🔎 Mercury 40 LIGHTNING XR (International) Reference Library — Exploded parts diagrams (31 diagrams), specifications, common issues, and maintenance checklist.
The Mercury 40 LIGHTNING XR (International) 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 LIGHTNING XR (International):
-
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 LIGHTNING XR (International).
▶Accessories (35 parts)
| Ref |
OEM Part # |
Part Name |
| - |
853741 |
CAP (No Trim) |
| 1 |
8M0046402 |
REMOTE CONTROL Comment: (No Trim) |
| 2 |
10-853989 |
SCREW |
| 3 |
23-853990 |
SPACER |
| 4 |
12-853991 |
WASHER |
| 5 |
11-400212 |
NUT, (M6) Stainless Steel |
| 6 |
85-8539921 |
TERMINAL EYE |
| 7 |
53-160572 |
E RING |
| 8 |
25-853993 |
GROMMET |
| 9 |
802611A1 |
TRIM METER KIT |
| 10 |
88-802612 |
BULB |
| 11 |
802613 |
DAMPER |
| 12 |
802614 |
BRACKET |
| 13 |
12-802615 |
INSULATED WASHER |
| 14 |
12-16335 |
WASHER |
| 15 |
13-168181 |
LOCKWASHER |
| 16 |
11-802617 |
NUT |
| 17 |
851875 |
SENDER, Trim |
| 18 |
54-17169 |
CLAMP |
| 19 |
10-8555445 |
SCREW |
| 20 |
10-16705 |
BOLT |
| 21 |
12-953921 |
WASHER, Stainless Steel |
| 22 |
84-8M0078284 |
LEAD WIRE |
| 23 |
91-802618 |
TOOL KIT |
| 24 |
50-12066Q10 |
ROPE |
| 25 |
168411 |
FLUSH PLUG |
| 26 |
79-804632T01 |
TEMPERATURE GAUGE, Water |
| 27 |
88-804634 |
BULB |
| 28 |
802613 |
DAMPER |
| 29 |
804635 |
BRACKET |
| 30 |
11-802617 |
NUT |
| 31 |
13-168181 |
LOCKWASHER |
| 32 |
804636 |
SENSOR, Water Temperature |
| 33 |
84-804637 |
LEAD WIRE |
| 34 |
8M0127367 |
HOUSING KIT, XL Extension |
▶Air Silencer (19 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-8M0081614 |
GASKET SET, Powerhead Comment: SN# 0N016162 & Up |
| 1 |
8555561 |
AIR SILENCER Comment: (Lightning XR/50) |
| 2 |
855557 |
LOCK PLATE |
| 3 |
10-855558 |
SCREW, (M5 x 16) |
| 4 |
855559 |
COVER |
| 5 |
26-855560 |
SEAL, Rubber |
| 6 |
10-162572 |
SCREW, Tapping |
| 7 |
8M0163143 |
C-LINK |
| 8 |
16333 |
ROD, Snap |
| 9 |
855562 |
STOPPER (Electric) |
| 10 |
855563001 |
LINK ROD |
| 11 |
855564 |
CAP |
| 12 |
853745 |
CAP |
| 13 |
11-16081 |
NUT |
| 14 |
8555611 |
ROD |
| 15 |
16333 |
ROD, Snap |
| 16 |
23-851858005 |
BUSHING |
| 17 |
8M0155127 |
KNOB, Choke |
| 18 |
27-802807 |
GASKET Comment: (Lightning XR/50) |
▶Bottom Cowl (46 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
2189-8537774 |
BOTTOM COWL Comment: (Gray) |
| 2 |
23-8537437 |
MOUNT, Rubber |
| 3 |
25-16823 |
GROMMET |
| 4 |
25-162263 |
GROMMET (Manual) |
| 5 |
25-16226 |
GROMMET (Non-Oil Injection) |
| 6 |
804057 |
PILOT LAMP (Oil Injection) |
| 7 |
25-16226 |
GROMMET |
| 8 |
25-8518502 |
GROMMET |
| 9 |
25-8518503 |
GROMMET |
| 10 |
25-162284 |
GROMMET |
| 11 |
19-855549 |
PLUG |
| 12 |
8518364 |
BRACKET |
| 13 |
10-823042075 |
SCREW |
| 14 |
13-168181 |
LOCKWASHER |
| 15 |
10-8248324 |
BOLT |
| 16 |
25-8518504 |
GROMMET (Remote Control) |
| 17 |
87-851883 |
SWITCH (Power Trim) |
| 18 |
10-8230427 |
BOLT, (M6 x 12) (Power Trim) |
| 19 |
25-953871 |
GROMMET (Power Trim) |
| 20 |
25-8518507 |
GROMMET (Manual Tilt) |
| 21 |
10-168288 |
BOLT (Manual Tilt) |
| 22 |
25-16226 |
GROMMET (Manual Tilt) |
| 23 |
10-16830 |
BOLT |
| 24 |
13-400256 |
LOCKWASHER, (M6) |
| 25 |
12-161404 |
WASHER |
| 26 |
23-853715007 |
SPACER |
| 27 |
12-953922 |
WASHER |
| 28 |
13-16221 |
WAVE WASHER |
| 29 |
8M0146267 |
COVER HOOK |
| 30 |
10-8230427 |
BOLT |
| 31 |
13-400256 |
LOCKWASHER, (M6) |
| 32 |
12-953921 |
WASHER, Stainless Steel |
| 33 |
162185 |
HOOK LEVER Comment: (Gray) |
| 34 |
26-16219 |
SEAL |
| 35 |
23-16220 |
BUSHING |
| 36 |
54-813275 |
CLAMP (Power Trim) |
| 37 |
10-162231 |
BOLT (Power Trim) |
| 38 |
87-804051A1 |
LANYARD SWITCH (Handle) |
| 39 |
823054 |
LANYARD (Handle) |
| 40 |
25-8518505 |
GROMMET |
| 41 |
87-804052A1 |
MAIN SWITCH (Electric) |
| 42 |
8029892,303,303 |
KEY (Electric) Comment: |
| 43 |
87-8M0127937 |
NEUTRAL SWITCH (Electric) |
| 44 |
12-9539211 |
WASHER (Electric) |
| 45 |
54-813275 |
CLAMP (Electric) |
| 46 |
10-162231 |
BOLT (Handle) |
▶Carburetor (33 parts)
| Ref |
OEM Part # |
Part Name |
| - |
853780A2 |
REPAIR KIT, Carburetor |
| 1 |
3303-853720A09 |
CARBURETOR Comment: (Upper) (Lightning XR/50) |
| 2 |
3303-853720A6 |
CARBURETOR Comment: (Center) (Lightning XR/50) |
| 3 |
3303-853720T12 |
