🔎 Mercury 40 LIGHTNING XR (International) Reference Library — Exploded parts diagrams (35 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 (36 parts)
| Ref |
OEM Part # |
Part Name |
| - |
853741 |
CAP (No Trim) |
| 1 |
10-853997A1 |
MOUNTING KIT, Twin Remote Control |
| 2 |
896444A01 |
TIE BAR KIT |
| 3 |
23-9528622 |
COLLAR |
| 4 |
12-9539210 |
WASHER |
| 5 |
10-8518666 |
BOLT |
| 6 |
18-8150267 |
COTTER PIN |
| 7 |
10-851866015 |
SCREW |
| 8 |
803548003 |
PLATE, Steering Rod |
| 9 |
11-161473 |
NUT, Nylon |
| 10 |
896444A02 |
TIE BAR KIT |
| 11 |
8M0074790 |
PLATE, Steering hook Comment: SN# ON175258 & Up |
| 12 |
8M0074791 |
STUD Comment: SN# ON175258 & Up |
| 13 |
11-8M0074788 |
NUT Comment: SN# ON175258 & Up |
| 14 |
12-879194343 |
WASHER Comment: SN# ON175258 & Up |
| 15 |
896445A01 |
CREVICE ASSEMBLY |
| 16 |
23-95286028 |
COLLAR |
| 17 |
12-9539210 |
WASHER |
| 18 |
10-851866016 |
SCREW |
| 19 |
11-161473 |
NUT, Nylon |
| 20 |
10-851866007 |
BOLT |
| 21 |
23-853826 |
SPACER |
| 22 |
84-8M0078284 |
LEAD WIRE |
| 23 |
91-802618 |
TOOL KIT |
| 24 |
50-812639003 |
ROPE, Starter Safety |
| 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 |
| 35 |
84-853799A4 |
CABLE ASSEMBLY, Yellow (Handle) |
▶Air Silencer (19 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-8M0081614 |
GASKET SET, Powerhead |
| 1 |
8555561 |
AIR SILENCER Comment: (40 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: (40 Lightning XR/50) |
▶Bottom Cowl, 0N134078 and below (46 parts)
| Ref |
OEM Part # |
Part Name |
| - |
8M0188346 |
STARTER MOTOR KIT |
| 1 |
2189-8537773 |
BOTTOM COWL |
| 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 |
SCREW, (M6 x 16) |
| 16 |
25-8518504 |
GROMMET (Remote Control) |
| 17 |
87-851883 |
SWITCH (Power Trim) |
| 18 |
10-8230427 |
BOLT (Power Trim) |
| 19 |
25-953871 |
GROMMET (Power Trim) |
| 20 |
25-8518507 |
GROMMET (Power Trim) |
| 21 |
10-168288 |
BOLT (Manual Tilt) |
| 22 |
25-16226 |
GROMMET (Manual Tilt) |
| 23 |
10-16830 |
BOLT |
| 24 |
12-161404 |
WASHER |
| 25 |
10-162231 |
BOLT (Handle) |
| 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 |
| 33 |
162184 |
HOOK LEVER |
| 34 |
26-16219 |
SEAL |
| 35 |
23-16220 |
BUSHING |
| 36 |
54-8M0130961 |
CLAMP (Power Trim) |
| 37 |
10-879194247 |
SCREW (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 |
54-8M0130961 |
CLAMP (Handle) |
▶Bottom Cowl, 0N134079 and up (47 parts)
| Ref |
OEM Part # |
Part Name |
| - |
8M0188346 |
STARTER MOTOR KIT |
| 1 |
100-8M0143843 |
BOTTOM COWL |
| 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 |
8M0056387 |
BRACKET Comment: Clutch Cable |
| 13 |
10-823042075 |
SCREW |
| 14 |
8M0085710 |
CLAMP Comment: Power Trim Switch |
| 15 |
10-8248324 |
SCREW, (M6 x 16) |
| 16 |
25-8518504 |
GROMMET (Remote Control) |
| 17 |
87-8M0057108 |
