Mercury 450 (4 CYL.) (1476510 THRU 1531568) Parts & Diagrams

OEM and aftermarket replacement parts for Mercury 450 (4 CYL.). Scroll down for exploded parts diagrams (22), specifications, and maintenance reference.

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Mercury 450 (4 CYL.) (1476510 THRU 1531568) Parts & Diagrams

🔎 Mercury 450 (4 CYL.) Reference Library — Exploded parts diagrams (22 diagrams), specifications, common issues, and maintenance checklist.

The Mercury 450 (4 CYL.) is a 4-Stroke, Inline 4-Cylinder, EFI, SOHC outboard motor. Commonly used on jon boats, pontoons, and mid-size utility craft.

Quick Reference Specifications

Specification Value
Engine Type 4-Stroke, Inline 4-Cylinder, EFI, SOHC
Horsepower 45 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 450 (4 CYL.):

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

Parts Diagrams & OEM Part Numbers

Expand the sections below to view detailed exploded parts diagrams and find the exact OEM replacement components for your Mercury 450 (4 CYL.).

▶BOTTOM COWL ASSEMBLY (54 parts) BOTTOM COWL ASSEMBLY
Ref OEM Part # Part Name
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)
9 10-29226 SCREW, DECORATIVE-MOULDING TO BOTTOM COWL
10 12-24671 WASHER, FIBRE-MOULDING FASTENING SCREW
11 11-29225 NUT, NYLON CAP-MOULDING FASTENTING SCREW
12 13-26995 LOCKWASHER, MOULDING FASTENING SCREW
13 11-26419 NUT, BRASS-MOULDING FASTENING SCREW
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, THROTTLLE 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 18-25191 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 11-20013 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, CONNECTOR 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 10-22956 SCREW, BRACKET TO BOTTOM COWL (7/8")
48 10-21091 SCREW, BRACKET TO BOTTOM COWL (1 1/8")
49 11-24652 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
54 19-31469 PLUG, BOTTOM COWL
▶CABURETOR LINKAGE AND CHOKE SOLENOID (38 parts) CABURETOR LINKAGE AND CHOKE SOLENOID
Ref OEM Part # Part Name
- 8M0084613 D WASHER, CHOKE WIRE CLAMP SCREW
-- 12-30164 WASHER, THROTTLE PICKUP BRACKET CLAMP SCREW
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, SOLENOID TO ADAPTOR
8 32-26693A1 SLEEVE, CHOKE SOLENOID WIRE AND HARNESS WIRE
9 54-24836 CLAMP, CHOKE WIRE TO STARTER SOLENOID
10 27031A1 PLUNGER ASSEMBLY, CHOKE SOLENOID
11 27710 ADAPTOR PLATE, CHOKE PLUNGER
12 25-26633 GROMMET, ADAPTOR PLATE
13 10-30097 SCREW, ADAPTOR PLATE TO CHOKE ROD BRACKET
14 12-26014 WASHER, CHOKE SOLENOID LINK
15 18-26953 COTTER PIN, CHOKE SOLENOID LINK FASTENING
16 1333-2002 CARBUERTOR ASSEMBLY, COMPLETE
17 27917 CLUSTER, THROTTLE LEVER ( UPPER CARBURETOR )
18 1395-6027 SCREW, SET - CLUSTER TO THROTTLE LEVER
19 90242A1 KNOB, CHOKE ROD
20 25-20116 GROMMET, CHOKE ROD
21 22462 U LINK, CHOKE KNOB TO CHOKE ROD
22 10-69022 SCREW, U LINK TO CHOKE KNOB
23 13-26996 LOCKWASHER, U LINK FASTENING SCREW
24 18-210711 COTTER PIN, CHOKE LEVER AND ROD FASTENING
25 28977 CHOKE ROD - UPPER
25A 28972A1 CHOKE ROD AND BRACKET ASSEMBLY - UPPER
26 10-30096 SCREW, UPPER CHOKE ROD TO LOWER CHOKE ROD
27 27918 CHOKE ROD - LOWER
28 17-25391 RIVET, CHOKE ROD TO THROTTLE SHAFT
29 24-28965 SPRING, CHOKE ROD TO RETAINER
30 31479 RETAINER, CHOKE ROD SPRING
31 10-28713 SCREW, RETAINER TO LOWER CARBURETOR
32 27870 CLAMP, THROTTLE PICKUP BRACKET
33 10-69022 SCREW, CLAMP TO THROTTLE PICKUP BRACKET
34 53719A2 BRACKET ASSMEBLY, THROTTLE PICKUP (NOT AS SHOWN)
35 10-29239 SCREW, THROTTLE BRACKET MOUNTING
▶CARBURETOR ASSEMBLY (44 parts) CARBURETOR ASSEMBLY
Ref OEM Part # Part Name
-- 1395-92621 REPAIR PARTS KIT (1 PER CARBURETOR)
1 1333-2099 CARBURETOR ASSEMBLE, COMPLETE (KA-19A)
2 1395-8673 FLOAT ASSEMBLY
3 17-20853 PIN, FLOAT LEVER PINION
4 1399-102 LEVER, FLOAT (LOWER)
5 1399-101 LEVER, FLOAT (UPPER)
6 1395-92581 INLET NEEDLE, SEAT AND GASKET
7 27-25033 GASKET, INLET SEAT
8 1399-99 GASKET, FLOAT BOWL COVER
9 1399-1133 COVER, FLOAT BOWL
10 10-22625 SCREW, FLOAT BOWL COVER (SHORT)
11 10-25850 SCREW, FLOAT BOWL COVER (LONG)
12 27-25851 GASKET, STRAINER COVER (LARGE)
13 1399-3938 SCREEN, FILTER
14 27-25849 GASKET, STRAINER COVER SCREW
15 27-25848 GASKET, STRAINER COVER SCREW
16 27-25848 GASKET, STRAINER COVER SCREW
17 10-25822 SCREW, STRAINER COVER FASTENING