CARBURETOR Comment: (Lower) (Lightning XR/50) |
| 4 |
135,162504 |
JET, Main Comment: (Lower-Lightning XR/50) |
| 5 |
80,803689 |
JET, Pilot Comment: (Lightning XR/50) |
| 6 |
19-855566 |
PLUG |
| 7 |
162545 |
FLOAT NEEDLE |
| 8 |
17-162561 |
PIN |
| 9 |
162532 |
FLOAT |
| 10 |
10-8536981 |
SCREW |
| 11 |
10-8M0054702 |
SCREW (Upper Carburetor) |
| 12 |
24-162641 |
SPRING, (11 mm) (Upper Carburetor) |
| 13 |
10-8129355 |
SCREW, Idle Adjusting |
| 14 |
24-162641 |
SPRING, (11 mm) |
| 15 |
162584 |
FLOAT BOWL (Lower Carburetor) |
| 16 |
27-855567 |
GASKET |
| 17 |
10-162603 |
SCREW |
| 18 |
10-8M0054703 |
SCREW, Drain |
| 19 |
27-8M0224378 |
GASKET |
| 20 |
812650018 |
MAIN NOZZLE Comment: (Lightning XR/50) |
| 21 |
8555401 |
COVER, Carburetor |
| 22 |
27-8555412 |
GASKET |
| 23 |
10-809571003 |
SCREW |
| 24 |
855568 |
COVER (Lower Carburetor) |
| 25 |
10-8M0062252 |
SCREW (Lower Carburetor) |
| 26 |
27-855569 |
GASKET (Lower Carburetor) |
| 27 |
21-851812 |
CHECK VALVE (Lower Carburetor) |
| 28 |
10-851813 |
SCREW (Lower Carburetor) |
| 29 |
11-851814 |
NUT (Lower Carburetor) |
| 30 |
8537312 |
DIAPHRAGM (Lower Carburetor) |
| 31 |
27-8555691 |
GASKET (Lower Carburetor) |
| 32 |
8537291 |
HOUSING, Pump (Lower Carburetor) |
▶Crankshaft, Piston and Connecting Rods (19 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-8M0081614 |
GASKET SET, Powerhead Comment: SN# 0N016162 & Up |
| 1 |
400-8M0046560 |
CRANKSHAFT ASSEMBLY |
| 2 |
30-16049T02 |
BEARING, Ball |
| 3 |
43-855552 |
GEAR, Drive |
| 4 |
53-853714 |
C CLIP |
| 5 |
41-880810 |
PIN, Piston |
| 6 |
629-880855 |
CONNECTING ROD |
| 7 |
31-880856 |
BEARING, Needle |
| 8 |
12-880857 |
WASHER |
| 9 |
96162 |
PISTON Comment: (.5 Oversize) |
| 10 |
39-16055A5 |
RING SET, Piston Comment: (.5 Oversize) |
| 11 |
41-803680003 |
PIN, Piston |
| 12 |
53-160571 |
CLIP |
| 13 |
853712 |
THRUST RING |
| 14 |
28-160531 |
KEY |
| 15 |
31-855553 |
BEARING, Main (Upper) |
| 16 |
26-803879 |
SEAL, Oil |
| 17 |
25-855554004 |
O-RING |
| 18 |
31-8130483 |
BEARING, Needle |
▶Cylinder Block (49 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-8M0081614 |
GASKET SET, Powerhead Comment: SN# 0N016162 & Up |
| 1 |
878-8M0082198 |
CYLINDER BLOCK Comment: (Lightning XR/50) |
| 2 |
10-166951 |
BOLT |
| 3 |
12-4002217 |
WASHER |
| 4 |
17-16119 |
PIN, Dowel |
| 5 |
17-9521812 |
PIN, Dowel |
| 6 |
22-812960006 |
NIPPLE Comment: SN# 0N009619 & Up |
| 7 |
32-898101272 |
HOSE, Rubber with Arrow (730mm) Comment: SN# 0N009619 & Up |
| 8 |
32-898101272 |
HOSE, Rubber with Arrow (730mm) Comment: SN# 0N009619 & Up |
| 9 |
32-898101272 |
HOSE, Rubber with Arrow (730mm) Comment: SN# 0N009619 & Up |
| 10 |
54-95224 |
CLIP |
| 11 |
979-96305 |
CYLINDER HEAD Comment: SN# 0N016161 & Below |
| 12 |
27-8M0062091 |
GASKET Comment: SN# 0N016161 & Below |
| 13 |
8M0231776 |
COVER |
| 14 |
27-8129394 |
GASKET Comment: SN# 0N016161 & Below |
| 15 |
10-8M0106717 |
BOLT |
| 16 |
12-8M0106725 |
WASHER |
| 17 |
10-166953 |
BOLT |
| 18 |
12-809931044 |
WASHER |
| 19 |
8537041 |
THERMOSTAT |
| 20 |
8537051 |
COVER |
| 21 |
27-8537024 |
GASKET |
| 22 |
10-823042 |
BOLT |
| 23 |
19-855549 |
PLUG |
| 24 |
97-823913Q |
ANODE |
| 25 |
10-167051 |
BOLT, (M6 x 20) |
| 26 |
8M0137792 |
LIFTING EYE |
| 27 |
10-168304 |
BOLT |
| 28 |
12-4002217 |
WASHER |
| 29 |
1100-8537131 |
END CAP, Lower |
| 30 |
25-8537091 |
O-RING |
| 31 |
26-8M0056308 |
SEAL, Oil |
| 32 |
26-8537078 |
SEAL, Oil |
| 33 |
10-167051 |
BOLT, (M6 x 20) |
| 34 |
8M0081401 |
COVER, Exhaust |
| 35 |
8537062 |
COVER, Exhaust |
| 36 |
27-812939020 |
GASKET |
| 37 |
10-8150683 |
BOLT |
| 38 |
12-809931044 |
WASHER |
| 39 |
22-898101961 |
NIPPLE |
| 40 |
32-8M0057113 |
LINE, Fuel (1000 mm) |
| 41 |
25-855551 |
GROMMET (Electric) |
| 42 |
33-8M0181926 |
SPARK PLUG Comment: (Lightning XR/50)(NGK-BR8HS-10) |
| 43 |
54-813275 |
CLAMP |
| 44 |
10-162231 |
BOLT |
| 45 |
803992 |
COVER PLATE (Manual) |
| 46 |
27-8M0081613 |
GASKET (Manual) |
| 47 |
10-162233 |
SCREW (Manual) |
| 48 |
17-16119 |
PIN, Dowel Comment: SN# 0N016162 & Up |
▶Driveshaft Housing (29 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-851887A08 |
GASKET SET, Lower Unit |
| 1 |
1599-8129434 |
HOUSING, Driveshaft Comment: (Gray-Long) |
| 2 |
10-8M0054995 |
BOLT |
| 3 |
12-16192 |
WASHER |
