Mercury 400 (1279685 THRU 1476509) Parts & Diagrams

OEM and aftermarket replacement parts for Mercury 400. Scroll down for exploded parts diagrams (19), specifications, and maintenance reference.

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Mercury 400 (1279685 THRU 1476509) Parts & Diagrams

🔎 Mercury 400 Reference Library — Exploded parts diagrams (19 diagrams), specifications, common issues, and maintenance checklist.

The Mercury 400 is a 4-Stroke, V10 64-degree, Naturally Aspirated outboard motor. Commonly used on jon boats, pontoons, and mid-size utility craft.

Quick Reference Specifications

Specification Value
Engine Type 4-Stroke, V10 64-degree, Naturally Aspirated
Horsepower 40 HP
Displacement 5700 cc (5.7L / 349 CID)
Bore x Stroke 92 mm x 86 mm (3.6 in. x 3.4 in.)
Spark Plug (Type & Gap) NGK ILFR6G-E
Engine Oil Capacity 7.0 L (7.4 US qt) with filter
Recommended Engine Oil Mercury FourStroke 25W-40
Gear Case Oil Capacity 970 mL (32.8 oz)
Idle Speed (in gear) 650–700 RPM (in gear)
Full Throttle RPM Range 5800-6400
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 400:

  • 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 400.

▶BOTTOM COWL ASSEMBLY (55 parts) BOTTOM COWL ASSEMBLY
Ref OEM Part # Part Name
- 21041 INSERT, TOP LOCK - BOTTOM COWL
-- 53-25539 FASTNER, TRADE MARK PLATE TO BOTTOM COWL
1 103-2354A3 BOTTOM COWL ASSEMBLY
2 29206 COVER, PLUG - BOTTOM COWL HARNESS HOLE
3 10-45893 SCREW, PLUG COVER TO BOTTOM COWL
4 13-26995 LOCKWASHER, PLUG COVER FASTENING SCREW
5 11-26419 NUT, PLUG COVER FASTENING SCREW
6 23760 BAFFLE, BOTTOM COWL
7 10-21106 SCREW, BAFFLE TO BOTTOM COWL
8 29229A1 TRIM MOULDING ASSEMBLY (CHROME) Comment: INCLUDED WITH 103-1597A3 BOTTOM COWL ASSEMBLY
9 10-29226 SCREW, DECORATIVE - MOULDING TO BOTTOM COWL Comment: INCLUDED WITH 103-1597A3 BOTTOM COWL ASSEMBLY
10 12-24671 WASHER, FIBRE - MOULDING FASTENING SCREW Comment: INCLUDED WITH 103-1597A3 BOTTOM COWL ASSEMBLY
11 11-29225 NUT, NYLON CAP - MOULDING FASTENING SCREW Comment: INCLUDED WITH 103-1597A3 BOTTOM COWL ASSEMBLY
12 13-26995 LOCKWASHER, MOULDING FASTENING SCREW Comment: INCLUDED WITH 103-1597A3 BOTTOM COWL ASSEMBLY
13 11-26419 NUT, BRASS - MOULDING FASTENING SCREW Comment: INCLUDED WITH 103-1597A3 BOTTOM COWL ASSEMBLY
14 27-20390 GASKET, POWERHEAD TO BOTTOM COWL
15 30109 GROUND STRAP, CYLINDER BLOCK TO BOTTOM COWL
16 20557 BRACKET, CABLE END ANCHOR
17 10-29200 SCREW, ANCHOR BRACKET TO BOTTOM COWL
18 29532 LEVER, THROTTLE CONTROL
19 30612 LEVER, SHIFT CONTROL
20 23-29529 BUSHING, THROTTLE AND SHIFT LEVER
21 12-8M0042641 WASHER, THROTTLE AND SHIFT LEVER FASTENING SCREW
22 10-37612 SCREW, THROTTLE AND SHIFT LEVER FASTENING
23 17-30978A1 PIN ASSEMBLY, CLEVIS YOKE
24 17-239281 ROLL PIN, CLEVIS YOKE PIN
25 10-20584 SCREW, CLEVIS YOKE PIN TO LEVER
26 13-29402 WASHER, WAVE - CLEVIS PIN FASTENING SCREW
27 11-8M0204718 NUT, CLEVIS PIN FASTENING SCREW
28 25180 SHIFT SHAFT ASSEMBLY, UPPER
29 27714 ROD (SLEEVE), SHIFT CONTROL END
30 11-25168 NUT, ADJUSTING - SHIFT SHAFT END
31 25134 ROD, LINK - SHIFT SHAFT END
32 18-210711 COTTER PIN, LINK ROD TO SHIFT SHAFT
33 12-20583 WASHER, SHIFT CONTROL END ROD
34 24-25065 SPRING, DETENT - SHIFT SHAFT
35 10-98256 SCREW, DETENT SPRING TO BOTTOM COWL
36 12-69057 WASHER, DETENT SPRING SCREW
37 11-8M0207775 NUT, DETENT SPRING FASTENING SCREW
38 32-8M0108355 TUBE, VENT - MAGNETO OUTLET (10 1/2")
39 22-996642 ELBOW, MAGNETO VENT TUBE
40 22-291112 NIPPLE, MAGNETO - VENT TUBE
41 21104A2 CONNECTOR BASE ASSEMBLY
42 13-21972 LOCKWASHER, CONNECTRO BASE
43 11-21971 NUT, CONNECTOR BASE TO BOTTOM COWL
44 54-25231 CLIP, CONNECTOR BASE LEAD WIRE
45 10-21106 SCREW, LEAD WIRE CLIP TO BOTTOM COWL
46 30999 BRACKET, LOCK KNOB - COWL FRONT COVER
47 10-21091 SCREW, BRACKET TO BOTTOM COWL (1 1/8")
48 10-56500 SCREW, BRACKET TO BOTTOM COWL (1 1/4")
49 11-8M0207775 NUT, BRACKET FASTENING SCREW