SWITCH, Power Trim |
| 18 |
10-162234 |
BOLT (Power Trim) |
| 19 |
25-953871 |
GROMMET (Power Trim) |
| 20 |
25-898101145 |
O-RING (Power Trim) |
| 21 |
8M0057109 |
BRACKET (Power Trim) |
| 22 |
25-16226 |
GROMMET (Manual Tilt) |
| 23 |
10-16830 |
BOLT |
| 24 |
12-161404 |
WASHER |
| 25 |
25-898101088 |
GROMMET (Power Trim) |
| 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 |
| 33 |
162184 |
HOOK LEVER |
| 34 |
26-16219 |
SEAL |
| 35 |
23-16220 |
BUSHING |
| 36 |
54-8M0130961 |
CLAMP (Power Trim) |
| 37 |
10-879194247 |
SCREW (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 |
10-8230427 |
BOLT, (M6 x 12) |
| 46 |
22-8M0057111 |
NIPPLE |
▶Carburetor (34 parts)
| Ref |
OEM Part # |
Part Name |
| - |
853780A2 |
REPAIR KIT, Carburetor |
| 1 |
3303-853720A09 |
CARBURETOR (Upper) Comment: (40 Lightning XR/50) |
| 2 |
3303-853720A6 |
CARBURETOR (Center) Comment: (40 Lightning XR/50) |
| 3 |
3303-853720T12 |
CARBURETOR (Lower) Comment: (40 Lightning XR/50) |
| 4 |
135,162504 |
JET, Main (Lower) Comment: (40 Lightning XR/50) |
| 5 |
80,803689 |
JET, Pilot Comment: (40 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: (40 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) |
| 33 |
25-8M0065583 |
GROMMET |
▶Crankshaft, Piston and Connecting Rods (19 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-8M0081614 |
GASKET SET, Powerhead |
| 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 |
39-8M0080348 |
RING SET, Piston Comment: (.5 Oversize) Services one piston |
| 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 (50 parts)
| Ref |
OEM Part # |
Part Name |
| - |
8M0188346 |
STARTER MOTOR KIT |
| 1 |
878-8M0082198 |
CYLINDER BLOCK Comment: (40 Lightning XR/50) |
| 2 |
10-166951 |
BOLT |
| 3 |
12-4002217 |
WASHER |
| 4 |
17-16119 |
PIN, Dowel |
| 5 |
17-9521812 |
PIN, Dowel |
| 6 |
21-853696 |
BLEED VALVE |
| 7 |
22-8M0064617 |
CONNECTOR |
| 8 |
32-95223009 |
TUBING, (220 mm) |
| 9 |
32-898101227 |
HOSE, Rubber (330 mm) |
| 10 |
54-95332002 |
CLIP |
| 11 |
979-96305 |
CYLINDER HEAD |
| 12 |
27-8M0062091 |
GASKET |
| 13 |
8M0231776 |
COVER |
| 14 |
27-8M0115016 |
GASKET |
| 15 |
10-8M0106717 |
BOLT |
| 16 |
12-8M0106725 |
WASHER |
| 17 |
10-898101953 |
SCREW |
| 18 |
32-812940010 |
TUBING, (160 mm) |
| 19 |
8537041 |
THERMOSTAT |
| 20 |
8537051 |
COVER |
| 21 |
27-8537024 |
GASKET |
| 22 |
10-823042 |
BOLT, Stainless Steel |
| 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 |
10-825009026 |
BOLT |
| 38 |
21-42657A3 |
CHECK VALVE |
| 39 |
22-898101961 |
NIPPLE |
| 40 |
32-851848005 |
HOSE, (260 mm) |
| 41 |
25-855551 |
GROMMET (Electric) |
| 42 |
33-8M0181926 |
SPARK PLUG Comment: (40 Lightning XR/50)(NGK-BR8HS-10) |
| 43 |
54-8M0130961 |
CLAMP |
| 44 |
10-879194247 |
SCREW |
| 45 |
803992 |
COVER PLATE (Manual) |