18 1395-6027 SCREW, THORTTLE STOP LEVER
19 8146791 LEVER, THORTTLE STOP (SEE NOTE BELOW)
20 1399-2012 SAHFT, THORTTLE
21 1399-1710 TUBE, IDLE
22 27-23180 GAKET, IDLE TUBE
23 10-23035 SCREW AND LOCKWASHER, THORTTLE SHUTTER
24 1399-1711 SHUTTER, THROTTLE
25 24-27160 SPRING, IDLE ADJUSTMENT SCREW
26 1399-1713 SCREW, IDLE ADJUSTMENT
27 10-28405 SCREW, PLUG - MAIN FUEL JET CHANNEL
28 27-28406 GASKET, JET CHANNEL PLUG SCREW
29 1399-1655 JET, MAIN FUEL (.055)
30 27-28409 GASKET, MAIN FUEL JET
31 1399-1888 NOZZLE, MAIN
32 10-23178 SCREW, PLUG - MAIN NOZZLE
33 24-20869 SPRING, THROTTLE SHAFT RETURN (UPPER CARBURETOR)
34 10-23030 SCREW, PLUG - BODY CHANNEL
35 19-20011 WELCH PLUG, BODY CHANNEL
36 27-757911 GASKET, CARBURETOR FLANGE
37 11-29250 NUT, CARUBRETOR MOUNTING STUD
38 1399-1461 JET, MAIN FUEL (.061)
39 27-28409 GASKET, MAIN FUEL JET
40 10-28405 SCREW, PLUG - MAIN FUEL JET CHANNEL
41 27-28406 GASKET, JET CHANNEL PLUG SCREW
42 27-757911 GASKET, CARUBRETOR FLANGE
43 11-29250 NUT, CARBURETOR MOUNTING STUD
▶CARBURETOR LINKAGE AND CHOKE SOLENOID (33 parts) CARBURETOR LINKAGE AND CHOKE SOLENOID
Ref OEM Part # Part Name
1 31593 CHOKE SOLENOID, TOP COWL Comment: SERIAL 01598788-09999999
2 22647 DISCONNECT, KNIFT - CHOKE SOLENOID LEAD
3 10-20540 SCREW, CHOKE SOLENOID TO TOP COWL
4 13-26992 LOCKWASHER, CHOKE SOLENOID SCREW
5 26716A1 GROUND STRAP ASSEMBLY, SOLENOID TO ADAPTOR
6 10-24773 SCREW, CHOKE SOLENOID TO TOP COWL
7 13-26991 LOCKWASHER, CHOKE SOLENOID SCREW
8 32-26693A1 SLEEVE, CHOKE SOLENOID LEAD
9 23-27783 S CLIP, CHOKE SOLENOID LEAD TO TOP COWL
10 90242A1 KNOB, CHOKE ROD
11 25-20116 GROMMET, CHOKE ROD
12 22462 U LINK, CHOKE ROD TO CHOKE KNOB
13 13-26996 LOCKWASHER, U LINK SCREW
14 10-69022 SCREW, U LINKM TO CHOKE KNOB
15 18-210711 COTTER PIN, U LINK TO CHOKE ROD
16 38604 SHUTTER, CHOKE - CARBURETOR (UPPER)
17 23-30438 BUSHING, NYLON - UPPER CHOKE SHUTTER
18 31519 ROD, CHOKE
19 17-25391 RIVET, CHOKE SHUTTER TO CHOKE ROD
20 16-30172 STUD, CARBURETOR - CHOKE SHUTTER PIVOT
21 12-30164 WASHER, CHOKE SHUTTER CARBURETOR STUD
22 11-20110 NUT, CHOKE SHUTTER TO CARBURETOR STUD
23 24-28965 SPRING, TENSION - CHOKE ROD
24 10-28713 SCREW, RETAINER TO LOWER CARBURETOR
25 27711 RETAINER, CHOKE ROD SPRING TO CARBURETOR
26 1333-2099 CARBURETOR ASSEMBLY, COMPLETE
27 53719A2 THROTTLE PICK-UP BRACKET ASSMEBLY
28 10-29239 SCREW, THROTTLE PICK-UP BRAKCET MOUNTING
29 27917 CLUSTER, THROTTLE LEVER ( UPPER CABURETOR )
30 1395-6027 SCREW, CLUSTER TO THROTTLE LEVER
31 48315A4 PLUGER AND LINK ASSEMBLY, CHOKE SOLENOID
32 12-30164 WASHER, PLUNGER AND LINK
33 18-26953 COTTER PIN, LINK TO UPPER CHOKE SHUTTER
▶CLAMP AND SWIVEL BRACKET (MERC 500) (49 parts) CLAMP AND SWIVEL BRACKET (MERC 500)
Ref OEM Part # Part Name
1 1440-1795A1 CLAMP BRACKET ASEMBLY
2 28403A3 THUMB SCREW ASSEMBLY
3 12-28404 WASHER, THUMB SCREW
4 8M0041936 TUBE, TILT -CLAMP BRACKET TO SWIVEL BRACKET
5 12-52864 SHIM, CLAMP BRACKET TO SWIVEL BRACKET
6 11-858869 NUT, TILT TUBE
7 53078 CAP, PALSTIC - TILT TUBE
8 16-59625 STUD, CLAMP BRACKET
9 23-59624 SPACER, CLAMP B RACKET 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 ANCH OR
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
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 WASHER, UPPER BUSHING RETAINER (OUTER)
31 10-28449 BOLT, NYLOCK - UPPER SHOCK MOUNTING PIN
32 55-28413 PIN, 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
39 11-71956 NUT, SWIVEL PIN RETAINING
40 10-33986 BOLT, UPPER MOUNT TO SWIVEL PIN
41 30711 BUMPER, TOP YOKE
42 12-26837 WASHER, LOWER - SWIVEL PIN
43 30462 BOTTOM YOKE
44 12-25176 WASHER, SWIVEL PIN TO BOTTOM YOKE
45 38-56267 SERIAL PLATE
46 10-25612 SCREW, DRIVE - SERIAL PLATE TO SWIVEL BRACKET
47 10-68298 BOLT, CARRIAGE - CLAMP BRACKET TO BOAT TRANSOM
48 12-68410 WASHER, CARRIAGE BOLT
49 11-82670912 NUT, CARRIAGE BOLT
▶CLAMP AND SWIVEL BRACKET ASSEMBLY (41 parts) CLAMP AND SWIVEL BRACKET ASSEMBLY
Ref OEM Part # Part Name
-- 53-27743 RING, RETAINING - SWIVEL PIN Comment: SERIAL 00000(1)-01507833
1 1440-1797A1 CLAMP BRACKET ASSEMBLY
2 28403A3 THUMB SCREW ASSEMBLY
3 12-28404 WASHER, THUMB SCREW
4 8M0041936 TUBE, TILT - CLAMP BRACKET TO SWIVEL BRACKET
5 12-52864 SHIM, CLAMP BRACKET TO SWIVEL BRACKET (.010)
6 11-858869 NUT, TILT TUBE FASTENING
7 53078 CAP, PLASTIC - TILT TUBE ENDS
8 16-59625 STUD, CLAMP BRACKET
