-830181 BUSHING
37 14-8M0009820 TAB WASHER
38 10-82484890 SCREW, (M10 x 90)
▶TOOLS (71 parts) TOOLS
Ref OEM Part # Part Name
- 91-8M0053505 INDICATOR TOOL, Backlash (2.31:1 GEAR RATIO)
1 44357Q2 FLUSHING ATTACHMENT
2 802889Q1 PUMP, Crankcase Oil
3 91-802653Q02 WRENCH, Oil Filter
4 91-8M0161873 HOLDER TOOL, Flywheel
5 91-83164M FLYWHEEL PULLER
6 91-99379 TIMING LIGHT
7 91-890451 ADAPTOR TOOL, Direct Voltage
8 91-854009A3 TACH MULTI METER, DMT 2000 Digital
9 91-823686A2 DIGITAL DIAGNOSTIC TESTER
10 91-8226086 CARTRIDGE
11 84-822560A7 HARNESS ASSEMBLY, Adaptor
12 84-822560A10 HARNESS ASSEMBLY, Adaptor
13 91-36392 GAUGE TOOL, Carburetor
14 91-809495001 REMOVER TOOL, Valve Guide
15 91-809496A1 INSTALLER TOOL, Valve Guide Bushing
16 91-809497A1 REAMER TOOL, Valve Guide
17 91-809494A1 COMPRESSOR TOOL, Valve Spring
18 NSS NOT SOLD SEPARATE
19 FT2997 COMPRESSOR TOOL, Piston Ring
20 92-8M0071838 ANTI-CORROSION GREASE, 8 oz
21 91-24697 EXPANDER TOOL, Piston Ring
22 91-74951 SPANNER WRENCH
23 91-822778A3 DOWN PRESSURE KIT
24 91-63209 HEAT LAMP
25 91-877321A1 INSTALLATION TOOL, Bearing
26 91-804063 CLAMP TOOL, Tubing
27 NSS NOT SOLD SEPARATE (P/N-CG-41-11)
28 NSS NOT SOLD SEPARATE (P/N -CG-41-14)
29 11-24156 NUT, (.625-18)
30 12-34961 WASHER
31 91-29310 PLATE
32 91-31229 SHAFT
33 91-36571T WRENCH TOOL, Driveshaft Bearing
34 91-37323 DRIVER ROD TOOL, Needle Bearings
35 91-15755T MANDREL
36 91-36569T DRIVE HEAD TOOL
37 91-27780 PULLER
38 91-37241 PULLER PLATE
39 91-37312T DRIVER HEAD TOOL
40 91-817011T INSTALLER TOOL, Needle Bearing
41 84-825003A1 CABLE ASSEMBLY, DDT, 10FT.
42 91-8098712 VACUUMMATE, Carburetor
43 91-817007T INSTALLER TOOL, Seal
44 91-43506T RETAINING TOOL, Bearing
45 91-817005 INSTALLER TOOL, Bearing
46 91-817006 INSTALLER TOOL, Water Pump Base Seal
47 91-817008A2 LOCATION TOOL, Pinion Gear
48 91-817009T DRIVER TOOL, Bearing Cup
49 91-12349A05 LOCATION TOOL, Pinion
50 91-13945 INSTALLATION TOOL, Bearing
51 91-13949 DRIVER TOOL, Oil Seal
52 91-14308T02 RACE TOOL, Bearing
53 91-14309T02 INSTALLATION TOOL, Bearing
54 91-14310T1 WEAR SLEEVE INSTALLATION TOOL
55 91-14311A04 PRE LOAD TOOL, Bearing
56 91-196601 INDICATOR TOOL, Backlash
57 91-31106T MANDREL, Bearing Driver Cup
58 91-31108T DRIVER, Oil Seal
59 91-34569A1 PULLER ASSEMBLY, Slide Hammer
60 91-46086A1 PULLER JAW ASSEMBLY
61 91-37350T MANDREL
62 91-817070 HOLDING TOOL, Driveshaft
63 91-58222A1 DIAL INDICATOR TOOL
64 91-85716 PULLER TOOL
65 91-83155 ADAPTER KIT, Dial Indicator