50 26552 SUPPORT, EXTERNAL WIRING HARNESS
51 10-20639 SCREW, HARNESS SUPPORT TO BOTTOM COWL
52 12-20084 WASHER, HARNESS SUPPORT FASTENING SCREW
53 11-29250 NUT, HARNESS SUPPORT FASTENING SCREW
▶CARBURETOR ASSEMBLY (43 parts) CARBURETOR ASSEMBLY
Ref OEM Part # Part Name
-- 1399-1712 REPAIR PARTS KIT (1 PER CARBURETOR)
1 1333-1700 CARBURETOR ASSEMBLY, COMPLETE (KA-9A) Comment: SERIAL )1307411-09999999
2 1399-1470 SHUTTER, CHOKE
3 10-23035 SCREW AND LOCKWASHER, CHOKE SHUTTER
4 1399-1713 SCREW, IDLE ADJUSTMENT
5 24-27160 SPRING, IDLE ADJUSTMENT SCREW
6 1399-1469 CHOKE SHAFT AND LEVER
7 54-28407 CLIP, CHOKE SHAFT RETAINING
8 10-28408 SCREW, RETAINING CLIP TO LOWER CARBURETOR
9 13-26995 LOCKWASHER, RETAINING CLIP SCREW
10 1395-8673 FLOAT ASSEMBLY
11 1399-102 LEVER, FLOAT (LOWER)
12 1399-101 LEVER, FLOAT (UPPER)
13 17-20853 PIN, FLOAT LEVER PINION
14 1395-92581 INLET NEEDLE, SEAT AND GASKET
15 27-25033 GASKET, INLET SEAT
16 1399-99 GASKET, FLOAT BOWL COVER
17 1399-1133 COVER, FLOAT BOWL
18 10-22625 SCREW, FLOAT BOWL COVER (SHORT)
19 10-25850 SCREW, FLOAT BOWL COVER (LONG)
20 27-25851 GASKET, STRAINER COVER (LARGE)
21 1399-3938 SCREEN, FILTER
22 27-25849 GASKET, STRAINER COVER (SMALL)
23 1399-1135 COVER, STRAINER
24 27-25848 GASKET, STRAINER COVER SCREW
25 10-25822 SCREW, STRAINER COVER FASTENING
26 8146791 LEVER, THROTTLE STOP (SEE NOTE BELOW)
27 1395-6027 SCREW, THROTTLE STOP LEVER
28 1399-1710 TUBE, IDLE
29 27-23180 GASKET, IDLE TUBE
30 1399-2012 SHAFT, THROTTLE
31 24-26890 SPRING, THROTTLE SHAFT RETURN (LOWER CARBURETOR)
32 1399-1711 SHUTTER, THROTTLE
33 10-23035 SCREW AND LOCKWASHER, THROTTLE SHUTTER
34 19-20011 WELCH PLUG, BODY CHANNEL
35 1399-1474 NOZZLE, MIAN
36 10-23178 SCREW, PLUG - MAIN NOZZLE
37 1399-1467 JET, MAIN FUEL (.067(
38 27-28409 GASKET, MAIN FUEL JET
39 10-28405 SCREW, PLUG - BODY CHANNEL
40 27-28406 GASKET, BODY CHANNEL PLUG SCREW
41 27-757911 GASKET, CARBURETOR FLANGE
42 11-29250 NUT, CARBURETOR MOUNTING STUD
▶CARBURETOR LINKAGE AND CHOKE SOLENOID (41 parts) CARBURETOR LINKAGE AND CHOKE SOLENOID
Ref OEM Part # Part Name
1 31593 CHOKE SOLENOID, TOP COWL
2 22647 DISCONNECT, KNIFE SPLICE - CHOKE SOLENOID
3 10-20540 SCREW, CHOKE SOLENOID TO TOP COWL
4 13-26992 LOCKWASHER, CHOKE SOLENOID SCREW
5 10-24773 SCREW, CHOKE SOLENOID TO TOP COWL
6 13-26991 LOCKWASHER, CHOKE SOLENOID SCREW
7 26716A1 GROUND STRAP ASSEMBLY, CHOKE SOLENOID TO ADAPTOR
8 32-26693A1 SLEEVE, CHOKE SOLENOID WIRE AND HARNESS WIRE
9 54-24836 CLAMP, CHOKE WIRE TO STARTER SOLENOID
10 8M0084613 "D" WASHER, CHOKE WIRE CLAMP
11 27031A1 PLUNGER ASSEMBLY, CHOKE SOLENOID
12 27710 ADAPTOR PLATE, CHOKE PLUNGER
13 25-26633 GROMMET, ADAPTOR PLATE
14 10-20055 SCREW, ADAPTOR PLATE TO CHOKE ROD BRACKET
15 13-26996 LOCKWASHER, ADAPTOR PLATE FASTENING SCREW
16 12-26014 WASHER, ADAPTOR PLATE FASTENING SCREW
17 12-26014 WASHER, CHOKE SOLENOID LINK
18 18-26953 COTTER PIN, CHOKE SOLENOID LINK FASTENING
19 1333-1700 CARBURETOR ASSEMBLY, COMPLETE Comment: SERIAL 01307411-09999999
20 27917 CLUSTER, THROTTLE LEVER (UPPER CARBURETOR)
21 1395-6027 SCREW, SET - CLUSTER TO THROTTLE LEVER
22 90242A1 KNOB, CHOKE ROD
23 25-20116 GROMMET, CHOKE ROD
24 22462 "U" LINK, CHOKE KNOB TO CHOKE ROD
25 10-69022 SCREW, "U" LINK TO CHOKE KNOB
26 13-26996 LOCKWASHER, "U" LINK FASTENING SCREW
27 18-26953 COTTER PIN, CHOKE LEVER AND ROD FASTENING
28 28977 CHOKE ROD - UPPER
28A 28972A1 CHOKE ROD AND BRACKET ASSEMBLY - UPPER
29 27918 CHOKE ROD - LOWER
30 10-30096 SCREW, UPPER CHOKE ROD TO LOWER CHOKE ROD
31 12-27882 WASHER, UPPER CHOKE ROD FASTENING SCREW
32 17-25391 RIVET, CHOKE ROD TO THROTTLE SHAFT
33 24-28965 SPRING, CHOKE ROD TO RETAINER
34 27711 RETAINER, CHOKE ROD SPRING
35 10-28713 SCREW, RETAINER TO LOWER CARBURETOR
36 27870 CLAMP, THROTTLE PICKUP BRACKET
37 10-69022 SCREW, CLAMP TO THROTTLE PICKUP BRACKET
38 12-30164 WAHSER, THROTTLE PICKUP BRACKET CLAMPING SCREW