| 46 |
27-8M0081613 |
GASKET (Manual) |
| 47 |
10-162233 |
SCREW (Manual) |
| 48 |
17-16119 |
PIN, Dowel |
| 49 |
12-16826 |
WASHER |
▶Driveshaft Housing (28 parts)
| Ref |
OEM Part # |
Part Name |
| - |
8M0127367 |
HOUSING KIT, XL Extension |
| 1 |
1599-8M0090843 |
HOUSING, Driveshaft, Short Comment: Long/X-Long |
| 2 |
10-8M0054995 |
BOLT |
| 3 |
12-16192 |
WASHER |
| 4 |
851856T01 |
SPLASH PLATE |
| 5 |
25-851850 |
GROMMET |
| 6 |
10-855544030 |
SCREW |
| 7 |
25-8518501 |
GROMMET |
| 8 |
11-815057 |
NUT |
| 9 |
8M0147035 |
SEAL, Rubber |
| 10 |
27-812939022 |
GASKET |
| 11 |
851852 |
PLATE, Exhaust |
| 12 |
27-812939024 |
GASKET |
| 13 |
8518511 |
SEAL, Rubber |
| 14 |
10-823042 |
BOLT, Stainless Steel |
| 15 |
17-16119 |
PIN, Dowel |
| 16 |
851853 |
EXTENSION, Exhaust |
| 17 |
10-855544031 |
SCREW |
| 18 |
27-812939019 |
GASKET |
| 19 |
851854 |
TUBE, Exhaust |
| 20 |
10-823042074 |
SCREW |
| 21 |
27-812939023 |
GASKET |
| 22 |
26-8537074 |
SEAL, X-Long |
| 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 |
▶Electrical Components (21 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-8M0081614 |
GASKET SET, Powerhead |
| 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 |
54-8M0130961 |
CLAMP (Electric) |
| 19 |
10-95396 |
BOLT (Electric) |
| 20 |
84-853740014 |
WIRE, Ground |
▶Electrical Components(Electric Models) (25 parts)
| Ref |
OEM Part # |
Part Name |
| - |
8M0188346 |
STARTER MOTOR KIT |
| 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: (40 Lightning XR/50) |
| 21 |
802809A1 |
SENSOR ASSEMBLY, Overheat Comment: (40 Lightning XR/50) |
| 22 |
8107532 |
STOPPER Comment: (40 Lightning XR/50) |
| 23 |
10-167051 |
BOLT Comment: (40 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 (20 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-8M0081614 |
GASKET SET, Powerhead |
| 1 |
35-8M0088825 |
FILTER ASSEMBLY, Fuel Comment: SN# 0N072167 & Up |
| 2 |
853735002 |
CUP Comment: SN# 0N072167 & Up |
| 3 |
25-851815006 |
O-RING Comment: SN# 0N072167 & Up |
| 4 |
35-853733002 |
FILTER Comment: SN# 0N072167 & Up |
| 5 |
25-8518151 |
O-RING Comment: SN# 0N072166 & Below |
| 6 |
11-400213 |
NUT |
| 7 |
12-16192 |
WASHER |
| 8 |
21-8518121 |
CHECK VALVE (Oil Injection) |
| 9 |
32-95394013 |
TUBING, (215 mm) (Oil Injection) |
| 10 |
32-851848011 |
TUBING, (300 mm) (Oil Injection) |
| 11 |
32-95394014 |
TUBING, (200 mm) (Oil Injection) |
| 12 |
32-95394015 |
TUBING, (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 |
32-851848014 |
TUBING, (350 mm) (Non-Oil Injection) |
| 18 |
32-95394016 |
TUBING, (530 mm) (Non-Oil Injection) |
| 19 |
27-803663017 |
GASKET |
▶Fuel Tank(Plastic- 6.6 Gallon) (18 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
1259-859063A2 |
TANK ASSEMBLY, Fuel (Quick Connect) |
| 2 |
36-816976Q1 |