9 23-59624 SPACER, CLAMP BRACKET STUD
10 13-8M0204647 LOCKWASHER, CLAMP BRACKET STUD
11 11-22053 NUT, STUD TO CLAMP BRACKETS
12 17-8M0026068 TILT LOCK PIN ASSEMBLY
13 26903A3 REVERSE LOCK ASSEMBLY
14 18-45882 COTTER PIN, REVERSE LOCK TO SHAFT
15 24-29821 SPRING, TENSION - REVERSE LOCK
16 17-25598 ROLL PIN, REVERSE LOCK SPRING ATTACHING
17 56349 SHAFT, REVERSE LOCK TO SWIVEL BRACKET
18 1442-2501A1 SWIVEL BRACKET ASSEMBLY
19 22-69059 FITTING, GREASE - SWIVEL BRACKET
20 26-32911 OIL SEAL, SWIVEL BRACKET Comment: SERIAL )1507834-09999999
21 19-77633Q LUBRICAP, SWIVEL BRACKET GREASE FITTING
22 29057 LEVER, TILT STOP - STARBOARD SIDE
23 29056 LEVER, TILT STOP - PORT SIDE
24 10-27791 SCREW, ANCHOR - TILT STOP LEVER
25 23-29055 SPACER, TILT STOP LEVER ANCHOR SCREW
26 10-27790 SCREW, RETAINING - TILT STOP LEVER
27 15-20473 SHIM, RETAINING SCREW - PORT SIDE
28 13-20846 WASHER, WAVE - RETAINING SCREW - PORT SIDE
29 11-24652 NUT, ANCHOR AND RETAINING SCREW
30 12-26837 WASHER, SWIVEL PIN TO BOTTOM YOKE (.065)
31 30462 YOKE, BOTTOM
32 17-28418A4 SWIVEL PIN AND TOP YOKE ASSEMBLY Comment: SERIAL )1507834-09999999
33 30711 BUMPER, TOP YOKE
34 10-33986 BOLT, UPPER MOUNT TO SWIVEL PIN
35 11-71956 NUT, RETAINING - SWIVEL PIN Comment: SERIAL )1507834-09999999
36 38-56267 SERIAL PLATE
37 10-25612 SCREW, DRIVE - SERIAL PLATE TO SWIVEL BRACKET
38 10-68298 BOLT, BLAMP BRACKET TO BOAT TRANSOM
39 12-68410 WASHER, CLAMP BRACKET BOLT
40 11-82670912 NUT, CLAMP BRACKET BOLT
▶COWLING AND FRONT COVER (24 parts) COWLING AND FRONT COVER
Ref OEM Part # Part Name
-- 92-271091 ADHESIVE COMPOUND (3 1/2 OUNCE KIT) EMBLEM 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 56848 KNOB, COWL FRONT COVER FASTENING
8 12-26702 WASHER, COVER FASTENING KNOB (NYLON) - LATE 500 MODELS
9 12-26825 WASHER, COVER FASTENING KNOB (STEEL)
10 24-31353 SPRING, TENSION - FASTENING KNOB
11 17-29077 ROLL PIN, TENSION SPRING TO KNOB
12 29343 BLANKET, SOUND ABSORBING - FRONT COVER - EARLY 500 MODELS
12A 31095 STRIP, RUBBER - COWL FRONT COVER - LATE 500 MODELS
13 2106-2353A2 WRAP AROUND COWL ASSEMBLY
14 21060 HANDLE, COWL LATCH
15 53-21058 "E" RING, COWL LATCH HINGE PIN
16 17-21057 PIN, HINGE - COWL LATCH HANDLE
17 25690 SWIVEL, COWL LATCH
18 25691 HOOK, COWL LATCH FASTENING
19 24825 BLANKET, SOUND ABSORBING - WRAP AROUND COWL
20 37-43198A84 DECAL, WRAP AROUND COWL - STARBOARD
21 37-43198A84 DECAL, WRAP AROUND COWL - PORT
22 37-31883 DECAL, WRAP AROUND COWL - REAR
▶CRANKSHAFT, PISTON AND CONNECTING ROD (29 parts) CRANKSHAFT, PISTON AND CONNECTING ROD
Ref OEM Part # Part Name
-- 39-28616A12 RING, PISTON (OVERSIZED .015)
1 11-8M0214915 NUT, FLYWHEEL
2 12-26617 WASHER, FLYWHEEL NUT
3 28-20094 KEY, FLYWHEEL DRIVE
4 400-2976A2 CRANKSHAFT
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 10-25313 SCREW, MAIN BEARING CLAMPING (1/2")
16 11-29469 NUT, MAIN BEARING CLAMPING SCREW
17 34-88498A1 REED SET, MATCHED - MAIN BEARING
18 34-20053 REED STOP,, MAIN BEARING REED VALVES
19 10-77280 SCREW, REED STOP MOUNTING (1/2")
20 11-29469 NUT, REED STOP MOUNTING SCREW
21 724-2537A2 PISTON AND PISTON PIN ASSEMBLY
22 40-20057 LOCK RING, PISTON PIN
23 39-27841A12 RING, PISTON
24 600-2748A2 CONNECTING ROD AND CAP ASSEMBLY (SEE NOTE BELOW)
25 10-45379 SCREW, CAP TO CONNECTING ROD
26 11-20061 NUT, CONNECTING ROD SCREW
27 29-20046T BEARING, NEEDLE - CRANKPIN
28 29-20063 BEARING, NEEDLE - PISTON PIN
▶CYLINDER BLOCK AND CRANKCASE ASSEMBLY (60 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 15-20082 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
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 AND BALANCE TUBE HOLES
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 36157 EXTENSION, EXHAUST - CYLINDER BLOCK
18 10-32079 SCREW, EXHAUST EXTENSION TO CYLINDER BLOCK
19 12-20028 WASHER, EXHAUST EXTENSION FASTENING SCREW
20 10-78841 SCREW, CRANKCASE TO CYLINDER BLOCK (1 1/2")
21 10-22039 SCREW, CRANKCASE TO CYLINDER BLOCK (2 3/4")
22 11-29250 NUT, CRANKCASE FASTENING SCREW
23 10-98260 SCREW, MAIN BEARING LOCKING
24 14-20091 TAB WASHER, BEARING LOCKING SCREW
25 10-20359 SCREW, CENTER MAIN BEARING LOCKING
26 1102-4181A3 END CAP ASSEMBLY, LOWER
27 21-28481A1 CHECK VALVE ASSEMBLY, LOWER END CAP
28 26-29477 OIL SEAL, LOWER
29 26-41953 OIL SEAL, UPPER
30 25-20081 "O" RING, LOWER END CAP