39 28007A1 BRACKET ASSEMBLY, THROTTLE PICKUP
40 10-29239 SCREW, THROTTLE BRACKET MOUNTING
▶CLAMP AND SWIVEL BRACKET (50 parts) CLAMP AND SWIVEL BRACKET
Ref OEM Part # Part Name
1 1440-1466A1 CLAMP BRACKET ASSEMBLY (SEE NOTE (1) BELOW)
2 28403A3 THUMB SCREW ASSEMBLY
3 12-28404 WASHER, THUMB SCREW
4 28122 TUBE, TILT - CLAMP BRACKET TO SWIVEL BRACKET
5 15-25600 SHIM, CLAMP BRACKET TO SWIVEL BRACKET
6 11-8M2014641 NUT, TILT TUBE
7 25606 CAP, PLASTIC - TILT TUBE
8 16-59625 STUD, CLAMP BRACKET
9 23-59624 SPACER, CLAMP BRACKET STUD
10 13-8M0204647 LOCKWASHER, CLAMP BRACKET STUD
11 11-22053 NUT, CLAMP BRACKET STUD
12 17-8M0026068 TILT LOCK PIN ASSEMBLY
13 32-28052 SLEEVE, RUBBER - TILT LOCK PIN BUMPER
14 30200A1 TILT STOP LEVER ASSEMBLY
15 10-28339 SCREW, TILT STOP LEVER ANCHOR
16 13-20846 WASHER, WAVE - LEVER ANCHOR SCREW
17 11-24652 NUT, LEVER ANCHOR SCREW
18 26903A3 REVERSE LOCK ASSEMBLY
19 18-45882 COTTER PIN, REVERSE LOCK TO SHAFT
20 24-29821 SPRING, REVERSE LOCK TENSION
21 17-25598 PIN, REVERSE LOCK SPRING ATTACHING
22 56349 SHAFT, REVERSE LOCK TO SWIVEL BRACKET
23 1444-1801A1 SWIVEL BRACKET ASSEMBLY
24 22-69059 FITTING, GREASE - SWIVEL BRACKET
25 26-32911 OIL SEAL (2 OIL SEALS REQUIRED ON LATER PRODUCTION ENGINES)
26 19-77633Q LUBRICAP, SWIVEL BRACKET GREASE FITTING
27 55-28415 PIN, UPPER SHOCK MOUNTING
28 23-28024 SPACER, UPPER BUSHING TO CLAMP BRACKET
29 12-28025 WASHER, UPPER BUSHING RETAINER (INNER)
30 12-28420 WAHSER, UPPER BUSHING RETAINER (OUTER)
31 10-28449 BOLT, NYLOCK - UPPER SHOCK MOUNTING PIN
32 55-28413 LOWER SHOCK MOUNTING
33 23-28032 SPACER, LOWER BUSHING TO SWIVEL BRACKET
34 12-28420 WASHER, LOWER BUSHING RETAINER (OUTER)
35 10-28449 BOLT, NYLOCK - LOWER SHOCK MOUNTING PIN
36 55-28054 SHOCK ABSORBER
37 23-28055 BUSHING, RUBBER - SHOCK ABSORBER
38 17-28418A4 SWIVEL PIN AND TOP YOKE ASSEMBLY Comment: SERIAL 00000000-01363346
39 11-71956 NUT, SWIVEL PIN RETAINING
40 17-28418A4 SWIVEL PIN AND TOP YOKE ASSEMBLY Comment: SERIAL 01363347-09999999
41 10-33986 BOLT, UPPER MOUNTS TO SWIVEL PIN
42 30711 BUMPER, TOP YOKE
43 30711 BUMPER, TOP YOKE
44 30462A1 BOTTOM YOKE ASSEMBLY Comment: SERIAL 01365072-09999999
45 12-25176 WASHER, SWIVEL PIN TO BOTTOM YOKE
46 38-29534 SERIAL PLATE
47 10-25612 SCREW, DRIVE - SERIAL PLATE TO SWIVEL BRACKET
48 10-68298 BOLT, CARRIAGE - CLAMP BRACKET TO BOAT TRANSOM
49 12-68410 WAHER, CARRIAGE BOLT
50 11-82670912 NUT, CARRIAGE BOLT
▶COWLING AND FRONT COVER (22 parts) COWLING AND FRONT COVER
Ref OEM Part # Part Name
-- 92-86166Q1 GLUE, ADHESIVE - BLANKET FASTENING
1 2104-2654A5 COWL FRONT COVER ASSEMBLY
2 26183A5 EMBLEM, FRONT COVER
3 10-29226 SCREW, BRACKET TO FRONT COVER
4 13-26995 LOCKWASHER, BRACKET FASTENING SCREW
5 11-26419 NUT, BRACKET FASTENING SCREW
6 29345 BUMPER, RUBBER - FRONT COVER BRACKET
7 10-29552 SCREW, COVER FASTENING
7A 56848 KNOB, COWL FRONT COVER FASTENING
8 12-26702 WASHER, COVER FASTENING KNOB (NYLON)
9 12-26825 WASHER, COVER FASTENING KNOB (STEEL)
10 24-30772 SPRING, TENSION - FASTENING KNOB
11 17-29077 ROLL PIN, TENSION SPRING TO KNOB
12 29343 BLANKET, SOUND ABSORBING - FRONT COVER
12A 31095 STRIP, RUBBER - COWL FRONT COVER
13 2106-2353A2 WRAP AROUND COWL ASSEMBLY Comment: ORDER CORRECT REPLACEMENT HANDLE, SWIVEL OR HOOK ACCORDING TO THEIR SIZE (#8 OR #10). BOTH SIZES WERE USED
14 10,46785A1 HANDLE, COWL LATCH
15 53-21058 "E" RING, COWL LATCH HINGE PIN
16 17-21057 PIN, HINGE - COWL LATCH HANDLE
17 10,46785A1 SWIVEL, COWL LATCH
18 10,30413 HOOK, COWL LATCH FASTENING
19 24825 BLANKET, SOUND ABSORBING - WRAP AROUND COWL
▶CRANKSHAFT, PISTON AND CONNECTING ROD (29 parts) CRANKSHAFT, PISTON AND CONNECTING ROD
Ref OEM Part # Part Name
-- 39-28616A12 RING, PISTON (.015)
1 11-8M0214915 NUT, FLYWHEEL
2 12-26617 WASHER, FLYWHEEL NUT
3 28-20094 KEY, FLYWHEEL DRIVE
4 400-2976A2 CRANKSHAFT Comment: SERIAL 01365968-09999999