CAP ASSEMBLY, Fuel-Manual Vent |
| 3 |
27-8169771 |
GASKET, Fuel Cap |
| 4 |
859059A2 |
PICK UP ASSEMBLY, Fuel (Threaded Connection) |
| 5 |
8M0084089 |
PICK UP ASSEMBLY, Fuel (Quick Connect) |
| 6 |
859056 |
FLOAT |
| 7 |
10-40056107 |
SCREW, (M5 x 16) |
| 8 |
12-859080 |
WASHER |
| 9 |
27-859072 |
GASKET |
| 10 |
32-8M0172378 |
HOSE ASSEMBLY, Fuel Comment: (2009 and Up) |
| 11 |
13330Q07 |
BULB ASSEMBLY, Primer |
| 12 |
21-13331A3 |
CHECK VALVE ASSEMBLY |
| 13 |
21-13331A4 |
CHECK VALVE ASSEMBLY |
| 14 |
NSS |
NOT SOLD SEPARATE, Clamp |
| 15 |
NSS |
NOT SOLD SEPARATE, Clamp |
| 16 |
22-89771Q2 |
CONNECTOR, (.250-18) |
| 17 |
22-8M0120628 |
CONNECTOR, Fuel |
| 18 |
54-853798 |
CLAMP |
▶Gear Housing, Driveshaft, Serial 0N116270 and Below (47 parts)
| Ref |
OEM Part # |
Part Name |
| - |
8M0127367 |
HOUSING KIT, XL Extension |
| 1 |
1600-8M0127361 |
GEAR HOUSING ASSEMBLY, Basic Comment: X-Long |
| 2 |
31-8130487 |
BEARING, Needle |
| 3 |
10-879194274 |
BOLT |
| 4 |
22-8M0229353 |
PLUG |
| 5 |
27-95220 |
GASKET |
| 6 |
853763003 |
STRAINER, Water, Set |
| 7 |
10-8555444 |
SCREW |
| 8 |
11-85372216 |
NUT |
| 9 |
8537632 |
STRAINER, Water |
| 10 |
10-8248324 |
SCREW, (M6 x 16) |
| 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 |
15-851855015 |
SHIM Comment: .15 |
| 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, Driveshaft, Serial 0N116271 and Up (47 parts)
| Ref |
OEM Part # |
Part Name |
| - |
8M0127367 |
HOUSING KIT, XL Extension |
| 1 |
1600-8M0127361 |
GEAR HOUSING ASSEMBLY, Basic Comment: X-Long |
| 2 |
31-8130487 |
BEARING, Needle |
| 3 |
10-879194274 |
BOLT |
| 4 |
22-8M0229353 |
PLUG |
| 5 |
27-95220 |
GASKET |
| 6 |
853763003 |
STRAINER, Water, Set |
| 7 |
10-8555444 |
SCREW |
| 8 |
11-85372216 |
NUT |
| 9 |
8537632 |
STRAINER, Water |
| 10 |
10-8248324 |
SCREW, (M6 x 16) |
| 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 |
15-851855015 |
SHIM Comment: .15 |
| 19 |
47-161542 |
IMPELLER |
| 20 |
28-161551 |
KEY |
| 21 |
46-16156004 |
HOUSING, Upper Water Pump |
| 22 |
16157005 |
INSERT, Water Pump |
| 23 |
27-16158011 |
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, Serial 0N116270 and Below (31 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 |
8M0119562 |
CARRIER ASSEMBLY, Bearing |
| 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 |
879150151 |
HUB |
| 69 |
48-802621005 |
PROPELLER, (12.5) |
| 70 |
851861 |
THRUST HUB (Rear) |
| 71 |
12-161409 |
WASHER |
| 72 |
11-161472 |
PROP NUT |
| 73 |
18-8150265 |
COTTER PIN |
| 74 |
853762 |
TRIM TAB |
| 75 |
10-167051 |
BOLT, (M6 x 20) |
▶Gear Housing, Propeller Shaft, Serial 0N116271 and Up (31 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-8M0125990 |
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 |
8M0119562 |
CARRIER ASSEMBLY, Bearing |