31 30-63742T BALL BEARING, LOWER END CAP
32 15-20085 SHIM, LOWER END CAP TO CRANKCASE AND BLOCK (.002-3-5-10)
33 10-29198 SCREW. LOWER END CAP MOUNTING
34 32-8M0108355 TUBE, BALANCE - MAIN BEARING
35 22-291112 CONNECTOR, BALANCE TUBE TO CYLINDER BLOCK
36 54-20386 CLAMP, BALANCE TUBE TO CONNECTORS
37 27-26923 GASKET, EXHAUST PLATE TO EXHAUST COVER
38 26922 PLATE, EXHAUST MANIFOLD
39 28240 COVER, EXHAUST MANIFOLD
40 10-28666 SCREW, MAINFOLD COVER AND HIGH TENSION LEAD MOUNTING
41 12-20028 WASHER, MANIFOLD COVER AND HIGH TENSION LEAD CLIP SCREWS
42 58124A1 SWITCH, MERCURY - EXHAUST MANIFOLD COVER
43 54-22875 CLAMP, MERCURY SWITCH TO MANIFOLD COVER
44 10-20401 SCREW, MERCURY SWITCH CLAMP FASTENING
45 8M0084613 "D" WASHER, CLAMP AND CLIP FASTENING SCREW
46 54-25231 CLIP, MERCURY SWITCH LEAD WIRE TO MAGNETO
47 10-20401 SCREW, LEAD WIRE CLIP FASTENING
48 27-22333 GASKET, CYLINDER BLOCK COVER
49 1000-1A1 CYLINDER BLOCK CCOVER ASSEMBLY
50 23-26348 BUSHING, CYLINDER BLOCK COVER
51 10-20653 SCREW, CYLINDER BLOCK COVER MOUNTING
52 11-24652 NUT, COVER MOUNTING SCREW
53 27-279361 GASKET, TRANSFER PORT COVER
54 27935 COVER, TRANSFER PORT
55 10-20540 SCREW, TRANSFER PORT COVER MOUNTING
56 22-62365A1 CHECK VALVE ASSEMBLY, BLLD HOSE (UPPER)
57 21-28481A1 CHECK VALVE ASSEMBLY, BLLED HOSE VALVE
58 32-9912688 HOSE, CYLINDER BLEED (6 1/2")
59 22-67902 CONNECTOR, CYLINDER BLEED HOSE (LOWER)
60 54-20387 CLAMP, BLEED HOSE TO CHECK VALVE AND CONNECTOR
▶DRIVE SHAFT HOUSING ASSEMBLY (45 parts) DRIVE SHAFT HOUSING ASSEMBLY
Ref OEM Part # Part Name
1 1522-1567 DRIVE SHAFT HOUSING
2 32-31117 TUBE, WATER INLET
3 26-25192 SEAL, WATER INLET TUBE
4 23-23651 SLEEVE, WATER INLET TUBE
5 27-24899 GASKET, DRIVE SHAFT HOUSING TO BOTTOM COWL
6 11-862902 NUT, POWERHEAD STUDS
7 10-25093 SCREW, GEAR HOUSING TO DRIVE SHAFT HOUSING
8 16-29103 STUD, DRIVE SHAFT HOUSING TO GEAR HOUSING
9 11-8M0204653 NUT, GEAR HOUSING AND DRIVE SHAFT HOUSING STUDS
10 28470 ROD, PUSH-REVERSE LOCK
11 17-24887 PIN, REVERSE LOCK LEVER
12 18-25191 COTTER PIN, PUSH ROD
13 24-25122 SPRING, TENSION-PUSH ROD
14 52920 LEVER, REVERSE LOCK
15 24926A1 MOUNT, RUBBER-UPPER
16 79680A1 COVER, UPPER MOUNT-OUTSIDE HALF
17 79680A1 COVER, UPPER MOUNT-INSIDE HALF
18 24929 PACKING, "U" CUP
19 12-24889 WASHER, UPPER MOUNT BOLT (17/32 ID)
20 12-24891 WASHER, RUBBER-UPPER MOUNT BOLT
21 23-30474 SPACER, UPPER MOUNT BOLT
22 12-11367 WASHER, UPPER MOUNT BOLT (25/64 ID)
23 11-23161 NUT, UPPER MOUNT BOLT
24 25305 CAP, RUBBER-UPPER MOUNT BOLT NUT
25 10-28772 SCREW, UPPER MOUNT COVER (1 1/2")
26 10-37941 SCREW, UPPER MOUNT COVER (1 3/4")
27 12-8M0204649 WASHER, MOUNTING COVER SCREW
28 11-35888 NUT, MOUNTING COVER SCREW
29 75304T1 MOUNT, RUBBER-LOWER
30 12-28053 WASHER, RUBBER-LOWER MOUNT
31 12-28051 WASHER, LOWER MOUNT
32 12-30119 WASHER, MOUNTING SCREW (1/8")
33 11-25096 NUT, MOUNTING SCREW
34 10-75284 SCREW, LOWER MOUNT (5 1/2")
35 25067 BUMPER, RUBBER-MOUNTING SCREW
36 28242 COVER, LOWER MOUNT (STARBOARD SIDE)
37 10-29256 SCREW, LOWER MOUNT COVER FASTENING
38 22-390721 PLUG,GREASE-REVERSE LOCK HOLE
39 12-28053 WASHER, RUBBER - LOWER MOUNT SCREW
40 75304T1 MOUNT, RUBBER - LOWER
41 12-30119 WASHER, LOWER MOUNT SCRW (1/8")
42 11-25096 NUT, LOWR MOUNT SCREW
43 28242 COVER, LOWER MOUNT (STARBOARD SIDE)
44 10-29256 SCREW, LOWER MOUNT COVER TO DRIVE SHAFT HOUSING
45 22-390721 PLUG, GREASE - REVERSE LOCK HOLE
▶FLYWHEEL ASSEMBLY AND STATOR (16 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
4 215-2026A2 FLYWHEEL ASSEMBLY Comment: SERIAL )1480088-01480159
5 29788 FLANGE, FLYWHEEL PULLEY
6 30306 PULLEY, FLYWHEEL
7 29787 HUB, FLANGE - FLYWHEEL PULLEY
8 17-26618 DOWEL PIN, FLYWHEEL PULLEY
9 50-25263 RATCHET, FLYWHEEL LATER FLYWHEELS HAVE CAST ON RATCHET
10 10-29238 SCRW,RATCHET TO FLYWHL LATER FLYWHEELS HAVE CAST ON RATCHET
11 398-2085A1 STATOR, ALTERNATOR - FLYWHEEL
12 22647 DISCONNECT, KNIFE SPLICE - STATOR LEAD WIRE
13 32-61115 SLEEVE, RUBBER - STATOR LEAD WIRE
14 10-57021 SCREW, STATOR TO UPPER END CAP Comment: SERIAL )1480088-01480159
15 54-24836 CLIP, STATOR LEAD TO CRANKCASE FLANGE
16 10-8M0113176 SCREW, STATOR LEAD CLIP FASTENING
▶FUEL PUMP ASSEMBLY (29 parts) FUEL PUMP ASSEMBLY
Ref OEM Part # Part Name
1 30269A2 FUEL PUMP ASSEMBLY