| 4 |
8518562 |
SPLASH PLATE Comment: (Gray) |
| 5 |
25-851850 |
GROMMET |
| 6 |
10-898103237 |
SCREW |
| 7 |
12-8M0108373 |
WASHER, Stainless Steel |
| 8 |
11-815057 |
NUT |
| 9 |
8M0147035 |
SEAL, Rubber |
| 10 |
27-812939022 |
GASKET |
| 11 |
8518521 |
PLATE, Exhaust Comment: (Gray) |
| 12 |
27-812939024 |
GASKET |
| 13 |
8518511 |
SEAL, Rubber |
| 14 |
10-823042 |
BOLT |
| 15 |
17-16119 |
PIN, Dowel |
| 16 |
851853 |
EXTENSION, Exhaust |
| 17 |
10-82304211 |
BOLT |
| 18 |
27-812939019 |
GASKET |
| 19 |
851854 |
TUBE, Exhaust |
| 20 |
10-82304211 |
BOLT |
| 21 |
27-812939023 |
GASKET |
| 22 |
25-8518501 |
GROMMET |
| 23 |
853783003 |
HOUSING, Extension (X-Long) |
| 24 |
10-879194274 |
BOLT (X-Long) |
| 25 |
853794 |
RETAINER (X-Long) |
| 26 |
8107532 |
STOPPER (X-Long) |
| 27 |
10-8230427 |
BOLT (X-Long) |
| 28 |
26-8537074 |
SEAL (X-Long) |
▶Electrical Components (20 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-8M0081614 |
GASKET SET, Powerhead Comment: SN# 0N016162 & Up |
| 1 |
16061005 |
CD UNIT |
| 2 |
25-8M0127927 |
O-RING |
| 3 |
16064006 |
COIL, Ignition |
| 4 |
85-855543 |
BOOT, With Resistance |
| 5 |
54-816311T |
TIE STRAP, (8.00 Inches) |
| 6 |
10-167051 |
BOLT, (M6 x 20) |
| 7 |
27-851834 |
GASKET |
| 8 |
8M0123143 |
BRACKET, Electrical |
| 9 |
851835 |
COVER |
| 10 |
10-8555442 |
SCREW |
| 11 |
23-8537437 |
MOUNT, Rubber |
| 12 |
25-8518153 |
GROMMET |
| 13 |
23-853715007 |
SPACER |
| 14 |
10-162232 |
BOLT |
| 15 |
12-161404 |
WASHER |
| 16 |
88-8538141 |
FUSE |
| 17 |
10-953965 |
BOLT |
| 18 |
54-813275 |
CLAMP (Electric) |
| 19 |
10-95396 |
BOLT (Electric) |
▶Electrical Components(Electric Models) (24 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
853811003 |
RECTIFIER |
| 2 |
10-8555443 |
SCREW |
| 3 |
853829A1 |
SOLENOID ASSEMBLY, Choke |
| 4 |
853830 |
PLUNGER |
| 5 |
10-162454 |
SCREW |
| 6 |
8M0098603 |
BRACKET |
| 7 |
10-162233 |
SCREW |
| 8 |
8555615 |
HOOK |
| 9 |
17-952189 |
PIN, Dowel |
| 10 |
84-85374011 |
HARNESS ASSEMBLY |
| 11 |
84-8537406 |
WIRE, Fuse |
| 12 |
87-851839 |
SOLENOID SWITCH |
| 13 |
87-8518391 |
SOLENOID SWITCH |
| 14 |
84-8537407 |
CABLE |
| 15 |
84-8537408 |
CABLE, Black |
| 16 |
84-8537409 |
CABLE |
| 17 |
84-85374010 |
CABLE |
| 18 |
85-8538161 |
CAP |
| 19 |
10-8230427 |
BOLT, (M6 x 12) |
| 20 |
802808A1 |
BUZZER ASSEMBLY, Overheat Comment: (Lightning XR/50) |
| 21 |
802809A1 |
SENSOR ASSEMBLY, Overheat Comment: (Lightning XR/50) |
| 22 |
8107532 |
STOPPER Comment: (Lightning XR/50) |
| 23 |
10-167051 |
BOLT Comment: (Lightning XR/50) |
| 24 |
84-85374012 |
HARNESS ASSEMBLY (Handle) |
▶Flywheel (21 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
262-8150242 |
FLYWHEEL |
| 2 |
8M0109038 |
PLATE ASSEMBLY, Coil |
| 3 |
160663 |
TRIGGER |
| 4 |
8537381 |
PULSE HOLDER |
| 5 |
160582 |
STATOR |
| 6 |
10-8230318 |
SCREW |
| 7 |
160742 |
COIL, Charger (Set) |
| 8 |
10-8230318 |
SCREW |
| 9 |
8537382 |
WIRE GUIDE |
| 10 |
10-8M0135299 |
SCREW |
| 11 |
54-851817 |
CLAMP |
| 12 |
10-8230314 |
SCREW |
| 13 |
54-816311T |
TIE STRAP, (8.00 Inches) |
| 14 |
8537101 |
TIMING PLATE |
| 15 |
853711 |
GUIDE PLATE |
| 16 |
10-166954 |
BOLT |
| 17 |
13-16818 |
LOCKWASHER |
| 18 |
15-8537953 |
SHIM Comment: (.25) |
| 19 |
10-8555441 |
SCREW |
| 20 |
11-851832 |
NUT |
| 21 |
12-8539911 |
WASHER |
▶Fuel Line (19 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-8M0081614 |
GASKET SET, Powerhead Comment: SN# 0N016162 & Up |
| 1 |
35-8M0088825 |
FILTER ASSEMBLY, Fuel |
| 2 |
8537351 |
CUP |
| 3 |
25-851815 |
O-RING |
| 4 |
35-8537331 |
FILTER |
| 5 |
25-8518151 |
O-RING |
| 6 |
11-400213 |
NUT |
| 7 |
12-16192 |
WASHER |
| 8 |
21-8518121 |
CHECK VALVE (Oil Injection) |
| 9 |
32-8M0057113 |
LINE, Fuel (1000 mm) (Oil Injection) |
| 10 |
32-8M0057113 |
LINE, Fuel (1000 mm) (Oil Injection) |
| 11 |
32-8M0057113 |
LINE, Fuel (1000 mm) (Oil Injection) |
| 12 |
32-8M0057113 |
HOSE, (80 mm) (Oil Injection) |
| 13 |
54-95395 |
CLIP, Stainless Steel (Oil Injection) |
| 14 |
22-853736 |
CONNECTOR, Fuel |
| 15 |
11-17480 |
NUT |
| 16 |
54-95395 |
CLIP, Stainless Steel (Non-Oil Injection) |
| 17 |
32-8M0057113 |
LINE, Fuel (1000 mm) (Non-Oil Injection) |
| 18 |
32-8M0057113 |
LINE, Fuel (1000 mm) (Non-Oil Injection) |