| 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 |
879150151 |
HUB |
| 69 |
48-802621005 |
PROPELLER, (12.5) |
| 70 |
851861 |
THRUST HUB (Rear) |
| 71 |
12-161409 |
WASHER |
| 72 |
11-161472 |
PROP NUT |
| 73 |
18-8150265 |
COTTER PIN |
| 74 |
853762 |
TRIM TAB |
| 75 |
10-167051 |
BOLT, (M6 x 20) |
▶Inlet Manifold and Reed Block (14 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-8M0081614 |
GASKET SET, Powerhead |
| 1 |
802810A1 |
MANIFOLD ASSEMBLY, Intake Comment: (40 Lightning XR/50) |
| 2 |
27-8M0047033 |
GASKET |
| 3 |
10-823042 |
BOLT |
| 4 |
8537192 |
REED BLOCK Comment: (40 Lightning XR/50) |
| 5 |
32-95394011 |
TUBING, (65 mm) |
| 6 |
32-95394012 |
TUBING, (155 mm) |
| 7 |
54-95395 |
CLIP, Stainless Steel |
| 8 |
10-855809003 |
BOLT |
| 9 |
12-809931044 |
WASHER |
| 10 |
13-16818 |
LOCKWASHER |
| 11 |
54-8M0130961 |
CLAMP |
| 12 |
10-8M0204707 |
BOLT, Stainless Steel |
| 13 |
10-8230317 |
SCREW |
▶Manual Tilt, Serial Number 0N096057 and Below (26 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
8M0183798 |
GRIP |
| 2 |
8M0051399 |
BUTTON |
| 3 |
10-803790001 |
SHAFT/BOLT, Reverse Lock Lever |
| 4 |
12-16826 |
WASHER, Stainless Steel |
| 5 |
804048 |
LEVER, Tilt Stopper |
| 6 |
12-953921 |
WASHER |
| 7 |
24-8040246 |
SPRING |
| 8 |
804050 |
LINK |
| 9 |
804046003 |
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 |
10-8M0098607 |
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 |
| 24 |
804049001 |
SHAFT |
| 25 |
24-824024012 |
SPRING |
| 26 |
24-824024011 |
SPRING |
▶Manual Tilt, Serial Number 0N096058 and Up (27 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
8M0183798 |
GRIP |
| 2 |
8M0051399 |
BUTTON |
| 3 |
10-803790001 |
BOLT, Shoulder |
| 4 |
12-16826 |
WASHER, Stainless Steel |
| 5 |
879288263 |
LEVER, Tilt Stopper |
| 6 |
12-953921 |
WASHER |
| 7 |
12-953925 |
WASHER |
| 8 |
23-898103107 |
BUSHING |
| 9 |
24-8040246 |
SPRING |
| 10 |
804050 |
LINK |
| 11 |
804046003 |
SHAFT, Reverse Lock |
| 12 |
53-160572 |
E RING |
| 13 |
24-953832 |
SPRING |
| 14 |
853774 |
STOP |
| 15 |
8251131 |
BRACKET |
| 16 |
8M0230676 |
STOPPER, Tilt |
| 17 |
879194006 |
SET PLATE |
| 18 |
10-8M0098607 |
BOLT |
| 19 |
24-8040245 |
SPRING Comment: (Long)(X-Long) |
| 20 |
804047 |
ROD, Reverse Lock |
| 21 |
804044 |
LOCK, Reverse (Starboard) |
| 22 |
804045004 |
ARM, Reverse Lock |
| 23 |
8040441 |
LOCK, Reverse (Port) |
| 24 |
18-8150261 |
COTTER PIN |
| 25 |
804049001 |
SHAFT |
| 26 |
24-824024012 |
SPRING |
| 27 |
24-824024011 |
SPRING |
▶Oil Injection Components (36 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 |
32-851848031 |
TUBING, (400 mm), To Oil Pump |
| 32 |
32-851848030 |
TUBING, (700 mm) |
| 33 |
54-8M0129429 |
CLIP |
| 34 |
32-8518482 |
TUBING, (230 mm) |
| 35 |
54-803525005 |
CLIP |
| 36 |
898101258 |
PLATE |