5 25-29619 "O" RING, DRIVE SHAFT SPLINE
6 500-5345A4 CENTER MAIN BEARING ASSEMBLY
7 17-20032 DOWEL PIN, CENTER MAIN BEARING
8 29-20046T BEARING, NEEDLE
9 20047 RACE, OUTER
10 53-20048 RING, SNAP - OUTER RACE CLAMPING
11 10-28666 SCREW, CENTER MAIN BEARING CLAMPING
12 17-20379 DOWEL PIN (STEPPED)
13 527-1619A4 MAIN BEARING ASSEMBLY (VALVE TYPE)
14 17-20032 DOWEL PIN, MAIN BEARING
15 10-26184 SCREW, MAIN BEARING CLAMPING
16 34-88498A1 REED SET, MATCHED - MAIN BEARING
17 34-20053 REED STOP, MAIN BEARING REED VALVES
18 12-26014 WASHER, REED STOP MOUNTING SCREW
19 10-77280 SCREW, REED STOP MOUNTING
20 724-2537A2 PISTON AND PISTON PIN ASSEMBLY
21 40-20057 LOCK RING, PISTON PIN
22 39-27841A12 RING, PISTON
23 600-2748A2 CONNECTING ROD AND CAP ASSEMBLY (SEE NOTE BELOW)
24 10-45379 SCREW, CAP TO CONNECTING ROD
25 11-20061 NUT, CONNECTING ROD SCREW
26 29-20046T BEARING, NEEDLE - CRANKPIN
27 29-20063 BEARING, NEEDLE - PISTON PIN
28 12-28121 WASHER, NEEDLE LOCATING
▶CYLINDER BLOCK AND CRANKCASE ASSEMBLY (56 parts) CYLINDER BLOCK AND CRANKCASE ASSEMBLY
Ref OEM Part # Part Name
1 1100-339A1 END CAP ASSEMBLY, UPPER
2 26-41953 OIL SEAL
3 25-20081 "O" RING, UPPER END CAP
4 30-63742T BALL BEARING, UPPER END CAP
5 15-20082A1 SHIM, UPPER END CAP TO CRANKCASE AND BLOCK (.002-3-5-10)
6 10-29198 SCREW, UPPER END CAP MOUNTING
7 831-2414A2 CYLINDER BLOCK AND CRANKCASE ASSEMBLY (SEE NOTE BELOW)
8 23-26348 BUSHING, CRANKCASE
9 17-20032 DOWEL PIN, CYLINDER BLOCK TO MAIN BEARING
10 17-20323 DOWEL PIN, CYLINDER BLOCK TO CENTER MAIN BEARING
11 22-328022 PLUG, PIPE - WATER PRESSURE HOLE
12 16-21831 STUD, CARBURETOR MOUNTING (1 1/4")
13 16-33111 STUD, CRANKCASE TO DRIVE SHAFT HOUSING (1 5/8")
14 17-43044 DOWEL PIN, CRANKCASE TO CYLINDER BLOCK
15 16-8M0034463 STUD, CYLINDER BLOCK TO DRIVE SHAFT HOUSING (3 7/16")
16 16-29989 STUD, CYLINDER BLOCK TO DRIVE SHAFT HOUSING (1 15/16")
17 22-390721 PLUG, PIPE - UPPER OR LOWER BLEED HOLE
18 10-78841 SCREW, CRANKCASE TO CYLINDER BLOCK (1 1/2")
19 10-22039 SCREW, CRANKCASE TO CYLINDER BLOCK (2 3/4")
20 12-20084 WASHER, CRANKCASE SCREW
21 11-29250 NUT, CRANKCASE FASTENING SCREW
22 10-98260 SCREW, MAIN BEARING LOCKING
23 14-20091 TAB WASHER, BEARING LOCKING SCREW
24 10-20359 SCREW, CENTER MAIN BEARING LOCKING
25 1102-4181A3 END CAP ASSEMBLY, LOWER
26 21-28481A1 CHECK VALVE ASSEMBLY, LOWER END CAP
27 26-29477 OIL SEAL, LOWER
28 26-41953 OIL SEAL, UPPER
29 25-20081 "O" RING, LOWER END CAP
30 30-63742T BALL BEARING, LOWER END CAP
31 15-20085A1 SHIM, LOWER END CAP TO CRANKCASE AND BLOCK (.002-3-5-10)
32 10-29198 SCREW, LOWER END CAP MOUNTING
33 27-26923 GASKET, MANIFOLD PLATE TO EXHAUST COVER
34 26922 PLATE, EXHAUST MANIFOLD
35 28240 COVER, EXHAUST MANIFOLD
36 10-28666 SCREW, MANIFOLD COVER AND HIGH TENSION LEAD CLIP MOUNTING
37 12-20028 WASHER, MANIFOLD COVER AND HIGH TENSION LEAD CLIP SCREWS
38 58124A1 SWITCH, MERCURY EXHAUST MANIFOLD COVER
39 54-22875 CLAMP, MERCURY SWITCH TO MANIFOLD COVER
40 10-20401 SCREW, MERCURY SWITCH CLAMP FASTENING
41 8M0084613 "D" WASHER, CLAMP AND CLIP FASTENING SCREW
42 54-25231 CLIP, MERCURY SWITCH LEAD WIRE TO MAGNETO
43 10-20401 SCREW, LEAD WIRE CLIP FASTENING
44 27-22333 GASKET, CYLINDER BLOCK COVER
45 1000-1A1 CYLINDER BLOCK COVER ASSEMBLY (SEE NOTE BELOW)
46 23-26348 BUSHING, CYLINDER BLOCK COVER
47 10-20653 SCREW, CYLINDER BLOCK COVER MOUNTING
48 11-24652 NUT, COVER MOUNTING SCREW
49 27-279361 GASKET, TRANSFER PORT COVER
50 27935 COVER, TRANSFER PORT
51 10-20540 SCREW, TRANSFER PORT COVER MOUNTING
52 22-62365A1 CHECK VALVE ASSEMBLY, BLEED HOSE (UPPER)
53 21-28481A1 CHECK VALVE ASSEMBLY, BLEED HOSE VALVE
54 32-9912688 HOSE, CYLINDER BLEED (6 1/2")
55 22-67902 CONNECTOR, CYLINDER BLEED HOSE (LOWER(
56 54-20387 CLAMP, BLEED HOSE TO CHECK VALVE AND CONNECTOR
▶DRIVE SHAFT HOUSING ASSEMBLY (41 parts) DRIVE SHAFT HOUSING ASSEMBLY
Ref OEM Part # Part Name
1 1522-1567 DRIVE SHAFT HOUSING