▶Fuel Tank(Plastic- 6.6 Gallon) (15 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
1259-859063A1 |
TANK ASSEMBLY, Fuel - Plastic 6.6 Gallon |
| 2 |
823536 |
GAUGE/CAP ASSEMBLY |
| 3 |
22-8M0175545 |
CONNECTOR KIT, Fuel |
| 4 |
25-823533 |
O-RING |
| 5 |
35-823534 |
SCREEN |
| 6 |
32-858610A37 |
HOSE ASSEMBLY, Fuel |
| 7 |
54-853798 |
CLAMP |
| 8 |
22-8M0120628 |
CONNECTOR, Fuel |
| 9 |
13330Q07 |
BULB ASSEMBLY, Primer |
| 10 |
21-13331A3 |
CHECK VALVE ASSEMBLY (Inlet) |
| 11 |
21-13331A4 |
CHECK VALVE ASSEMBLY (Outlet) |
| 12 |
54-4158210 |
CLAMP, Nylon (Large) |
| 13 |
54-41582Q7 |
CLAMP, Nylon (Small) |
| 14 |
22-89771Q2 |
CONNECTOR, (.250-18) |
| 15 |
54-41582Q7 |
CLAMP, Nylon |
▶Gear Housing(Driveshaft) (48 parts)
| Ref |
OEM Part # |
Part Name |
| - |
853792A10 |
REPAIR KIT, Water Pump |
| 0 |
825132A18 |
GEAR HOUSING ASSEMBLY, Complete Comment: (Black-X-Long) |
| 1 |
1600-8M0127361 |
GEAR HOUSING ASSEMBLY, Basic Comment: (X/Long) |
| 2 |
31-8130487 |
BEARING, Needle |
| 3 |
10-879194274 |
BOLT |
| 4 |
22-8M0229353 |
SCREW, Drain |
| 5 |
27-95220 |
GASKET |
| 6 |
853763003 |
STRAINER, Water (Set) |
| 7 |
10-8555444 |
SCREW |
| 8 |
11-85372216 |
NUT |
| 9 |
8537632 |
STRAINER, Water |
| 10 |
10-8248324 |
BOLT |
| 11 |
22-953682 |
SCREW, Drain |
| 12 |
27-95220011 |
GASKET |
| 13 |
45-16136007 |
DRIVESHAFT Comment: (X-Long) |
| 14 |
30-161283 |
BEARING, Ball |
| 15 |
24-953836 |
SPRING |
| 16 |
43-16138004 |
GEAR, Pinion |
| 17 |
11-85372217 |
NUT |
| 18 |
15-851855005 |
SHIM Comment: (.5) |
| 19 |
47-161542 |
IMPELLER |
| 20 |
28-161551 |
KEY |
| 21 |
46-161563 |
HOUSING, Upper Water Pump |
| 22 |
161573 |
INSERT |
| 23 |
27-16158017 |
GASKET |
| 24 |
851857 |
GUIDE PLATE |
| 25 |
27-8M0155405 |
GASKET |
| 26 |
46-8260532 |
HOUSING, Water Pump Lower |
| 27 |
17-952188 |
PIN, Dowel |
| 28 |
26-8537079 |
SEAL, Oil |
| 29 |
15-8537954 |
SHIM |
| 30 |
25-16131 |
O-RING |
| 31 |
10-879194276 |
BOLT |
| 32 |
26-161682 |
SEAL |
| 33 |
32-16170007 |
TUBE, Water Comment: (X-Long) |
| 34 |
26-161712 |
SEAL |
| 35 |
23-9528615 |
COLLAR |
| 36 |
26-8537074 |
SEAL |
| 37 |
8M0172382 |
CAM |
| 38 |
17-16179 |
PIN |
| 39 |
16186006 |
CAM ROD Comment: (X-Long) |
| 40 |
23-161762 |
BUSHING |
| 41 |
25-161772 |
O-RING |
| 42 |
25-161782 |
O-RING |
| 43 |
8107532 |
STOPPER |
| 44 |
10-8230427 |
BOLT |
| 45 |
851859 |
CONNECTOR |
| 46 |
17-952189 |
PIN, Dowel |
▶Gear Housing, Propeller Shaft (30 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-851887A08 |
GASKET SET, Lower Unit |
| 1 |
1600-8M0127361 |
GEAR HOUSING ASSEMBLY, Basic Comment: (X/Long) |
| 47 |
31-8130488 |
BEARING, Needle |
| 48 |
43-8129442 |
GEAR, Forward |
| 49 |
15-851860001 |
SHIM Comment: (.1) |
| 50 |
44-195132 |
PROPELLER SHAFT |
| 51 |
52-812946003 |
CLUTCH |
| 52 |
17-161502 |
PIN, Clutch |
| 53 |
24-8126456 |
SPRING |
| 54 |
24-176673 |
SPRING |
| 55 |
8537641 |
HOLDER, Spring |
| 56 |
30-161322 |
BALL, Steel |
| 57 |
161521 |
FOLLOWER, Cam |
| 58 |
825119A4 |
CARRIER ASSEMBLY, Bearing Comment: (Gray) |
| 59 |
31-8130487 |
BEARING, Needle |
| 60 |
26-161302 |
SEAL, Oil |
| 61 |
30-161323 |
BEARING, Ball |
| 62 |
25-161312 |
O-RING |
| 63 |
43-8129453 |
GEAR, Reverse |
| 64 |
12-161408 |
WASHER |
| 65 |
10-8M0086977 |
BOLT |
| 66 |
12-16826 |
WASHER, Stainless Steel |
| 67 |
161453 |
THRUST HUB |
| 68 |
48-802628003 |
PROPELLER Comment: (10) |
| 69 |
851861 |
THRUST HUB (Rear) |
| 70 |
12-161409 |
WASHER |
| 71 |
11-161472 |
PROP NUT |
| 72 |
18-8150265 |
COTTER PIN |
| 73 |
853762 |
TRIM TAB |
| 74 |
10-167051 |
BOLT, (M6 x 20) |
▶Inlet Manifold and Reed Block (14 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-8M0081614 |
GASKET SET, Powerhead Comment: SN# 0N016162 & Up |
| 1 |
853717A3 |
MANIFOLD ASSEMBLY, Inlet Comment: (Lightning XR/50) |
| 2 |
27-8M0047033 |
GASKET |
| 3 |
10-168286 |
BOLT |
| 4 |
8537192 |
REED BLOCK Comment: (Lightning XR/50) |
| 5 |
32-8M0057113 |
LINE, Fuel (1000 mm) |
| 6 |
32-8M0057113 |
LINE, Fuel (1000 mm) |
| 7 |
54-95395 |
CLIP, Stainless Steel |
| 8 |
10-855809003 |
BOLT, (M6 x 85) |
| 9 |
12-809931044 |
WASHER |
| 10 |
13-16818 |
LOCKWASHER |
| 11 |
54-813275 |
CLAMP |
| 12 |
10-95314 |
SCREW |
| 13 |
10-8230317 |
SCREW |
▶Manual Tilt (23 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
8M0183798 |
GRIP |