▶Power Trim (16 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
8M0219173 |
POWER TRIM ASSEMBLY |
| 2 |
23-16176009 |
BUSHING |
| 3 |
23-16176010 |
BUSHING |
| 4 |
23-161765 |
BUSHING |
| 5 |
10-8230427 |
BOLT |
| 6 |
84-898101089 |
GROUND WIRE |
| 7 |
23-16176011 |
BUSHING |
| 8 |
12-853822002 |
WASHER |
| 9 |
53-804027003 |
C RING |
| 10 |
54-953951 |
CLAMP |
| 11 |
54-17169 |
CLAMP |
| 12 |
10-8555445 |
SCREW |
| 13 |
17-8M0091499 |
PIN |
| 14 |
17-8M0091498 |
PIN, Cylinder |
| 15 |
10-879194248 |
BOLT |
| 16 |
12-898101937 |
WASHER |
▶Power Trim Components (24 parts)
| Ref |
OEM Part # |
Part Name |
| - |
8M0219173 |
POWER TRIM ASSEMBLY |
| 1 |
8M0234862 |
MOTOR |
| 2 |
898101259 |
BRACKET |
| 3 |
25-16131014 |
O-RING (Component of O-Ring Set) |
| 4 |
10-16078 |
SCREW |
| 5 |
25-161315 |
O-RING |
| 6 |
10-851866013 |
SCREW |
| 7 |
851877002 |
COUPLING |
| 8 |
35-851876 |
FILTER |
| 9 |
10-8518663 |
BOLT |
| 10 |
10-8518664 |
BOLT |
| 11 |
827674002 |
PUMP |
| 12 |
25-161314 |
O-RING |
| 13 |
853768001 |
JOINT, (Metal) |
| 14 |
10-851866014 |
SCREW |
| 15 |
8M0131044 |
TANK, Reservoir |
| 16 |
896440A01 |
CAP ASSEMBLY |
| 17 |
25-16131A05 |
O-RING SET |
| 18 |
827672A05 |
RELIEF VALVE ASSEMBLY |
| 19 |
NSS |
NOT SOLD SEPARATE, O-Ring (Component of O-Ring Set) |
| 20 |
813442A04 |
VALVE ASSEMBLY |
| 21 |
26-898101245 |
WASHER, Sealing |
| 22 |
813442A03 |
MANUAL VALVE ASSEMBLY |
| 23 |
53-804027002 |
C RING |
▶Recoil Starter (36 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 |
10-162637 |
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 |
853755002 |
CAP, Starter Handle |
| 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 |
13-17025 |
LOCKWASHER |
| 36 |
10-8M0204707 |
SCREW, (M6 x 25) |
▶Remote Control Components (47 parts)
| Ref |
OEM Part # |
Part Name |
| - |
8M0223091 |
SINGLE REMOTE CONTROL |
| 1 |
802977 |
CAP |
| 2 |
19-802978 |
PLUG |
| 3 |
802974 |
GRIP |
| 4 |
802973 |
LEVER, Control |
| 5 |
10-823042067 |
SCREW |
| 6 |
802975 |
NEUTRAL LOCK ARM |
| 7 |
24-802976 |
SPRING |
| 8 |
10-823042067 |
SCREW |
| 9 |
12-8029651 |
WASHER |
| 10 |
37-802987 |
DECAL |
| 11 |
10-802986 |
SCREW, Adjusting |
| 12 |
12-8029652 |
WASHER |
| 13 |
53-160572 |
E RING |
| 14 |
802985 |
COVER |
| 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 |
| - |
37-87819110 |
DECAL, Shift (F-N-R) Comment: (Mariner) |
▶Shift Components (18 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 |
| 14 |
12-953925 |
WASHER |
| 15 |
18-8150262 |
COTTER PIN |
| 16 |
804037 |
LEVER, Shift (Handle) |
| 17 |
26-16219 |
SEAL (Handle) |
| 18 |
12-16826 |
WASHER, Stainless Steel |
▶Starter Motor (38 parts)
| Ref |
OEM Part # |
Part Name |
| - |
8M0188346 |
STARTER MOTOR KIT |
| 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 |
11-853722026 |
NUT |
| 12 |