2 32-25187 TUBE, WATER INLET
3 25-24961 RING, RUBBER - WATER INLET TUBE
4 26-25192 SEAL, WATER INLET TUBE
5 23-23651 SLEEVE, WATER INLET TUBE
6 24945 BAFFLE, EXHAUST RELIEF
7 10-25255 SCREW, BAFFLE TO DRIVE SHAFT HOUSING
8 27-24899 GASKET, DRIVE SHAFT HOUSING TO BOTTOM COWL
9 11-862902 NUT, POWERHEAD STUDS
10 10-25093 SCREW, GEAR HOUSING TO DRIVE SHAFT HOUSING
11 16-29103 STUD, DRIVE SHAFT HOUSING TO GEAR HOUSING
12 11-8M0204653 NUT, GEAR HOUSING AND DRIVE SHAFT HOUSING STUDS
13 28470 ROD, PUSH - REVERSE LOCK
14 17-24887 PIN, REVERSE LOCK LEVER
15 18-25191 COTTER PIN, PUSH ROD
16 24-25122 SPRING, TENSION - PUSH ROD
17 52920 LEVER, REVERSE LOCK
18 24926A1 MOUNT, RUBBER - UPPER
19 79680A1 COVER, UPPER MOUNT - OUTSIDE HALF
20 79680A1 COVER, UPPER MOUNT - INSIDE HALF
21 24929 PACKING, "U" CUP
22 12-24889 WASHER, UPPER MOUNT STUD (17/32 ID)
23 12-24891 WASHER, RUBBER - UPPER MOUNT STUD
24 23-30474 SPACER, UPPER MOUNT STUD Comment: SERIAL 01363347-09999999
25 12-11367 WASHER, UPPER MOUNT STUD (25/64 ID) Comment: SERIAL 01363347-09999999
26 11-23161 NUT, UPPER MOUNT STUD
27 25305 CAP, RUBBER - UPPER MOUNT
28 10-28772 SCREW, UPPER MOUNT COVER (1 1/2")
29 10-29389 SCREW, UPPER MOUNT COVER (1 7/8")
30 12-8M0204649 WASHER, MOUNTING COVER SCREW
31 11-35888 NUT, MOUNTING COVER SCREW
32 75304T1 MOUNT, RUBBER - LOWER
33 12-28053 WASHER, RUBBER - LOWER MOUNT
34 12-28051 WASHER, LOWER MOUNT
35 12-30119 WASHER, MOUNTING SCREW (1/8") Comment: USE WITH 30133A1 AND 30462A1 BOTTOM YOKE)
36 11-25096 NUT, MOUNTING SCREW
37 10-75284 SCREW, LOWER MOUNT (5 1/2") Comment: SERIAL 01365073-09999999
38 25067 BUMPER, RUBBER - MOUNTING SCREW
39 28242 COVER, LOWER MOUNT (STARBOARD SIDE)
40 10-29256 SCREW, LOWER MOUNT COVER FASTENING
41 22-390721 PLUG, GREASE - REVERSE LOCK HOLE
▶FLYWHEEL ASSEMBLY AND STATOR (18 parts) FLYWHEEL ASSEMBLY AND STATOR
Ref OEM Part # Part Name
1 11-8M0214915 NUT, FLYWHEEL
2 12-26617 WASHER, FLYWHEEL NUT
3 28-20094 KEY, FLYWHEEL DRIVE
4 215-3289A1 FLYWHEEL ASSEMBLY
5 29788 FLANGE, FLYWHEEL PULLEY (SEE NOTE BELOW)
5A 12-25293 WASHER, PULLY TO FLYWHEEL (SEE NOTE BELOW)
6 30306 PULLEY, FLYWHEEL
6A 22823 PULLEY, FLYWHEEL
7 29787 HUB, FLANGE - FLYWHEEL PULLEY
8 17-26618 DOWEL PIN, FLYWHEEL PULLEY
9 50-25263 RATCHET, FLYWHEEL
10 10-29238 SCREW, RATCHET TO FLYWHEEL
11 398-1455 STATOR, ALTERNATOR - FLYWHEEL
12 22647 DISCONNECT, KNIFE SPLICE - STATOR LEAD WIRE
13 32-26693A1 SLEEVE, RUBBER - STATOR LEAD WIRE
14 10-68918 SCREW, STATOR TO UPPER END CAP
15 54-24836 CLIP, STATOR LEAD TO CRANKCASE FLANGE
16 10-8M0113176 SCREW, STATOR LEAD CLIP FASTENING
▶FUEL PUMP ASSEMBLY (30 parts) FUEL PUMP ASSEMBLY
Ref OEM Part # Part Name
- 22-390721 PLUG, PIPE - FUEL PUMP
-- 32-30040 FUEL LINE, UPPER TO LOWER FILTER Comment: USE WITH 29178A2 FUEL PUMP
1 30269A2 FUEL PUMP ASSEMBLY Comment: SERIAL 01362198-09999999
2 27-23005 GASKET, CHECK VALVE TO HOUSING
3 21-8M0082362 VALVE, CHECK
4 23004 RETAINER, CHECK VALVE
5 10-43725 SCREW, RETAINER TO HOUSING
6 27-24863 GASKET, FUEL PUMP
7 23014 DIAPHRAGM, FUEL PUMP
8 23008 COVER, FUEL PUMP
9 27-30276 GASKET, FUEL PUMP COVER
10 10-29126 SCREW, FUEL PUMP MOUNTING (1 3/4")
11 10-29029 SCREW, FUEL PUMP MOUNTING (1 1/2")
12 22-22949 CONNECTOR, PUMP INLET TO FUEL LINE
13 22-22946 SLEEVE, RUBBER - CONNECTOR
14 22-22948 NUT, CONNECTOR TO FUELK LINE
15 32-30035 FUEL LINE, FUEL PUMP TO LOWER FILTER
16 22-22995 ELBOW, FUEL PUMP INLET
17 22-22946 SLEEVE, RUBBER
18 22-22948 NUT, ELBOW
19 32-30036 FUEL LINE, FUEL PUMP TO ADAPTOR
20 22833 ADAPTOR, CHECK UNIT (FUEL LINE)
21 23069 STEM, CHECK UNIT ADAPTOR
22 25-16524 "O" RING, ADAPTOR STEM
23 24-23067T SPRING, ADAPTOR STEM
24 30188 CUP WASHER, ADAPTOR
25 10-20784 SCREW, ADAPTOR TO BOTTOM COWL
26 11-24652 NUT, ADAPTOR SCREW
27 32-38527 FUEL LINE, UPPER TO LOWER FILTER Comment: (USE WITH 30269A2 FUEL PUMP
28 22-25956 TEE ASSEMBLY, LOWER FILTER Comment: (USE WITH 30269A2 FUEL PUMP