| 2 |
8M0051399 |
BUTTON |
| 3 |
10-803790001 |
SHAFT/BOLT, Reverse Lock Lever |
| 4 |
12-16192 |
WASHER |
| 5 |
804048 |
LEVER, Tilt Stopper |
| 6 |
12-953921 |
WASHER, Stainless Steel |
| 7 |
24-8040246 |
SPRING |
| 8 |
804050 |
LINK |
| 9 |
804046 |
SHAFT, Reverse Lock |
| 10 |
53-160572 |
E RING |
| 11 |
24-953832 |
SPRING |
| 12 |
853774 |
STOP |
| 13 |
8251131 |
BRACKET |
| 14 |
8M0230676 |
STOPPER, Tilt |
| 15 |
17-9521813 |
PIN, Spring |
| 16 |
879194006 |
SET PLATE |
| 17 |
10-8230426 |
BOLT |
| 18 |
24-8040245 |
SPRING Comment: (Long)(X-Long) |
| 19 |
804047 |
ROD, Reverse Lock |
| 20 |
804044 |
LOCK, Reverse (Starboard) |
| 21 |
804045004 |
ARM, Reverse Lock |
| 22 |
8040441 |
LOCK, Reverse (Port) |
| 23 |
18-8150261 |
COTTER PIN |
▶Oil Injection Components (35 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
851840A1 |
PUMP ASSEMBLY, Oil |
| 2 |
25-8518154 |
O-RING |
| 3 |
10-851841 |
BOLT |
| 4 |
12-953927 |
WASHER |
| 5 |
10-8M0098600 |
BOLT |
| 6 |
13-400256 |
LOCKWASHER, (M6) |
| 7 |
43-8555521 |
GEAR, Driven |
| 8 |
23-851858 |
BUSHING |
| 9 |
163332 |
SNAP, Link Rod |
| 10 |
8M0079379 |
LINK ROD |
| 11 |
11-16081 |
NUT |
| 12 |
853745 |
CAP |
| 13 |
1270-851842 |
TANK, Oil |
| 14 |
25-8518153 |
GROMMET |
| 15 |
23-853715007 |
SPACER |
| 16 |
23-8537437 |
MOUNT, Rubber |
| 17 |
10-162232 |
BOLT |
| 18 |
12-161404 |
WASHER |
| 19 |
36-851843 |
CAP |
| 20 |
27-851844 |
GASKET |
| 21 |
851845 |
HOOK |
| 22 |
21-8518122 |
CHECK VALVE |
| 23 |
851846 |
SENSOR |
| 24 |
35-851847A1 |
FILTER ASSEMBLY, Oil |
| 25 |
8537351 |
CUP |
| 26 |
25-851815 |
O-RING |
| 27 |
35-8518471 |
FILTER |
| 28 |
25-8518151 |
O-RING |
| 29 |
11-400213 |
NUT |
| 30 |
12-16192 |
WASHER |
| 31 |
32-8518481 |
TUBING |
| 32 |
32-8518481 |
TUBING, (1 Meter) |
| 33 |
54-8M0129429 |
CLIP |
| 34 |
32-8518482 |
TUBING, (230 mm) |
| 35 |
54-803525005 |
CLIP |
▶Power Trim (20 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
8251124 |
STOP, Tilt Comment: (Gray) |
| 2 |
16208 |
GRIP |
| 3 |
23-9528616 |
COLLAR |
| 4 |
10-8M0062251 |
BOLT |
| 5 |
12-168261 |
WASHER |
| 6 |
24-953837 |
SPRING |
| 7 |
851873A1 |
POWER TRIM ASSEMBLY Comment: (See Breakdown on Power Trim Components) |
| 8 |
17-8M0115482 |
PIN, Upper Cylinder |
| 9 |
23-8113682 |
SLEEVE |
| 10 |
23-161765 |
BUSHING |
| 11 |
10-16223 |
BOLT, (M6 x 14) |
| 12 |
12-898101937 |
WASHER |
| 13 |
17-8518741 |
PIN, Lower Cylinder |
| 14 |
23-9528617 |
COLLAR |
| 15 |
23-8113682 |
SLEEVE |
| 16 |
23-16176011 |
BUSHING |
| 17 |
11-85372219 |
NUT |
| 18 |
12-8M0060184 |
WASHER |
| 19 |
54-17169 |
CLAMP |
| 20 |
10-8555445 |
SCREW |
▶Power Trim Components (42 parts)
| Ref |
OEM Part # |
Part Name |
| - |
851873A1 |
POWER TRIM ASSEMBLY |
| 1 |
8276751 |
MOTOR |
| 2 |
10-8518662 |
BOLT |
| 3 |
23-9528620 |
COLLAR |
| 4 |
827672A2 |
RELIEF VALVE (Down) |
| 5 |
25-161314 |
O-RING |
| 6 |
8276741 |
PUMP |
| 7 |
25-161314 |
O-RING |
| 8 |
10-8518663 |
BOLT |
| 9 |
10-8518664 |
BOLT |
| 10 |
35-851876 |
FILTER |
| 11 |
851877 |
DRIVE JOINT |
| 12 |
25-161315 |
O-RING |
| 13 |
827672A3 |
RELIEF VALVE (Up) |
| 14 |
25-8555541 |
O-RING |
| 15 |
25-161316 |
O-RING |
| 16 |
851878 |
FILTER |
| 17 |
851879A1 |
VALVE SEAT ASSEMBLY |
| 18 |
25-161317 |
O-RING |
| 19 |
25-161318 |
O-RING |
| 20 |
851879A2 |
VALVE SEAL ASSEMBLY |
| 21 |
25-161317 |
O-RING |
| 22 |
25-161318 |
O-RING |
| 23 |
851880 |
SPOOL |
| 24 |
851881 |
BACKUP RING |
| 25 |
24-851882 |
SPRING |
| 26 |
827670T03 |
ROD ASSEMBLY, Trim Piston |
| 27 |
25-8555542 |
O-RING |
| 28 |
25-8555543 |
O-RING |
| 29 |
8518811 |
BACKUP RING |
| 30 |
8276761 |
PISTON |
| 31 |
25-8555543 |
O-RING |
| 32 |
8518811 |
BACKUP RING |
| 33 |
12-953929 |
WASHER |
| 34 |
23-9528618 |
COLLAR |
| 35 |
24-8518821 |
SPRING |
| 36 |
25-161319 |
O-RING |
| 37 |
25-8126411 |
O-RING |
| 38 |
8134421 |
MANUAL VALVE |
| 39 |
53-953451 |
C RING |
| 40 |
19-8555491 |
PLUG |
| 41 |
25-1613110 |
O-RING |
▶Recoil Starter (35 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
8M0225922 |
STARTER ASSEMBLY, Recoil |
| 2 |
23-8518583 |
BUSHING |
| 3 |
804026 |
SLIDING PLATE |
| 4 |
24-804024 |
SPRING, Starter |
| 5 |
804022 |
REEL |
| 6 |
12-9539212 |
WASHER |
| 7 |
53-804027 |
C RING |
| 8 |
24-8040242 |
SPRING, Return |
| 9 |
804023 |