10-162632 |
BOLT |
| 13 |
13-898101181 |
LOCKWASHER |
| 14 |
12-898101215 |
WASHER |
| 15 |
89-853809T |
SOLENOID, Starter |
| 16 |
10-162233 |
SCREW |
| 17 |
8518362 |
BRACKET |
| 18 |
10-162234 |
BOLT |
| 19 |
851838 |
COVER |
| 20 |
10-823042073 |
SCREW |
| 21 |
851836 |
BRACKET |
| 22 |
8518361 |
BRACKET |
| 23 |
10-823042073 |
SCREW |
| 24 |
10-8M0098607 |
BOLT |
| 25 |
10-8M0204707 |
SCREW, (M6 x 25) |
| 26 |
12-953921 |
WASHER |
| 27 |
23-8M0021168 |
COLLAR, (9.3 mm) |
| 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 |
54-8M0130961 |
CLAMP |
| 36 |
10-162231 |
BOLT |
| 37 |
898101257 |
STOPPER |
▶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 |
| 10 |
12-953925 |
WASHER |
| 11 |
18-8150262 |
COTTER PIN |
▶Steering Handle (41 parts)
| Ref |
OEM Part # |
Part Name |
| - |
803996T09 |
HANDLE KIT Comment: SN# 0N114791 & Up |
| 1 |
8M0047218 |
HANDLE, Steering Comment: SN# 0N114791 & Up |
| 2 |
37-8M0097201 |
DECAL |
| 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 Comment: SN# 0N114790 & Below |
| 15 |
10-16087 |
SCREW, Adjusting Comment: SN# 0N114790 & Below |
| 16 |
12-16826 |
WASHER, Stainless Steel Comment: SN# 0N114790 & Below |
| 17 |
11-400212 |
NUT, (M6) Stainless Steel Comment: SN# 0N114790 & Below |
| 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 |
8M0074787 |
STUD Comment: SN# ON175258 & Up |
| 26 |
12-8M0074789 |
WASHER Comment: SN# ON175258 & Up |
| 27 |
11-8M0074788 |
NUT Comment: SN# ON175258 & Up |
| 28 |
8M0074786 |
BRACKET, Steering Comment: SN# ON175258 & Up |
| 29 |
10-162636 |
BOLT |
| 30 |
10-85554410 |
SCREW |
| 31 |
12-953921 |
WASHER |
| 32 |
54-953951 |
CLAMP |
| 33 |
10-8230427 |
BOLT |
| 34 |
8537392 |
BRACKET, Throttle Link |
| 35 |
10-16223 |
BOLT, (M6 x 14) |
| 36 |
12-16826 |
WASHER, Stainless Steel |
| 37 |
898101311 |
FRICTION PIECE Comment: SN# 0N114791 & Up |
| 38 |
8M0051383 |
NUT Comment: SN# 0N114791 & Up |
| 39 |
24-8M0051384 |
SPRING, Stainless Steel Comment: SN# 0N114791 & Up |
| 40 |
10-8M0204707 |
BOLT Comment: SN# 0N114791 & Up |
▶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: (40) |
| 8 |
803156 |
LEVER, Advancer |
| 9 |
10-4000333 |
SCREW, (M6 x 40) |
| 10 |
24-803157 |
SPRING, Throttle Cam |
| 11 |
12-953921 |
WASHER |
| 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 |
| 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 |
| - |
803799A1 |
IGNITION CHECKER |
| 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) |
| 2 |
100-8M0128854 |
TOP COWL ASSEMBLY Comment: (Silver-Manual) |
| 3 |
851851004 |
SEAL, Rubber |
| 4 |
8M0129136 |
CAP, Cowl Comment: (Silver Manual) |
| 5 |
11-400212 |
NUT |
| 6 |
12-953921 |
WASHER |
| 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 (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, Nylon |
| 6 |
23-8537435 |