▶GEAR HOUSING ASSEMBLY, COMPLETE(PAGE 1) (38 parts) GEAR HOUSING ASSEMBLY, COMPLETE(PAGE 1)
Ref OEM Part # Part Name
- 27-31367 GASKET, WATER INTAKE SCREEN TO HOUSING
1 1603-1868A4 GEAR HOUSING ASSEMBLY
2 16-8M0133358 STUD, GEAR HOUSING TO DRIVE SHAFT HOUSING
3 31-62091T BEARING, ROLLER - DRIVE SHAFT
4 23-23651 SLEEVE, WATER INLET TUBE
5 32-23652 TUBE, WATER INLET - LOWER
6 26-20232 SEAL, WATER TUBE
7 35-23654 SCREEN, WATER INTAKE - GEAR HOUSING
8 10-79953Q04 SCREW, GREASE FILLER AND FLUSHING HOLE
9 12-191833 WASHER, GREASE FILLER AND FLUSHING HOLE SCREW
10 10-28653 SCREW, GEAR HOUSING VENT
11 19643 WASHER, GEAR HOUSING VENT SCREW
12 25136 SHAFT, SHIFT - LOWER
13 53-29641 CLIP, RETAINING - SHIFT SHAFT
14 25-25439 "O" RING, SHAFT SHAFT BUSHING
15 23-46284A1 BUSHING ASSEMBLY, SHIFT SHAFT
16 26-892361 OIL SEAL
17 52918 CAM, LOWER - REVERSE LOCKING
18 52919 CAM, UPPER - REVERSE
19 45-29617A1 DRIVE SHAFT ASSEMBLY
20 53-29116 RING, RETAINING - BALL BEARING
21 43-20834 GEAR, PINION
22 14-29163 TAB WASHER, PINION GEAR SCREW
23 10-20925 SCREW, PINION GEAR TO DRIVE SHAFT
24 15-20929A1 SHIM, DRIVE SHAFT BEARING TO HOUSING
25 30-72961 BEARING, BALL - DRIVE SHAFT
26 25-26722 "O" RING, WATER PUMP CARTRIDGE
27 46-29117A1 WATER PUMP CARTRIDGE ASSEMLBY
28 26-90562 OIL SEAL
29 28091 INSERT, WATER PUMP CARTRIDGE
30 28-28657 KEY, WATER PUMP CARTRIDGE
31 47-89983T IMPELLER, WATER PUMP
32 28-8M0032837 PIN, IMPELLER DRIVE
33 20272 PLATE, OUTLET - WATER PUMP COVER
34 20270A2 WATER PUMP COVER ASSEMBLY
35 26-23517 OIL SEAL
36 25-20273 RING, RUBBER - CENTRIFUGAL SLINGER
37 25-29619 "O" RING, UPPER - DRIVE SHAFT
▶GEAR HOUSING ASSEMBLY, COMPLETE(PAGE 2) (29 parts) GEAR HOUSING ASSEMBLY, COMPLETE(PAGE 2)
Ref OEM Part # Part Name
- 1603-1868A2 GEAR HOUSING ASSEMBLY, COMPLETE - SEE NOTE BELOW
1 1603-1868A4 GEAR HOUSING ASSEMBLY (SEE PAGE 13 FOR PARTS BREAKDOWN)
38 760394 CAM, SHIFT
39 20930 FOLLOWER, CAM
40 20843 SLIDE, CROSS PIN
41 24-20254 SPRING, CAM FOLLOWER PIN
42 15-20928A1 SHIM, BALL BEARING TO GEAR HOUSING
43 30-20840 BEARING, BALL - FORWARD GEAR
44 43-20975A5 FORWARD GEAR ASSEMBLY
45 31-20249 BEARING, ROLLER - FORWARD GEAR
46 52-32189 RATCHET, SLIDING CLUTCH
47 17-20841 PIN, CROSS - RATCHET TO PROPELLER SHAFT
48 53-20842 RING, RETAINING - CROSS PIN
49 44-25254 SHAFT, PROPELLER
50 43-20975A5 REVERSE GEAR ASSEMBLY
51 20864 RING, ADAPTOR - BALL BEARING
52 30-20839T BEARING, BALL - REVERSE GEAR
53 15-20927A1 SHIM, ADAPTOR RING TO GEAR HOUSING
54 20862A1 BEARING CARRIER ASSEMBLY
55 31-20249 BEARING, ROLLER
56 26-90562 OIL SEAL
57 25-20863 "O" RING, BEARING CARRIER
58 12-22970 WASHER, GEAR HOUSING COVER
59 20865 COVER, GEAR HOUSING
60 12-25251 WASHER, BACKING (1/8)
61 48-22914A2 PROPELLER ASSEMBLY (2 BLADE - ALUMINUM
62 12-25252 WASHER, BACKING (1/32)
63 14-25250 TAB WASHER, PROPELLER NUT
64 11-29825 NUT, PROPELLER (NYLON)
▶MAGNETO ADAPTOR AND PILOT ASSEMBLY (61 parts) MAGNETO ADAPTOR AND PILOT ASSEMBLY
Ref OEM Part # Part Name
- 29321A7 MAGNETO ADAPTOR AND PILOT ASSEMBLY, COMPLETE
-- 20136 FLANGE, DRIVEN PULLEY (OLD STYLE)
1 394-2271A2 MAGNETO ASSEMBLY, COMPLETE (4D-3)
2 45-27951 SHAFT, MAGNETO DRIVE
3 39560A1 MAGNETO PILOT ASSEMBLY
4 30-20066 BEARING, BALL - MAGNETO PILOT
5 24-27944 SPRING, HORSESHOE - MAGNETO PILOT
6 17-27962 PIN, ANCHOR - HORSESHOE SPRING TO PILOT
7 12-8M0204649 WASHER, HORSESHOE SPRING TO ANCHOR PIN
8 27946A1 ECONOMISER COLLAR AND PIN ASSEMBLY
9 17-27961 PIN, ECONOMISER COLLAR - SPRING RETAINER
10 22-25094 FITTING, GREASE - ECONOMISER COLLAR
11 38230A1 THROTTLE ACTUATOR ASSEMBLY
12 23-26602 BUSHING, NYLON - THROTTLE ACTUATOR
13 10-20665 SCREW, THROTTLE ACTUATOR TO ECONOMISER COLLAR
14 12-847883 WASHER, THROTTLE ACTUATOR SCREW
15 27947 SWIVEL, LINKAGE - ECONOMISER COLLAR
16 25996A1 SWIVEL, AND LINK ROD ASSEMBLY
17 66856A1 ADAPTOR, MAGNETO
18 22-25094 FITTING, GREASE - MAGNETO ADAPTOR