RATCHET |
| 10 |
24-8040241 |
SPRING, Friction |
| 11 |
8040261 |
SLIDING PLATE |
| 12 |
804025 |
FRICTION PLATE |
| 13 |
10-162637 |
BOLT |
| 14 |
50-804028 |
ROPE, Starter |
| 15 |
804029 |
HANDLE, Starter |
| 16 |
8M0054758 |
GUIDE |
| 17 |
10-162636 |
BOLT |
| 18 |
804031 |
STOPPER, Reel |
| 19 |
804032 |
ARM, Stopper |
| 20 |
24-8040243 |
SPRING, Stopper |
| 21 |
12-9539213 |
WASHER |
| 22 |
18-81502611 |
COTTER PIN |
| 23 |
84-85374013 |
WIRE |
| 24 |
804033 |
HOLDER, Cable |
| 25 |
10-804034 |
SCREW |
| 26 |
23-8113683 |
SLEEVE |
| 27 |
10-8M0204707 |
SCREW, (M6 x 25) |
| 28 |
13-400256 |
LOCKWASHER, (M6) |
| 29 |
10-8M0204707 |
SCREW, (M6 x 25) |
| 30 |
12-16826 |
WASHER, Stainless Steel |
| 31 |
23-8M0021168 |
COLLAR, (9.3 mm) |
| 32 |
804036 |
LOCK ARM, Starter |
| 33 |
8M0231222 |
PULLEY, Starter |
| 34 |
10-168307 |
BOLT |
| 35 |
13-400256 |
LOCKWASHER, (M6) |
▶Remote Control Components (47 parts)
| Ref |
OEM Part # |
Part Name |
| - |
8M0223091 |
SINGLE REMOTE CONTROL |
| 1 |
10-8555446 |
SCREW |
| 2 |
802995 |
SWITCH COVER |
| 3 |
87-802994A1 |
SWITCH ASSEMBLY, Power Trim And Tilt |
| 4 |
87-802997A1 |
NEUTRAL SWITCH |
| 5 |
10-8555447 |
SCREW |
| 6 |
802808A1 |
OVERHEAT BUZZER |
| 7 |
84-802998A1 |
CABLE ASSEMBLY, Red (Red) |
| 8 |
54-816311T |
TIE STRAP, (8.00 Inches) |
| 9 |
87-802988A1 |
SWITCH |
| 10 |
8029892,303,303 |
KEY Comment: |
| 11 |
802990 |
COVER |
| 12 |
87-802992A1 |
SAFETY SWITCH |
| 13 |
823054 |
LANYARD |
| 14 |
84-802991A1 |
HARNESS ASSEMBLY |
| 15 |
802971 |
DETENT PLATE |
| 16 |
8029691 |
ROLLER |
| 17 |
802972 |
RETAINER |
| 18 |
10-163341 |
SCREW |
| 19 |
23-8029633 |
BUSHING |
| 20 |
802968 |
THRUST PLATE |
| 21 |
802967 |
GEAR, Drive |
| 22 |
10-171741 |
BOLT |
| 23 |
11-16081 |
NUT, Stainless Steel |
| 24 |
802969 |
ROLLER |
| 25 |
8M0135304 |
ARM, Throttle |
| 26 |
23-8029631 |
BUSHING |
| 27 |
802982 |
DRUM |
| 28 |
13-8029661 |
WAVE WASHER |
| 29 |
10-953861 |
SCREW |
| 30 |
10-802979 |
BOLT |
| 31 |
12-16192 |
WASHER |
| 32 |
802984 |
REAR PANEL |
| 33 |
802980 |
HOUSING, Rear |
| 34 |
24-8029761 |
SPRING |
| 35 |
802983 |
RETAINER |
| 36 |
8029692 |
ROLLER |
| 37 |
10-163341 |
SCREW |
| 38 |
23-8029632 |
BUSHING |
| 39 |
802964 |
FRICTION ARM, Throttle |
| 40 |
13-802966 |
WAVE WASHER |
| 41 |
12-802965 |
WASHER |
| 42 |
802962 |
SHIFT GEAR |
| 43 |
23-802963 |
BUSHING |
| 44 |
10-95386 |
BOLT |
| 45 |
8M0085508 |
LEVER |
| 46 |
23-8029634 |
BUSHING |
▶Service/Support Material (1 parts)
| Ref |
OEM Part # |
Part Name |
| 0 |
37-85926610 |
DECAL, Shift (F-N-R) Comment: (Black) |
▶Shift Components (17 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
161864 |
SHIFT ROD |
| 2 |
161843 |
LEVER, Shift Rod |
| 3 |
851862 |
SHIFT ARM |
| 4 |
23-163361 |
BUSHING |
| 5 |
13-8537234 |
WAVE WASHER |
| 6 |
54-851863 |
CLIP |
| 7 |
24-8M0138736 |
STOPPER |
| 8 |
10-8107551 |
BOLT |
| 9 |
8M0138737 |
CLAMP |
| 10 |
851865 |
SHIFT SHAFT |
| 11 |
12-953925 |
WASHER |
| 12 |
54-851863 |
CLIP |
| 13 |
8M0079131 |
SOCKET, Cable Joint |
| 14 |
12-953925 |
WASHER |
| 15 |
18-8150262 |
COTTER PIN |
| 16 |
804037 |
LEVER, Shift (Handle) |
| 17 |
26-16219 |
SEAL (Handle) |
▶Starter Motor (36 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
50-853805A3 |
STARTER MOTOR ASSEMBLY |
| 2 |
8M0188338 |
PINION |
| 3 |
12-953926 |
WASHER |
| 4 |
8M0135544 |
HOLDER, Brush |
| 5 |
10-16821 |
SCREW |
| 6 |
23-8M0135546 |
BUSHING |
| 7 |
25-161784 |
O-RING |
| 8 |
23-8M0135545 |
BUSHING |
| 9 |
12-16826 |
WASHER, Stainless Steel |
| 10 |
13-400256 |
LOCKWASHER, (M6) |
| 11 |
11-400212 |
NUT, (M6) Stainless Steel |
| 12 |
10-162632 |
BOLT |
| 13 |
13-16079 |
LOCKWASHER |
| 14 |
12-160721 |
WASHER |
| 15 |
89-853809T |
SOLENOID, Starter |
| 16 |
10-162233 |
SCREW |
| 17 |
8518362 |
BRACKET |
| 18 |
10-162234 |
BOLT |
| 19 |
851838 |
COVER |
| 20 |
10-823042073 |
BOLT |
| 21 |
851836 |
BRACKET |
| 22 |
8518361 |
BRACKET |
| 23 |
10-823042073 |
BOLT |
| 24 |
10-8230426 |
BOLT |
| 25 |
10-8M0204707 |
SCREW, (M6 x 25) |
| 26 |
12-953921 |
WASHER, Stainless Steel |
| 27 |
23-9528613 |
COLLAR |
| 28 |
12-953923 |
WASHER, Rubber |
| 29 |
851837 |
MOUNT, Rubber |
| 30 |
84-8537403 |
CABLE |
| 31 |
85-8538161 |
CAP |
| 32 |
84-8M0069792 |
WIRE, Battery |
| 33 |
85-853816 |
CAP |
| 34 |