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 FUEL 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 30186 ADAPTOR, CHECK UNIT ( FUEL LINE )
21 30187 STEM, CHECK UNIT ADAPTOR
22 25-16524 O RING, ADAPTOR STEM
23 24-30189 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
27A 32-32094 FUEL LINE, FUEL PUMP TO FILTER TO FILTER
28 22-25956 TEE ASSEMBLY, LOWER FILTER
▶GEAR HOUSING ASSEMBLY, COMPLETE(MERC 450M & 500E-1) (PAGE 1) (47 parts) GEAR HOUSING ASSEMBLY, COMPLETE(MERC 450M & 500E-1) (PAGE 1)
Ref OEM Part # Part Name
- 1626-1972A3 GEAR HOUSING ASSEMBLY, COMPLETE (STANDARD) - SEE NOTE BELOW
1 1626-1972A1 GEAR HOUSING ASSEMBLY
2 16-32027 STUD, WATER PUMP BODY AND BASE TO GEAR HOUSING
3 16-32017 STUD, GEAR HOUSING TO DRIVE SHAFT HOUSING
4 31-62091T BEARING, ROLLER - DRIVE SHAFT
5 56622A1 SHAFT, SHIFT - LOWER
6 53-29641 CLIP, RETAINING - SHIFT SHAFT
7 25-25439 "O" RING, SHIFT SHAFT BUSHING
8 23-46284A1 BUSHING ASSEMBLY, SHIFT SHAFT
9 26-892361 OIL SEAL, SHIFT SHAFT BUSHING
10 52918 CAM, LOWER - REVERSE LOCKING
11 52919 CAM, UPPER - REVERSE LOCKING
12 45-38466 DRIVE SHAFT (STANDARD)
13 15-20929A1 SHIM, DRIVE SHAFT BEARING TO GEAR HOUSING
14 30-72961 BEARING, BALL - DRIVE SHAFT
15 53-29116 RING, SNAP - BALL BEARING RETAINING
16 15-20929A1 SHIM, BEARING TO WATER PUMP BASE
17 43-20834 GEAR, PINOIN - DRIVE SHAFT
18 14-29163 TAB WASHER, PINOIN GEAR FASTENING SCREW
19 10-20925 SCREW, PINOIN GEAR TO DRIVE SHAFT
20 25-26855 "O" RING, WATER PUMP BASE
21 46-32012A1 WATER PUMP BASE ASSEMBLY
22 26-90562 OIL SEA, WATER PUMP BASE
23 17-29596T DOWELL PIN, WATER PUMP BASE TO WATER PUMP BODY
24 16-20990 STUD, WATER PUMP BASE
25 26-32005 SEAL, WATER PUMP BODY TO WATER INTAKE TUBE
26 32-31994 TUBE, WATER INTAKE - GEAR HOUSING
27 26-38970 SEAL, WATER INTAKE TUBE TO GEAR HOUSING
28 23-32052 SLEEVE, WATER INTAKE TUBE
29 27-32011 GASKET, LOWER - WATER PUMP BASE TO FACE PLATE
30 32009 PLATE, FACE - WATER PUMP BASE TO WATER PUMP BODY
31 27-32010 GASKET, UPPER - FACE PLATE TO WATER PUMP BODY
32 47-89983T IMPELLER, WATER PUMP
33 28-8M0032837 PIN, IMPELLER DRIVE
34 46-32013A1 WATER PUMP BODY ASSEMBLY
35 32001 INSERT, WATER PUMP BODY
36 26-32121 OIL SEA, WATER PUMP BODY
37 13-26992 LOCKWASHER, WATER PUMP BODY AND BASE STUDS
38 11-29598 NUT, WATER PUMP BODY AND BASE FASTENING STUDS
39 26-25192 SEAL, WATER PUMP BODY TO WATER INLET TUBE
40 25-20273 RING, RUBBER - CENTRIFUGAL SLINGER (DRIVE SHAFT)
41 25-29619 "O" RING, UPPER - DRIVE SHAFT
42 10-29608 SCREW, GEAR HOUSING FLUSHING HOLE
43 16-68202 GASKET, GEAR HOUSING FLUSHING HOLE SCREW
44 26-8M0214917 SEAL, GEAR HOUSING FLUSHING HOLE
45 10-79953Q04 SCREW, GREASE FILLER AND VENT HOLE
46 12-191833 WASHER, GREASE FILLER AND VENT HOLE SCREW
▶GEAR HOUSING ASSEMBLY, COMPLETE(MERC 450M & 500E-1) (PAGE 2) (38 parts) GEAR HOUSING ASSEMBLY, COMPLETE(MERC 450M & 500E-1) (PAGE 2)
Ref OEM Part # Part Name
- 1626-1972A3 GEAR HOUSING ASSEMBLY, COMPLETE (STANDARD) - SEE NOTE BELOW
-- 43-20975A5 REVERSE GEAR ASSEMBLY, COMPLETE
1 1626-1972A1 GEAR HOUSING ASSEMBLY (SEE PAGE FOR PARTS BREAKDOWN)
47 760394 CAM, SHIFT
48 20930 FOLLOWER, CAM
49 20843 SLIDE, CROSS PIN
50 24-20254 SPRING, COMPRESSION - CAM FOLLOWER
51 15-31154A1 SHIM, BEARING CUP TO GEAR HOUSING
52 43-20975A5 FORWARD GEAR ASSEMBLY
53 31-20249 BEARING, ROLLER - FORWARD GEAR ASSEMBLY
54 31-31215A1 TAPERED ROLLER BEARING ASSEMBLY
55 31-31216 CUP, TAPERED ROLLER BEARING
56 52-32189 RATCHET, SLIDING CLUTCH
57 17-20841 PIN, CROSS - RATCHET TO PROPELLER SHAFT
58 53-20842 RING, RETAINING - CROSS PIN
59 44-32000 SHAFT, PROPELLER
60 43-20975A5 REVERSE GEAR ASSEMBLY
61 12-32004 WASHER, THRUST - REVERSE GEAR
62 30-20839T BEARING, BALL - REVERSE GEAR
63 15-20927A1 SHIM, THRUST WASHER TO GEAR HOUSING
64 25-31986 "O" RING, BEARING CARRIER
65 53014T1 BEARING CARRIER ASSEMBLY
66 31-20249 BEARING, ROLLER - BEARING CARRIER
67 26-90562 OIL SEAL, BEARING CARRIER
68 28-30281 KEY, LOCATING - BEARING CARRIER
69 12-31993 WASHER, GEAR HOUSING COVER
70 11-87763 COVER, GEAR HOUSING
71 12-25251 WASHER, BACKING - PROPELLER SHAFT (1/8)
72 38859A1 THRUST HUB AND WASHER ASSEMBLY
73 12-31992 WASHER, CUPPED - THRUST HIB
74 12-32007 WASHER, SPLINED - PROPELLER SHAFT
75 11-82671120 NUT, PROPELLER
76 31237 WATER PICKUP, GEAR HOUSING
77 27-30557 GASKET, WATER PICKUP TO GEAR HOUSING
78 10-30559 SCREW, WATER PICKUP TO GEAR HOUSING