19 12-27939 WASHER, MAGNETO PILOT
20 14-27960 TAB WASHER, ADAPTOR CAP FASTENING
21 13-27959 WASHER, WAVE - MAGNETO BALL BEARING TENSION
23 10-30110 SCREW, ADAPTOR AND PILOT TO MAGNETO
24 10-78841 SCREW, ADAPTOR AND PILOT TO CRANKCASE
25 12-20084 WASHER, ADAPTOR AND PILOT TO CRANKCASE SCREW
26 11-22053 NUT, ADAPTOR AND PILOT TO CRANKCASE SCREW
27 53458 PLATE, THROTTLE STOP
28 37-29315 DECAL, THROTTLE STOP PLATE (STOP ADJUSTMENTS)
30 11-20088 NUT, THROTTLE STOP ADJUSTING SCREW
31 26852 CAP, NYLON - ADJUSTING SCREW
32 10-69035 SCREW, THROTTLE STOP PLATE TO ADAPTOR
33 28-28657 KEY, MAGNETO DRIVING
34 29784 HUB, DRIVEN PULLEY (NEW STYLE - SEE NOTE BELOW)
35 29783A1 DRIVEN PULLEY ASSEMBLY (NEW STYLE - SEE NOTE BELOW)
36 17-24873 ROLL PIN, FLANGE LOCATING (NEW STYLE - SEE NOTE BELOW)
37 29785 FLANGE, DRIVEN PULLEY (NEW STYLE - SEE NOTE BELOW)
38 12-20138 WASHER, PULLEY CLAMPING SCREW
39 10-32228 SCREW, PULLEY CLAMPING
40 20140 BELT, TIMING
41 27949 ROD, LINK - UPPER
42 11-25168 NUT, UPPER LINK ROD ADJUSTING
43 27948 SWIVEL, UPPER AND LOWER LINK RODS
44 28061 LEVER, LINKAGE - UPPER
45 27941 LEVER, LINKAGE - LOWER
46 F17950 ROD, LINK - LOWER
47 27940 SHAFT, VERTICAL
48 23-22981 BUSHING, NYLON - VERTICAL SHAFT
49 17-25870 ROLL PIN, VERTICAL SHAFT AND LINKAGE LEVERS
50 12-8M0204649 WASHER, UPPER AND LOWER SWIVEL
51 11-8267089 NUT, UPPER AND LOWER SWIVEL TO LEVER AND BRACKET
52 10-25781 SCREW, SET - LINKAGE LEVER
53 12-25866 WASHER, VERTICAL SHAFT - CENTER
54 33-813416 SPARK PLUG
55 85-63709A1 PROTECTOR, SPARK PLUG
57 25-25429 "O" RING, HIGH TENSION LEAD CABLE TO END CAP COVER
58 54-29425 CLIP, HIGH TENSION LEAD CABLE FASTENING
59 54-25231 CLIP, MERCURY SWITCH AND HARNESS LEADS TO MAGNETO
60 10-20401 SCREW, LEAD CLIP TO MAGNETO
61 8M0084613 "D" WASHER, CLIP FASTENING SCREW
62 394-1134A1 GROUND STRAP ASSEMBLY, MAGNETO TO CRANKCASE
▶MAGNETO ASSEMBLY (47 parts) MAGNETO ASSEMBLY
Ref OEM Part # Part Name
- 394-2271A2 MAGNETO ASSEMBLY, COMPLETE (4D-3)
1 394-1570 FRAME, MAGNETO HOUSING
2 10-25510 SCREW, SET - COIL BRIDGE
3 394-1051 LOCKWIRE, COIL BRIDGE SET SCREW
4 30-24998 BEARING, BALL (DRIVE END)
5 394-1067A1 MAGNETIC ROTOR AND SHAFT
6 30-49090 BEARING, BALL (OPPOSITE DRIVE END)
7 394-1637 SUPPORT, BALL BEARING
8 10-25509 SCREW AND LOCKWASHER, SUPPORT TO FRAME
9 84-60466A13 WIRE ASSEMBLY, PRIMARY GROUND LEAD
10 10,10-29182 SCREW, PRIMARY GROUND
11 12-30267 WASHER, PRIMARY GROUND TERMINAL HOLDING
12 394-1579 INSULATOR, PRIMARY GROUND TERMINAL
13 12-29099 WASHER, INSULATING - PRIMARY GROUND SCREW
14 23-62769 BUSHING, INSULATING - HOUSING FRAME
15 12-26014 WASHER, PRIMARY GROUND SCREW
16 11-24656 NUT, LOCK - PRIMARY GROUND SCREW
17 11-68219 NUT, PRIMARY GROUND SCREW
18 394-1128A1 COIL ASSEMBLY
19 394-1050 CLIP, COIL - HIGH TENSION
20 13-23836 LOCKWASHER, COIL TERMINAL
21 394-1131 NUT, COIL CLIP FASTENING
22 393-1504A11 BREAKER ASSEMBLY
23 393-1586 GROMMET, PLASTIC - BREAKER BRACKET
24 16-29230 STUD, PRIMARY LEAD AND TENSION SPRING FASTENING
25 11-29236 NUT, PRIMARY LEAD FASTENING
26 394-1106A1 HOLDER AND CAM WICK ASSMELBY
27 12-26439 WASHER, BREAKER PIVOT PIN
28 18-26953 COTTER PIN, BREAKER TO PIVOT PIN
29 10-20597 SCREW, BREAKER HOLDER TO HOUSING
30 394-1130A1 CONDENSER
31 10-25509 SCREW AND LOCKWASHER, CONDENSER FASTENING
32 27-29166 GASKET, MAGNETO COVER
33 394-1577A2 COVER, MAGNETO
34 10-29418 SCREW, COVER TO FRAME
35 14-29157 TAB WASHER, COVER FASTENING SCREW
36 394-2602A1 MAGNETO ROTOR ASSEMBLY
37 394-1110 CLIP, SPRING
38 27-25725 GASKET, END CAP OVER
39 394-1561A2 END CAP COVER ASSEMBLY
40 394-1065A1 LEAD ASSEMBLY, HIGH TENSION
41 394-1056A1 BRUSH AND SPRING ASSEMBLY
42 10-25517 SCREW, HIGH TENSION CABLE FASTENING
43 29121 PIPE PLUG, END CAP COVER
44 10-29418 SCREW, END CAP COVER TO MAGNETO COVER
45 14-29157 TAB WASHER, COVER FASTENING SCREW
46 22-996642 ELBOW, PLASTIC - MAGNETO COVER VENT