10-8230427 |
BOLT |
| 35 |
54-813275 |
CLAMP |
| 36 |
10-162231 |
BOLT |
▶Steering Drag Link Components (12 parts)
| Ref |
OEM Part # |
Part Name |
| - |
853824A2 |
DRAG LINK KIT, Steering |
| 1 |
853825 |
CAP |
| 2 |
8538241 |
ROD, Drag Link |
| 3 |
23-9528621 |
COLLAR |
| 4 |
12-9539210 |
WASHER |
| 5 |
11-161473 |
NUT, Nylon |
| 6 |
23-9528622 |
COLLAR |
| 7 |
10-8518666 |
BOLT |
| 8 |
18-8150267 |
COTTER PIN |
| 9 |
8M0079131 |
SOCKET, Cable Joint |
| 10 |
12-953925 |
WASHER |
| 11 |
18-8150262 |
COTTER PIN |
▶Steering Handle (37 parts)
| Ref |
OEM Part # |
Part Name |
| - |
803996T09 |
HANDLE KIT |
| 1 |
803996 |
HANDLE, Steering |
| 2 |
37-804020 |
DECAL, Throttle |
| 3 |
160861 |
GRIP |
| 4 |
10-8150461 |
SCREW |
| 5 |
23-8518582 |
BUSHING |
| 6 |
23-8518581 |
BUSHING |
| 7 |
13-804017 |
WAVE WASHER |
| 8 |
12-804508 |
WASHER |
| 9 |
8M0077708 |
HOLDER ASSEMBLY, Steering Handle |
| 10 |
16-879194300 |
STUD |
| 11 |
12-168261 |
WASHER |
| 12 |
11-85372215 |
NUT |
| 13 |
84-804018001 |
WIRE, Throttle |
| 14 |
813026 |
FRICTION PIECE |
| 15 |
10-16087 |
SCREW, Adjusting |
| 16 |
12-16826 |
WASHER, Stainless Steel |
| 17 |
11-400212 |
NUT, (M6) Stainless Steel |
| 18 |
803998 |
SHAFT, Throttle |
| 19 |
23-16336 |
BUSHING |
| 20 |
23-16191 |
SPACER |
| 21 |
23-8537152 |
SPACER |
| 22 |
18-8150263 |
COTTER PIN |
| 23 |
804055 |
BRACKET, Support |
| 24 |
10-8230427 |
BOLT, (M6 x 12) |
| 25 |
16-8116541 |
STUD |
| 26 |
12-16192 |
WASHER |
| 27 |
11-95374 |
NUT, Nylon |
| 28 |
804019005 |
BRACKET, Steering |
| 29 |
10-162636 |
BOLT |
| 30 |
10-85554410 |
SCREW |
| 31 |
12-953921 |
WASHER, Stainless Steel |
| 32 |
54-953951 |
CLAMP |
| 33 |
10-8230427 |
BOLT, (M6 x 12) |
| 34 |
8537392 |
BRACKET, Throttle Link |
| 35 |
10-16223 |
BOLT |
| 36 |
12-16826 |
WASHER, Stainless Steel |
▶Throttle Linkage (28 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
853742003 |
ARM, Actuator |
| 2 |
10-16201 |
BOLT |
| 3 |
12-161404 |
WASHER |
| 4 |
23-9528612 |
COLLAR |
| 5 |
10-16830 |
BOLT |
| 6 |
11-400212 |
NUT, (M6) Stainless Steel |
| 7 |
8537502 |
CAM, Throttle Comment: (Lightning) |
| 8 |
803156 |
LEVER, Advancer |
| 9 |
10-4000333 |
BOLT |
| 10 |
24-803157 |
SPRING, Throttle Cam |
| 11 |
12-953921 |
WASHER, Stainless Steel |
| 12 |
23-9528613 |
COLLAR |
| 13 |
853744001 |
BALL JOINT |
| 14 |
13-400256 |
LOCKWASHER, (M6) |
| 15 |
8M0054756 |
L-LINK |
| 16 |
8555616 |
L-LINK |
| 17 |
853745 |
CAP |
| 18 |
11-16081 |
NUT |
| 19 |
163332 |
SNAP, Link Rod |
| 20 |
8M0079131 |
SOCKET, Cable Joint |
| 21 |
12-953925 |
WASHER |
| 22 |
18-8150262 |
COTTER PIN |
| 23 |
803993 |
ARM, Throttle Stop (Handle) |
| 24 |
10-8M0204707 |
SCREW, (M6 x 25) (Handle) |
| 25 |
12-16826 |
WASHER, Stainless Steel (Handle) |
| 26 |
23-8M0021168 |
COLLAR, (9.3 mm) (Handle) |
| 27 |
803994 |
S-LINK (Handle) |
| 28 |
803995 |
SNAP, Link Rod (Handle) |
▶Tools (30 parts)
| Ref |
OEM Part # |
Part Name |
| - |
91-8M0059838 |
TOOL, Flywheel Stripper |
| 1 |
91-8539966 |
TOOL |
| 2 |
91-8539968 |
TOOL |
| 3 |
91-80313314 |
SNAP TOOL, Clutch Pin |
| 4 |
23-9528623 |
COLLAR |
| 5 |
25-161773 |
O-RING |
| 6 |
91-80313310 |
MEASURING TOOL SHAFT |
| 7 |
91-8M0050354 |
PULLER TOOL, Bearing |
| 8 |
12-1614011 |
WASHER |
| 9 |
11-85372221 |
NUT |
| 10 |
91-80313312 |
CLAMP TOOL, Backlash Measuring |
| 11 |
10-803134 |
BOLT |
| 12 |
91-80313313 |
PLATE TOOL, Dial Gauge |
| 13 |
91-8M0060180 |
PULLER TOOL, Bearing |
| 14 |
11-85372220 |
NUT |
| 15 |
12-1614010 |
WASHER |
| 16 |
91-8031332 |
FLANGE |
| 17 |
91-8031338 |
STOPPER TOOL, Shaft |
| 18 |
91-8031333 |
SHAFT |
| 19 |
91-8031334 |
GUIDE TOOL |
| 20 |
91-8031335 |
RETAINER TOOL |
| 21 |
91-8031336 |
FLANGE |
| 22 |
91-8031339 |
STOPPER TOOL, Shaft |
| 23 |
91-8031337 |
GUIDE TOOL |
| 24 |
91-85399612 |
WRENCH TOOL |
| 25 |
91-8031331 |
SOCKET TOOL |
| 26 |
91-8M0101491 |
WRENCH TOOL |
| 27 |
91-8539962 |
INSTALL/REMOVER TOOL, Piston Pin |
| 28 |
91-803133 |
INSTALLER TOOL, Piston Ring |
| 29 |
91-804761 |
FLYWHEEL PULLER KIT |
▶Top Cowl (13 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
2189-853778A14 |
TOP COWL ASSEMBLY Comment: (Silver-Electric-Un-Decaled) |
| 2 |
100-8M0128854 |
TOP COWL ASSEMBLY Comment: (Silver-Manual-Un-Decaled) |
| 3 |
8M0094876 |
SEAL |
| 4 |
8M0129136 |