79 13-8M0204647 LOCKWASHER, WATER PICKUP FASTENING SCREW
80 11-8M0204653 NUT, DRIVE SHAFT HOUSING TO GEAR HOUSING STUD (7/16)
81 11-23161 NUT, DRIVE SHAFT HOUSING TO GEAR HOUSING STUD (3/8)
▶GEAR HOUSING ASSEMBLY, COMPLETE(MERC 500M & E) (PAGE 1) (34 parts) GEAR HOUSING ASSEMBLY, COMPLETE(MERC 500M & E) (PAGE 1)
Ref OEM Part # Part Name
- 1603-1868A2 GEAR HOUSING ASSEMBLY, COMPLETE Comment: SEE NOTE BELOW
1 1603-1868A1 GEAR HOUSING ASSEMBLY
2 16-8M0133358 STUD, GEAR HOUSING TO DRIVE SHAFT HOUSING
3 31-62091T BEARING, ROLLER - DRIVE SHAFT
4 25136 SHAFT, SHIFT - LOWER
5 53-29641 CLIP, RETAINING - SHIFT SHAFT
6 23-46284A1 BUSHING ASSEMBLY, SHIFT SHAFT
7 26-892361 OIL SEAL
8 25-25439 "OIL" RING, SHIFT SHAFT BUSHING
9 52918 CAM, LOWER - REVERSE LOCKING
10 52919 CAM, UPPER - REVERSE LOCKING
11 45-29617A1 DRIVE SHAFT ASSEMBLY
12 53-29116 RING, RETAINING - BALL BEARING
13 43-20834 GEAR, PINION
14 14-29163 TAB WASHER, PINION GEAR SCREW
15 10-20925 SCREW, PINION GEAR TO DRIVE SHAFT
16 15-20929A1 SHIM, DRIVE SHAFT BEARING TO HSG.
17 30-72961 BEARING, BALL - DRIVE SHAFT
18 25-26722 "O"RING, WATER PUMP CARTRIDGE
19 46-29117A1 WATER PUMP CARTRIDGE ASSEMBLY
20 26-90562 OIL SEAL
21 28091 INSERT, WATER PUMP CARTRIDGE
22 28-28657 KEY, WATER PUMP CARTRIDGE
23 47-89983T IMPELLER, WATER PUMP
24 28-8M0032837 PIN, IMPELLER DRIVE
25 20272 PLATE, OUTLET - WATER PUMP COVER
26 20270A2 WATER PUMP COVER ASSEMBLY
27 26-23517 OIL SEAL
28 25-20273 RING, RUBBER - CENTRIFUGAL SLINGER
29 25-29619 "O"RING, UPPER - DRIVE SHAFT
30 10-79953Q04 SCREW, GREASE FILLER AND FLUSHING HOLE
31 12-191833 WASHER, GREASE FILLER AND FLUSHING HOLE SCREW
32 10-28653 SCREW, GEAR HOUSING VENT
33 19643 WASHER, GEAR HOUSING VENT SCREW
▶GEAR HOUSING ASSEMBLY, COMPLETE(MERC 500M & E) (PAGE 2) (35 parts) GEAR HOUSING ASSEMBLY, COMPLETE(MERC 500M & E) (PAGE 2)
Ref OEM Part # Part Name
- 1603-1868A2 GEAR HOUSING ASSEMBLY, COMPLETE Comment: SEE NOTE BELOW
-- 43-20975A5 REVERSE GEAR ASSEMBLY, COMPLETE
1 1603-1868A1 GEAR HOUSING ASSEMBLY Comment: SEE PAGE 34 FOR PARTS BREAKDOWN
34 32-23652 TUBE, WATER INLET - LOWER
35 23-23651 SLEEVE, WATER INLET TUBE
36 26-20232 SEAL, WATER TUBE
37 35-23654 SCREEN, WATER INTAKE - GEAR HOUSING
38 760394 CAM, SHIFT
39 20930 FOLLOWER, CAM
40 20843 SLIDE, CROSS PIN
41 24-20254 SPRING, CAM FOLLOWER PIN
42 15-31154A1 SHIM, TAPERED BEARING CUP TO HOUSING
43 31-31215A1 TAPERED ROLLER BEARING ASSEMBLY
44 31-31216 CUP, TAPERED ROLLER BEARING
45 43-20975A5 FORWARD GEAR ASSEMBLY
46 31-20249 BEARING, ROLLER - FORWARD GEAR
47 52-32189 RATCHET, SLIDING CLUTCH
48 17-20841 PIN, CROSS - RATCHET TO PROPELLER SHAFT
49 53-20842 RING, RETAINING - CROSS PIN
50 44-25254 SHAFT, PROPELLER
51 43-20975A5 REVERSE GEAR ASSEMBLY
52 20864 RING, ADAPTOR - BALL BEARING
53 30-20839T BEARING, BALL - REVERSE GEAR
54 15-20927A1 SHIM, ADAPTOR RING TO GEAR HOUSING
55 25-20863 "O"RING, BEARING CARRIER
56 20862A1 BEARING CARRIER ASSEMBLY
57 31-20249 BEARING, ROLLER
58 26-90562 OIL SEAL
59 12-22970 WASHER, GEAR HOUSING COVER
60 20865 COVER, GEAR HOUSING
61 12-25251 WASHER, BACKING (1/8)
62 48-22914A2 PROPELLER ASSEMBLY, COMPLETE (2 BLADE - ALUMINUM)
63 12-25252 WASHER, BACKING (1/32)
64 14-25250 TAB WASHER, PROPELLER NUT
65 11-29825 NUT, PROPELLER (NYLON)
▶GEAR HOUSING ASSEMBLY, COMPLETE(MERC 500M-2 & 500E-2) (P. 1) (43 parts) GEAR HOUSING ASSEMBLY, COMPLETE(MERC 500M-2 & 500E-2) (P. 1)
Ref OEM Part # Part Name
- 1626-2040A3 GEAR HOUSING ASSEMBLY, COMPLETE (STANDARD) -SEE NOTE BELOW
1 1626-2040A1 GEAR HOUSING ASSEMBLY
2 16-32027 STUD,WATER PUMP BODY AND BASE TO GEAR HOUSING
3 16-32017 STUD,GEAR HOUSING TO DRIVE SHAFT HOUSING
4 31-62091T BEARING, ROLLER - DRIVE SHAFT
5 56622A1 SHAFT,SHIFT - LOWER
6 53-29641 CLIP,RETAINING - SHIFT SHAFT
7 25-25439 "O"RING,SHIFT SHAFT BUSHING
8 23-46284A1 BUSHING ASSEMBLY,SHIFT SHAFT
9 26-892361 OIL SEAL,SHIFT SHAF BUSHING
10 52918 CAM,LOWER - REVERSE LOCKING
11 52919 CAM,UPPER - REVERSE LOCKING
12 45-38466 DRIVE SHAFT(STANDARD)
13 15-20929A1 SHIM,BEARING TO GEAR HOUSING
14 30-72961 BEARING,BALL - DRIVE SHAFT
15 53-29116 RING,SNAP - BALL BEARING RETAINING
16 15-20929A1 SHIM,BEARING TO WATER PUMP BASE
17 43-20834 GEAR,PINION - DRIVE SHAFT
18 14-29163 TAB WATER,PINION GEAR FASTENING SCREW
19 10-20925 SCREW, PINION GEAR TO DRIVE SHAFT
20 27-32771 GASKET,WATER PUMP BASE TO GEAR HOUSING