▶MERC 400ML AND MERC 400EL PARTS LIST (0 parts) MERC 400ML AND MERC 400EL PARTS LIST
▶MERC 400S AND MERC 400SL PARTS LIST (0 parts) MERC 400S AND MERC 400SL PARTS LIST
▶MISCELLANEOUS PARTS/ACCESSORIES (1 parts) MISCELLANEOUS PARTS/ACCESSORIES
Ref OEM Part # Part Name
- 94-39394 SHIPPING CARTON (MOTOR)
▶RECTIFIER, STARTER SOLENOID AND WIRING HARNESS (25 parts) RECTIFIER, STARTER SOLENOID AND WIRING HARNESS
Ref OEM Part # Part Name
1 32177A2 RECTIFIER ASSEMBLY
2 32-26693A1 SLEEVE, RECTIFIER LEAD (RED)
3 22647 DISCONNECT, KNIFE SPLICE - RECTIFIER LEAD WIRES
4 13-8M0204647 LOCKWASHER, RECTIFIER MOUNTING SCREW
5 11-21929 NUT, RECTIFIER MOUNTING SCREW
6 28597 BRACKET, RECTIFIER MOUNTING
7 10-21091 SCREW, RECTIFIER BRACKET TO BOTTOM COWL
8 11-24652 NUT, BRACKET MOUNTING SCREW
9 54-24836 CLAMP, LEAD WIRE TO RECTIFIER BRACKET - UPPER (1/4)
10 54-22740 CLAMP, LEAD WIRE TO RECTIFIER BRACKET - LOWER (3/8)
11 10-8M0113176 SCREW, LEAD WIRE CLAMP TO BRACKET
12 8M0084613 "D" WASHER, CLAMP FASTENING SCREW
13 32445A1 SOLENOID, STARTER
14 28016A1 GROUND STRAP ASSEMBLY, SOLENOID TO STARTER
15 84-93389A12 WIRE, STARTER TO STARTER SOLENOID
16 13-8M0204647 LOCKWASHER, SOLENOID TERMINAL (5/16)
17 11-26062 NUT, CAP - SOLENOID TERMINAL - OUTSIDE (5/16)
18 10,13-26996 LOCKWASHER, SOLENOID TERMINAL
19 10,11-68219 NUT, SOLENOID TERMINAL
20 10-29238 SCREW, SOLENOID TO STARTER MOTOR
21 33401 WIRING HARNESS (INTERNAL)
22 24-28975 SPRING, GARTER - INTERNAL WIRING HARNESS
23 26079A2 PLATE, BACKING - WIRING HARNESS
24 10-45893 SCREW, BACKING PLATE TO BOTTOM COWL
25 54-22783 "S" CLIP, WIRING HARNESS LEADS TO BOTTOM COWL
▶TOP COWL AND STARTER ASSEMBLY (49 parts) TOP COWL AND STARTER ASSEMBLY
Ref OEM Part # Part Name
-- 12-20583 WASHER, TOP COWL STUD (1/32")
1 177-2355A4 TOP COWL ASSEMBLY
2 16-20500 STUD, REAR - TOP COWL TO COVER
3 16-20353 STUD, FRONT - TOP COWL TO CRANKCASE
4 25-20116 GROMMET, CHOKE KNOB
5 28967 SCREEN, VENT - TOP COWL
6 10-26668 SCREW, VENT SCREEN TO TOP COWL
7 29228A1 TRIM MOULDING ASSEMBLY, TOP COWL
8 10-29226 SCREW, DECORATIVE - MOULDING TO TOP COWL
9 10-29227 SCREW, BRASS - MOULDING TO TOP COWL
10 13-26995 LOCKWASHER, MOULDING FASTENING SCREW
11 11-26419 NUT, MOULDING FASTENING SCREW
12 37-46023A1 DECAL SET, TOP COWL
13 23-20326 SPACER, TOP COWL STUD
14 12-20028 WASHER, TOP COWL STUD (1/16")
15 12-69057 WASHER, TOP COWL STUD (3/4" OD)
16 11-8267089 NUT, TOP COWL FASTENING
17 20155 RETAINER, STARTER SPRING
18 24-29340T02 SPRING, STARTER REWIND
19 23-28912 BUSHING, SPRING GUIDE
20 50-30994 SHEAVE ASSEMBLY
21 30596 PAWL, STARTER
22 13-36206 WASHER, WAVE - STARTER PAWL
23 23-28919 BUSHING, NYLON - SHEAVE SHAFT SPACER
24 45477A1 SPACER, SHEAVE SHAFT
25 26179 RETAINER, WAVE WASHER
26 12-26180 WASHER, WAVE WASHER RETAINER
27 13-20160 WASHER, WAVE - RETAINER TENSION
28 30595 PLATE, RETAINER - STARTER PAWL
29 45477A1 SHAFT, SHEAVE
30 50-12066Q10 STARTER CABLE ASSEMBLY
31 28747 HANDLE, STARTER CABLE
32 79470A1 RETAINER, STARTER CABLE AND HANDLE
33 30045 PLATE, ROPE GUIDE
34 10-28642 SCREW, DRIVE, ROPE GUIDE PLATE TO TOP COWL
35 14-20165 TAB WASHER, SHEAVE SHAFT NUT
36 11-20166 NUT, SHEAVE SHAFT (LEFT HAND THREAD)
37 31875 HANDLE, CHROME - TOP COWL
38 31003 HANDLE, INSIDE - TOP COWL
39 1398-3119 BUTTON, BUMPER - TOP COWL HANDLE
40 12-69057 WASHER, LOWER HANDLE STUD (3/4" OD)
41 12-8M0204649 WASHER, CENTER HANDLE STUD (1/2" OD)
42 11-21825 NUT, INSIDE HANDLE TO CHROME HANDLE STUDS
43 10-56500 SCREW, FRONT - HANDLE TO TOP COWL (1 1/4")
44 11-8267089 NUT, FRONT HANDLE FASTENING SCREW
45 10-29199 SCREW, CENTER - HANDLE TO TOP COWL (1")
46 23-29561 BUSHING, REAR HANDLE STUD
47 13-26992 LOCKWASHER, REAR HANDLE STUD
48 11-21825 NUT, REAR HANDLE STUD

100-Hour / Annual Service Checklist

Regular maintenance keeps your Mercury 400 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.

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