CAP, Cowl Comment: (Silver Manual) |
| 5 |
11-400212 |
NUT, (M6) Stainless Steel |
| 6 |
12-953921 |
WASHER, Stainless Steel |
| 7 |
8518513 |
SEAL (Electric) |
| 8 |
8518841 |
COVER, Fill Comment: (Silver-Electric) |
| 9 |
8151051 |
HINGE (Electric) |
| 10 |
851885 |
PLATE, Spring (Electric) |
| 11 |
10-16223 |
BOLT, (M6 x 14) (Electric) |
| 12 |
11-400212 |
NUT, (M6) Stainless Steel (Electric) |
| 13 |
25-162281 |
SEAL, Rubber (Manual) |
▶Transom and Swivel Brackets(Manual) (52 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
1400-8M0151529 |
CLAMP BRACKET Comment: (Starboard) |
| 2 |
1400-8M0151531 |
CLAMP BRACKET Comment: (Port) |
| 3 |
898101191 |
TILT TUBE |
| 4 |
11-85372214 |
CAP NUT (Handle) |
| 5 |
11-853722029 |
NUT |
| 6 |
23-8537435 |
BUSHING |
| 7 |
23-8113681 |
BUSHING |
| 8 |
10-162638 |
BOLT |
| 9 |
804040 |
DISTANCE PIECE |
| 10 |
13-400256 |
LOCKWASHER, (M6) |
| 11 |
11-400213 |
NUT, (M8) Stainless Steel |
| 12 |
10-804042A1 |
THUMB SCREW ASSEMBLY |
| 13 |
12-95379 |
PAD |
| 14 |
804041 |
THRUST ROD |
| 15 |
24-8126455 |
SPRING |
| 16 |
851872 |
CAP |
| 17 |
10-82304215 |
BOLT |
| 18 |
10-8129356 |
BOLT |
| 19 |
851871 |
LOCKING PLATE, Upper |
| 20 |
25-851870 |
GROMMET |
| 21 |
8M0079616 |
RUBBER |
| 22 |
8M0075036 |
SWIVEL TUBE |
| 23 |
162041 |
THRUST PLATE, Upper Comment: SN# 0N005307 & Below |
| 24 |
23-8537436 |
BUSHING |
| 25 |
162052 |
FRICTION PLATE |
| 26 |
3407-813029A12 |
SWIVEL BRACKET Comment: SN# 0N005307 & Below |
| 27 |
10-4000354 |
SCREW, (M8 x 30) |
| 28 |
24-953831 |
SPRING |
| 29 |
84-898101089 |
GROUND WIRE |
| 30 |
10-8230427 |
BOLT, (M6 x 12) |
| 31 |
8239121 |
ANODE |
| 32 |
13-400256 |
LOCKWASHER, (M6) |
| 33 |
10-16830 |
BOLT |
| 34 |
25-16109003 |
O-RING |
| 35 |
16204004 |
THRUST PLATE, Lower |
| 36 |
10-851866012 |
BOLT |
| 37 |
12-953928 |
WASHER |
| 38 |
12-851867 |
WASHER |
| 39 |
8M0075315 |
MOUNT |
| 40 |
12-879194343 |
WASHER |
| 41 |
8M0064214 |
BRACKET |
| 42 |
53-8537142 |
C-RING |
| 43 |
8537732 |
RUBBER DAMPER |
| 44 |
11-85372218 |
NUT |
| 45 |
851869 |
COVER |
| 46 |
10-167051 |
BOLT, (M6 x 20) |
| 47 |
84-8537405 |
GROUND WIRE |
| 48 |
12-16826 |
WASHER, Stainless Steel |
| 49 |
22-824969 |
FITTING, Grease |
| 50 |
808599 |
CAP |
| 51 |
97-804043 |
ANODE |
| 52 |
10-8M0147119 |
BOLT |
▶Transom and Swivel Brackets(Power Trim) (51 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
96225 |
BRACKET, Transom - Starboard Comment: (Gray) |
| 2 |
3406-803856 |
BRACKET, Transom - Port Comment: (Gray) |
| 3 |
10-851866 |
BOLT |
| 4 |
11-853722029 |
NUT |
| 5 |
11-85372214 |
CAP NUT |
| 6 |
23-161764 |
BUSHING |
| 7 |
23-8113681 |
BUSHING |
| 8 |
161982 |
THRUST ROD |
| 9 |
10-162635 |
CLAMP SCREW |
| 10 |
12-95379 |
PAD |
| 11 |
3407-8130296 |
SWIVEL BRACKET Comment: (Gray) |
| 12 |
8537701 |
SWIVEL TUBE Comment: (Gray) |
| 13 |
23-8537436 |
BUSHING |
| 14 |
162052 |
FRICTION PLATE |
| 15 |
10-8230423 |
BOLT |
| 16 |
24-953831 |
SPRING |
| 17 |
162041 |
THRUST PLATE, Upper |
| 18 |
16204004 |
THRUST PLATE, Lower |
| 19 |
25-16109003 |
O-RING |
| 20 |
53-8537142 |
C-RING |
| 21 |
22-824969 |
FITTING, Grease |
| 22 |
12-16826 |
WASHER, Stainless Steel |
| 23 |
808599 |
CAP |
| 24 |
8M0075315 |
MOUNT |
| 25 |
8537863 |
YOKE, Bottom Comment: (Gray) |
| 26 |
8537732 |
RUBBER DAMPER |
| 27 |
10-851866012 |
BOLT |
| 28 |
12-953928 |
WASHER |
| 29 |
12-851867 |
WASHER |
| 30 |
11-85372218 |
NUT |
| 31 |
12-879194343 |
WASHER |
| 32 |
8518691 |
COVER Comment: (Gray) |
| 33 |
10-167051 |
BOLT, (M6 x 20) |
| 34 |
84-8537405 |
GROUND WIRE |
| 35 |
84-898101089 |
GROUND WIRE |
| 36 |
10-8230427 |
BOLT, (M6 x 12) |
| 37 |
10-8230427 |
BOLT, (M6 x 12) (Handle) |
| 38 |
12-953921 |
WASHER, Stainless Steel |
| 39 |
8M0079616 |
RUBBER |
| 40 |
10-8129356 |
BOLT |
| 41 |
25-851870 |
GROMMET |
| 42 |
851871 |
LOCKING PLATE, Upper |
| 43 |
8518721 |
COVER Comment: (Gray) |
| 44 |
10-82304215 |
BOLT |
| 45 |
8239121 |
ANODE |
| 46 |
10-162232 |
BOLT |
| 47 |
18-8150266 |
COTTER PIN |
| 48 |
10-802619 |
BOLT |
| 49 |
12-953928 |
WASHER |
| 50 |
12-168262 |
WASHER |
| 51 |
11-802620 |
NUT |
100-Hour / Annual Service Checklist
Regular maintenance keeps your Mercury 40 LIGHTNING XR (International) 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.