66 91-83165T PULLER ASSEMBLY
67 91-856875A1 INSTALLATION TOOL, Bearing
68 91-817057A02 BACKLASH INDICATOR TOOL
69 91-817058A1 DRIVER TOOL, Bearing
70 91-877840A1 HOLDING TOOL, Driveshaft
▶TRANSOM BRACKET (33 parts) TRANSOM BRACKET
Ref OEM Part # Part Name
1 3418-822866T04 BRACKET ASSEMBLY, Transom Comment: (PORT)
2 22-8M0169588 FITTING, Grease
3 17-99604 PIN, Groove
4 3418-822865T05 BRACKET, Transom Comment: (STARBOARD)
5 893704T01 LEVER ASSEMBLY, Tilt Lock
6 24-99622 SPRING
7 23-65830 NYLINER
8 24-812708 SPRING
9 812709 KNOB
10 17-99615 PIN, Groove
11 12-19619 WASHER
12 18486F5 BRACKET, Anchor
13 97-818298Q1 ANODE KIT
14 10-8M0204707 SCREW, (M6 x 25)
15 12-8M0204649 WASHER, (.281 x .500 x .060) Stainless Steel
16 10-4000354 SCREW, (M8 x 30) Comment: (30 MM)
17 10-4000355 SCREW, (M8 x 35) Comment: (35 MM)
18 13-400257 LOCKWASHER, (M8)
19 11-401388 NUT, (M8) Stainless Steel
20 8M0041938 TILT TUBE
21 11-858869 NUT, (.875-14)
22 19624A1 SEAL KIT Comment: (NON-HANDLE)
23 25-29619 O-RING, (.583 x .103) Comment: (NON-HANDLE)
24 23-78861 SPACER Comment: (NON-HANDLE)
25 54-22740 CLIP
26 8M0084613 C WASHER
27 10-878609 SCREW, (#10-16 x .600)
28 10-814259 SCREW, (.500-20 x 4.00)
29 12-8M0204648 WASHER, (1.5 x 3.05 x 0.13) Stainless Steel
30 11-82671117 NUT, (.500-20)
31 10-4009040 SCREW, (M10 x 40) Stainless Steel
32 12-4002319 WASHER
33 11-40140 NUT, (M10)
▶TRIM SWITCH KIT (8 parts) TRIM SWITCH KIT
Ref OEM Part # Part Name
- 87-18286A18 SWITCH KIT, Trim (10.00 Feet)
1 18861 RETAINER
2 814820 ADAPTOR
3 NSS NOT SOLD SEPARATE
4 88-8M0207796 FUSE, 20 Ampere
5 84-95084A2 CABLE ASSEMBLY
6 84-11149A2 CABLE ASSEMBLY, (6.00 Inches)
7 10-813523 SCREW, (#10-16 x 2.25)
▶Top Cowl (16 parts) Top Cowl
Ref OEM Part # Part Name
1 4019-825239T4 TOP COWL ASSEMBLY Comment: (SILVER)
2 NSS NOT SOLD SEPARATE
3 826291F1 LATCH Comment: (SILVER)
4 10-8231871 SCREW, (M4 x 14.5)
5 8,13-26995 LOCKWASHER, Stainless Steel
6 11-8237515 NUT, (M4)
7 8M0153618 SEAL
8 825243A03 SOUND BLANKET KIT
9 NSS NOT SOLD SEPARATE
10 893763 BRACKET ASSEMBLY, Latch Roller
11 10-4006731 SCREW, (M6 x 16)
12 8M0038412 BRACKET
13 10-8231871 SCREW, (M4 x 14.5)
14 8,13-26995 LOCKWASHER, Stainless Steel
15 11-8237515 NUT, (M4)
16 47341A11 ROPE AND HANDLE KIT, Manual Starting

100-Hour / Annual Service Checklist

Regular maintenance keeps your Mercury 40 (4-STROKE)(4 CYL.) 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.

Недавно просмотренные продукты