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Mercury 500 (1421113 THRU 1639472) Parts & Diagrams

🔎 Mercury 500 Reference Library — Exploded parts diagrams (22 diagrams), specifications, common issues, and maintenance checklist.

The Mercury 500 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	50 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)	650 ± 50 RPM (in gear)
Full Throttle RPM Range	5000-6000
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 500:

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 500.

▶BOTTOM COWL ASSEMBLY (54 parts)

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)

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)

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)

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)

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)

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)

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)

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)

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)

Ref	OEM Part #	Part Name
1	1545-2337A4	DRIVE SHAFT HOUSING
2	32-31998	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	35394A1	COVER, TRIM - DRIVE SHAFT HOUSING
7	10-30742	SCREW, TRIM COVER TO DRIVE SHAFT HOUSING
8	37-32109	DECAL, "FULL GEAR SH IFT" - STARBOARD
9	37-32110	DECAL, "FULL GEAR SHIFT" - PORT
10	32016	BAFFLE, EXHAUST RELIEF
11	10-25255	SCREW, RELIEF BAFFLE TO DRIVE SHAFT HOUSING
12	27-31995	GASKET, DRIVE SHAFT HOUSING TO BOTTOM COWL
13	11-862902	NUT, POWERHEAD STUDS
14	19-29850	PLUG, PLASTIC - WATER PICK-UP SCREW HOLE
15	16-8M0022145	STUD, DRIVE SHAFT HOUSING TO GEAR HOUSING (1 3/4")
16	16-57935	STUD, DRIVE SHAFT HOUSING TO GEAR HOUSING (3")
17	11-8M0204653	NUT, GEAR HSG, TO DRIVE SHAFT HOUSING STUDS (7/16)
18	18-25191	COTTER PIN, PUSH ROD TO REVERSE LOCK
19	28470	ROD, PUSH - REVERSE LOCK
20	17-24887	PIN, REVERSE LOCK LEVER
21	24-25122	SPRING, TENSION - PUSH ROD
22	52920	LEVER, REVERSE LOCK
23	25305	CAP, RUBBER - UPPER MOUNT BOLT NUT
24	11-23161	NUT, UPPER MOUNT BOLT
25	12-30519	WASHER, UPPER MOUNT BOLT (3/8 ID)
26	12-30521	WASHER, RUBBER - UPPER MOUNT BOLT
27	12-30520	WASHER, UPPER MOUNT BOLT (37/64 ID)
28	79680A1	COVER, UPPER MOUNT - OUTSIDE HALF
29	79680A1	COVER, UPPER MOUNT - INSIDE HALF
30	75305	MOUNT, RUBBER - UPPER
31	24929	PACKING, "U" CUP - UPPER MOUNT COVERS
32	10-37941	SCREW, UPPER MOUNT COVER - REAR (1 3/4")
33	10-28772	SCREW, UPPER MOUNT COVER - FRONT (1 1/2")
34	12-8M0204649	WASHER, MOUNT COVER FASTENING SCREW
35	11-35888	NUT, UPPER MOUNT COVER FASTENING SCREW
36	25067	BUMPER, RUBBER - LOWER MOUNT SCREW
37	10-75284	SCREW, LOWER MOUNT (5 1/2")
38	12-28051	WASHER, LOWER MOUNT SCREW
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)

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)

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)

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)

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)

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)

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)

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)

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)

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)

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)

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)

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 500 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.

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