21 25-26855 "O"RING,WATER PUMP BASE
22 46-39531A1 WATER PUMP BASE ASSEMBLY
23 26-90562 OIL SEAL,WATER PUMP BASE
24 17-29596T DOWEL PIN,WATER PUMP BASE TO WATER PUMP BODY
25 27-19553 GASKET,LOWER - WATER PUMP BASE TO FACE PLATE
26 32768 PLATE,FACE - WATER PUMP BASE TO WATER PUMP BODY
27 27-19551 GASKET,UPPER - FACE PLATE TO WATER PUMP BODY
28 47-89983T IMPELLER,WATER PUMP
29 28-8M0032837 PIN,IMPELLER DRIVE
30 46-60366Q1 WATER PUMP BODY ASSEMBLY
31 32001 INSERT,WATER PUMP BODY
32 26-32121 OIL SEAL,WATER PUMP BODY
33 13-26992 LOCKWASHER,WATER PUMP BODY AND BASE STUDS
34 11-29598 NUT,WATER PUMP BODY AND BASE FASTENING STUDS
35 26-25192 SEAL,WATER PUMP BODY TO WATER INLET TUBE
36 25-20273 RING,RUBBER - CENTRIFUGAL SLINGER(DRIVE SHAFT)
37 25-29619 "O"RING,UPPER - DRIVE SHAFT
38 10-29608 SCREW,GEAR HOUSING FLUSHING HOLE
39 27-8M0214916 GASKET,GEAR HOUSING FLUSHING HOLE SCREW
40 26-8M0214917 SEAL,GEAR HOUSING FLUSHING HOLE
41 10-79953Q04 SCREW,GREASE FILLER AND VENT HOLE
42 12-191833 WASHER,GREASE FILLER AND VENT HOLE SCREW
▶GEAR HOUSING ASSEMBLY, COMPLETE(MERC 500M-2 & 500E-2) (P. 2) (35 parts) GEAR HOUSING ASSEMBLY, COMPLETE(MERC 500M-2 & 500E-2) (P. 2)
Ref OEM Part # Part Name
- 1626-2040A3 GEAR HOUSING ASSY.COMP.(STANDARD)-SEE NOTE BELOW
1 1626-2040A1 GEAR HOUSING ASSEMBLY(SEE PAGE 42 FOR PARTS BREAKDOWN)
43 760394 CAM,SHIFT
44 20930 FOLLOWER,CAM
45 20843 SLIDEE,CROSS PIN
46 24-20254 SPRING,COMPRESSION - CAM FOLLOWER
47 15-31154A1 SHIM,BEARING CUP TO GEAR HOUSING
48 43-20975A5 FORWARD GEAR ASSEMBLY
49 31-20249 BEARING,ROLLER - FORWARD GEAR ASSEMBLY
50 31-31215A1 TAPARED ROLLER BEARING ASSEMBLY
51 31-31216 CUP,TAPERED ROLLER BEARING
52 52-32189 RATCHET,SLIDING CLUTCH
53 17-20841 PIN,CROSS - RATCHET TO PROPELLER SHAFT
54 53-20842 RING,RETAINING - CROSS PIN
55 44-32000 SHAFT,PROPELLER
56 43-20975A5 REEVERSE GEAR ASSEMBLY
57 12-32004 WASHER,THRUST - REVERSE GEAR
58 30-20839T BEARING,BALL - REVERSE GEAR
59 15-20927A1 SHIM,THRUSTT WASHER TO GEAR HSG.
60 25-31986 "O"RING,BEARING CARRIER
61 53014T1 BEARING CARRIER ASSEMBLY
62 31-20249 BEARING,ROLLER - BEARING CARRIER
63 26-90562 OIL SEAL,BEARING CARRIER
64 28-30281 KEY,LOCATING - BEARING CARRIER
65 12-31993 WASHER,GEAR HOUSING COVER
66 11-87763 COVER,GEAR HOUSING
67 12-25251 WASHER,BACKING - PROPELLER SHAFT(1/8)
68 38859A1 THRUSTT HUB AND WAHSER ASSEMBLY
69 12-31992 WASHER,CUPPED - THRUST HUB
70 12-32007 WASHER,SPLINED - PROPELLER SHAFT
71 11-82671120 NUT,PROPELLER
72 97-31640Q4 TRIM TAB,GEAR HOUSING
73 10-32470 SCREW,TRIM TAB TO GEAR HOUSING
74 11-8M0204653 NUT,DRIVE SHAFT HOUSING TO GEAR HOUSING ST(7/16)
75 11-23161 NUT,DRIVE SHAFT HOUSING TO GEAR HOUSING STUD(3/8)
▶MAGNETO ADAPTOR AND PILOT ASSEMBLY (63 parts) MAGNETO ADAPTOR AND PILOT ASSEMBLY
Ref OEM Part # Part Name
- 29321A7 MAGNETO ADAPTOR AND PILOT ASSEMBLY, COMPLETE
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 10-31009 SCREW, THROTTLE ACTUATOR TO ECONOMISER COLLAR
14 12-847883 WASHER, THROTTLE ACTUATOR SCREW
15 27947 SWIVEL, LINKAGE-ECONMISER 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
22 27955 CAP, MAGNETO ADAPTOR AND PILOT FASTENING
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)
29 10-24933 SCREW, THROTTLE STOP ADJUSTING
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
35 29783A1 DRIVEN PULLEY ASSEMBLY
36 17-24873 ROLL PIN. FLANGE LOCATING
37 29785 FLANGE, DRIVEN PULLEY
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 LINKS RODS
44 28061 LEVER, LINKAGE-UPPER
45 27941 LEVER, LINKAGE-LOWER
46 27950 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
56 84-821945A46 CABLE, HIGH TENSION LEAD-SPARK PLUG
57 25-25429 "O" RING, HIGH TENSION HEAD 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 (INTERNAL PARTS) (46 parts) MAGNETO ASSEMBLY (INTERNAL PARTS)
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 MAGNETO ROTOR AND SHAFT
6 30-49090 BEARING, BALL (OPPOSITE DRIVE END)
7 394-1637 SUPPORT, BALL BEARING
8 10-25509 SCREW AND LOCKWASHER, SUPPORT FRAME
9 84-60466A13 WIRE ASSEMBLY, PRIMARY GROUNG LEAD
10 10,10-29182 SCREW, PRIMARY GROUND
11 12-30267 WASHER, PRIMARY GROUND TERMINAL HOLDING
12 394-1579 INSULATOR, PRIMARY GORUND TERMINAL
13 12-29099 WASHER, INSULATING - PRIMARY GROUNG 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
25 11-29236 NUT, PRIMARY LEAD FASTENING