BUSHING |
| 7 |
23-8113681 |
BUSHING |
| 8 |
10-16263009 |
SCREW |
| 9 |
804040001 |
DISTANCE PIECE |
| 10 |
12-16192 |
WASHER |
| 11 |
11-879194337 |
NUT |
| 12 |
10-804042A1 |
THUMB SCREW ASSEMBLY |
| 13 |
12-95379 |
PAD |
| 14 |
804041 |
THRUST ROD |
| 15 |
24-8126455 |
SPRING |
| 16 |
851872 |
CAP |
| 17 |
10-879194274 |
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 |
| 24 |
23-8537436 |
BUSHING |
| 25 |
162052 |
FRICTION PLATE |
| 26 |
3407-813029A12 |
SWIVEL BRACKET |
| 27 |
10-4000354 |
SCREW, (M8 x 30) |
| 28 |
24-953831 |
SPRING |
| 29 |
84-898101089 |
GROUND WIRE |
| 30 |
10-8230427 |
BOLT |
| 31 |
97-823912002 |
ANODE |
| 32 |
10-8230427 |
BOLT |
| 33 |
10-162232 |
BOLT |
| 34 |
25-16109003 |
O-RING |
| 35 |
16204004 |
THRUST PLATE |
| 36 |
10-851866012 |
SCREW |
| 37 |
12-953928 |
WASHER |
| 38 |
12-851867 |
WASHER |
| 39 |
8M0075315 |
MOUNT |
| 40 |
12-879194343 |
WASHER |
| 41 |
8M0064214 |
YOKE, Bottom |
| 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 |
84-898101091 |
CABLE ASSEMBLY, Ground |
| 51 |
97-804043 |
ANODE |
| 52 |
10-8M0147119 |
BOLT |
▶Transom and Swivel Brackets(Power Trim) (50 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
3406-803856001 |
CLAMP BRACKET, Starboard |
| 2 |
3406-803856002 |
CLAMP BRACKET, Port |
| 3 |
853769001 |
BOLT ASSEMBLY |
| 4 |
11-853722029 |
NUT, Nylon |
| 5 |
11-85372214 |
CAP NUT (Handle) |
| 6 |
23-161764 |
BUSHING |
| 7 |
16198003 |
THRUST ROD |
| 8 |
18-8150266 |
COTTER PIN |
| 9 |
10-162635 |
CLAMP SCREW |
| 10 |
12-95379 |
PAD |
| 11 |
1400-8M0122057 |
SWIVEL BRACKET |
| 12 |
8M0075038 |
SWIVEL TUBE |
| 13 |
23-16336007 |
BUSHING |
| 14 |
162052 |
FRICTION PLATE |
| 15 |
803774004 |
THRUST PLATE |
| 16 |
25-16109002 |
O-RING |
| 17 |
8M0079616 |
RUBBER |
| 18 |
10-8129356 |
BOLT |
| 19 |
851871 |
LOCKING PLATE, Upper |
| 20 |
25-851870 |
GROMMET |
| 21 |
851872 |
CAP |
| 22 |
10-879194274 |
BOLT |
| 23 |
22-824969 |
FITTING, Grease |
| 24 |
10-879194254 |
BOLT |
| 25 |
24-953831 |
SPRING |
| 26 |
23-95286027 |
COLLAR |
| 27 |
84-898101089 |
GROUND WIRE |
| 28 |
10-8230427 |
BOLT |
| 29 |
97-823912002 |
ANODE |
| 30 |
10-162232 |
BOLT |
| 31 |
84-8537405 |
GROUND WIRE |
| 32 |
10-802619 |
BOLT |
| 33 |
12-953928 |
WASHER |
| 34 |
12-879194341 |
WASHER |
| 35 |
11-802620 |
NUT |
| 36 |
815094005 |
STOPPER, Tilt |
| 37 |
16208 |
GRIP |
| 38 |
17-95218017 |
PIN, Spring |
| 39 |
24-95383010 |
SPRING |
| 40 |
853786005 |
YOKE, Bottom |
| 41 |
53-804027001 |
C-RING |
| 42 |
8537732 |
RUBBER DAMPER |
| 43 |
10-167051 |
BOLT, (M6 x 20) |
| 44 |
851869 |
COVER |
| 45 |
8M0075315 |
MOUNT |
| 46 |
10-851866012 |
SCREW |
| 47 |
12-953928 |
WASHER |
| 48 |
12-851867 |
WASHER |
| 49 |
12-879194343 |
WASHER |
| 50 |
11-85372218 |
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.