26 394-1106A1 HOLDER AND CAM WICK ASSEMBLY
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 ASEMBLY
37 394-1110 CLIP, SPRING
38 27-25725 GASKET, END CAP COVER
39 394-1561A2 END CAP COVER ASSEMBLY
40 394-1056A1 BRUSH AND SPRING ASSEMBLY
41 10-25517 SCREW, HIGH TENSION CABLE FASTENING
42 29121 PIPE PLUG, END CAP COVER
43 10-29418 SCREW, END CAP COVER TO MAGNETO COVER
44 14-29157 TAB WASHER, COVER FASTENING SCREW
45 22-996642 ELBOW, PLASTIC - MAGNETO COVER VENT
▶STARTER MOTOR, STARTER SOLENOID, RECTIFIER AND WIRING HARNES (37 parts) STARTER MOTOR, STARTER SOLENOID, RECTIFIER AND WIRING HARNES
Ref OEM Part # Part Name
1 32177A2 RECTIFIER ASSEMBLY
2 13-8M0204647 LOCKWASHER, RECTIFIER MOUNTING SCREW
3 11-21929 NUT, RECTIFIER MOUNTING SCREW
4 32-28373 SLEEVE, RECTIFIER LEADS
5 10-35400 SCREW, HARNESS AND STATOR LEADS TO RECTIFER
6 11-8M0204718 NUT, HARNESS AND STATOR LEAD FASTENING SCREW
7 32177A2 RECTIFIER ASSEMBLY
8 32-61115 SLEEVE, RECTIFIER ( RED LEAD WIRE )
9 22647 DISCONNECT, KNIFE - RECTIFIER LEAD WIRE
10 13-8M0204647 BLOCKWASHER, RECTIFIER MOUNTING SCREW
11 11-21929 NUT, RECTIFIER MOUNTING SCREW
12 28597 BRACKET, RECTIFIER MOUNTING
13 10-21091 SCREW, RECTIFIER BRACKET TO BOTTOM COWL
14 11-24652 NUT, BRACKET MOUNTING SCREW
15 50-55601A2 STARTER MOTOR (DELCO-REMY) SEE NOT BELOW
16 10-22698 SCREW, STARTER MOTOR TO CRANKCASE FLANGE
17 13-8M0204647 LOCKWASHER, STARTER MOTOR MOUNTING SCREW
18 84-93389A12 WIRE, STARTER MOTOR TO STARTER SOLENOID
19 10-69035 SCREW, GROUND WIRE TO STARTER MOTOR
20 13-26992 LOCKWASHER, GROUND WIRE FASRENING SCREW
21 28016A1 GROUND STRAP ASSEMBLY
22 32445A1 STARTER SOLENOID
23 10,13-26996 LOCKWASHER, SOLENOID TERMINAL
24 10,11-68219 NUT, SOLENOID TERMINAL
25 13-8M0204647 LOCKWASHER, SOLENOID (5/16)
26 11-22053 NUT, SOLENOID TERMINAL - INSIDE (5/16)
27 11-26062 NUT, CAP - SOLENOID TERMINAL - OUTSIDE (5/16)
28 10-29238 SCREW, STARTER SOLENOID TO STARTER MOTOR
29 54-24836 CLAMP, HARNESS LEAD WIRE (1/4)
30 54-25231 CLAMP, HARNESS LEAD LEAD WIRE (1/8)
31 8M0084613 "D" WASHER, CLAMP FASTENING SCREW
32 10-8M0113176 SCREW, HARNESS LEAD WIRE FASTENING
33 33401 WIRING HARNESS (INTERNAL)
34 26079A2 PLATE, BACKING - WIRING HARNESS
35 10-45893 SCREW. BACKING PLATE TO BOTTOM COWL
36 24-28975 SPRING, GARTER - INTERNAL WIRING HARNESS
37 54-22783 "S" CLIP, WIRING HARNING LEAD TO BOTTOM COWL
▶TOP COWL AND STARTER ASSEMBLY (49 parts) TOP COWL AND STARTER ASSEMBLY
Ref OEM Part # Part Name
-- 37-46023A1 DECAL SET, TOP COWL
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 23-20326 SPACER, TOP COWL STUD
13 12-20028 WASHER, TOP COWL STUD (1/16")
14 12-69057 WASHER, TOP COWL STUD (3/4" OD)
15 12-20583 WASHER, TOP COWL STUD (1/32")
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 Comment: SEE NOTE BELOW
21 30596 PAWL, STARTER Comment: SEE NOTE BELOW
22 13-36206 WASHER, WAVE - STARTER PAWL Comment: SEE NOTE BELOW
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 Comment: SEE NOTE BELOW
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 31119 PAD, 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 SPACER, 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 450 (4 CYL.) running reliably season after season. Most of these tasks can be performed with basic tools and the factory service manual.

  1. Replace water pump impeller and inspect wear plate
  2. Change engine oil and oil filter (check drain plug washer)
  3. Replace spark plugs and check ignition timing
  4. Drain and refill lower unit gear oil; inspect for water contamination
  5. Inspect fuel lines, primer bulb, and fuel filter for deterioration
  6. Check and replace sacrificial anodes (zinc or aluminum)
  7. Inspect propeller for damage; check shaft seal and cotter pin
  8. Check valve clearance (refer to service manual for specifications)
  9. Lubricate all grease points (steering, tilt tube, shift linkage)
  10. Inspect control cables and throttle/shift linkage for smooth operation
  • Pro Tip: Always flush the engine with fresh water after saltwater use — even a quick 10-minute flush significantly extends component life.
  • Pro Tip: Use fuel stabilizer in the tank before winter storage, and fog the cylinders to prevent internal corrosion during extended periods of non-use.

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