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Mercury 500 (2116318 THRU 2305100) Parts & Diagrams

🔎 Mercury 500 Reference Library — Exploded parts diagrams (20 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 AND SHIFT LINKAGE (65 parts)

Ref	OEM Part #	Part Name
1	2116-2990A1	BOTTO COWL ASSEMBLY
2	29206	COVER, PLUG - BOTTOM COWL HARNESS HOLE
3	10-45893	SCREW, PLUG COVER TO BOTTOM COWL (REMOVE - NOT REQUIRED O
4	13-26995	LOCKWASHER, PLUG COVER SCREW
5	11-26419	NUT, PLUG COVER SCREW
6	16-68169	STUD, BOTTOM COWL TO REAR SUPPORT BRACKET
7	11-8267089	NUT, BOTTOM COWL STUD
8	32-8M0108355	TUBE, VENT - MAGNETO OUTLET (8 3/4")
9	22-31521	ELBOW, MAGNETO VENT TUBE TO BOTTOM COWL
10	21104A2	CONNECTOR BASE ASSEMBLY
11	13-21972	LOCKWASHER, CONNECTOR BASE
12	11-21971	NUT, CONNECTOR BASE TO BOTTOM COWL
13	54-25231	CLIP, CONNECTOR BASE LEAD WIRE
14	10-22815	SCREW, LEAD WIRE CLIP TO BOTTOM COWL
15	60948A1	COVER PLATE ASSEMBLY
16	37944	PAD, SOUND - COVER PLATE
17	10-8M0113176	SCREW, COVER PLATE TO BOTTOM COWL
18	37695	BOOT, CONTROL CABLE
19	23760	BAFFLE, BOTTOM COWL
20	10-21106	SCREW, BAFFLE TO BOTTOM COWL
21	37637	BOOT, FUEL CONNECTOR
22	37692	SUPPORT, EXTERNAL WIRING HARNESS
23	10-21937	SCREW, HARNESS SUPPORT TO BOTTOM COWL (2")
24	11-8M0207775	NUT, HARNESS SUPPORT SCREW
25	32-8M0108355	HOSE, WATER TELL TALE - CYLINDER BLOCK TO BOTTOM COWL
26	22-291112	CONNECTOR, WATER TELL TALE HOSE - BOTTOM COWL
27	54-22976	CLAMP, WATER TELL TALE HOSE TO CONNECTOR
28	42819A2	PLATE ASSEMBLY, EXHAUST EXTENSION
29	12-38453	WASHER, NYLON - WATER INLET TUBE
30	26-38452	SEAL, RUBBER - WATER TUBE
31	38500	REATINER - WATER TUBE SEAL
32	10-69069	SCREW, RETAINER TO EXHAUST EXTENSION PLATE
33	10-56500	SCREW, EXHAUST EXTENSION PLATE TO DRIVE SHAFT HOUSING
34	11-8M0207775	NUT, EXHAUST EXTENSION PLATE SCREW
35	59037A2	LEVER, QUICK DISCONNECT - THROTTLE AND SHIFT CABLES
36	24-38005	SPRING, COMPRESSION - QUICK DISCONNECT LEVER
37	23-37927	BEARING, NYLON - QUICK DISCONNECT LEVER
38	17-239281	PIN, ROLL - QUICK DISCONNECT LEVER
39	37926	RETAINER, NYLON BEARING TO EXHAUST EXTENSION PLATE
40	10-37923	SCREW, BEARING RETAINER TO EXHAUST EXTENSION PLATE
41	27-796501	GASKET, POWERHEAD TO EXHAUST EXTENSION PLATE
42	38156	SEAL, RUBBER - EXHAUST EXTENSION PLATE
43	99136	STRIP, RUBBER SEAL RETAINING
44	10-37571	SCREW, RETAINING STRIP TO EXHAUST EXTENSION PLATE
45	27-385011	GASKET, EXHAUST EXTENSION PLATE TO DRIVE SHAFT HOUSING
46	45677A1	SHIFT SHAFT ASSEMBLY, UPPER (LONG SHAFT)
47	24-37693	SPRING, DETENT - SHIFT SHAFT
48	10-98256	SCREW, DETENT SPRING TO EXHAUST EXTENSION PLATE
49	12-69057	WASHER, DETENT SPRING SCREW
50	11-8M0207775	NUT, DETENT SPRING SCREW
51	37948A5	ACTUATOR, SHIFT CONTROL
52	12-24664	WASHER, SHIFT CONTROL ACTUATOR
53	11-8267089	NUT, SHIFT CONTROL ACTUATOR TO UPPER SHIFT SHAFT
54	24-37934	SPRING, QUICK DISCONNECT - SHIFT CABLE
55	10-38069	SCREW, QUICK DISCONNECT SPRING TO SHIFT CONTROL ACTUATOR
56	37932	BEARING, NYLON - SHIFT CONTROL ACTUATOR
57	10-36137	SCREW, BEARING TO SHIFT CONTROL ACTUATOR
58	13-21272	LOCKWASHER, BEARING SCREW
59	37935	RAIL, SHIFT CONTROL BEARING
60	10-69028	SCREW, RAIL TO EXHAUST MANIFOLD COVER
61	13-26992	LOCKWASHER, RAIL SCREW
62	46933A1	GROUND STRAP ASSEMBLY, CRANKCASE TO BOTTOM COWL (3 5/8") S Comment: SERIAL 02167844-09999999
63	46933A2	GROUND STRAP ASSEMBLY, DRIVE SHAFT HOUSING TO BOTTOM COWL (3 Comment: SERIAL 02167844-09999999
64	10-45218	SCREW, GROUND STRAP Comment: SERIAL 02167844-09999999
65	13-69432	WASHER, GROUND STRAP SCREW Comment: SERIAL 02167844-09999999

▶CARBURETOR ASSEMBLY (38 parts)

Ref	OEM Part #	Part Name
--	1395-92621	REPAIR PARTS KIT (1 PER CARBURETOR)
1	1333-3015	CARBURETOR ASSEMBLY, COMPLETE (KA-21C)
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 (SMALL)
15	1399-1135	COVER, STRAINER
16	27-25848	GASKET, STRAINER COVER SCREW
17	10-25822	SCREW, STRAINER COVER FASTENING
18	1395-6027	SCREW, THROTTLE STOP LEVER
19	8146791	LEVER, THROTTLE STOP (SEE NOTE BELOW)
20	1399-2012	SHAFT, THROTTLE
21	1399-3036	TUBE, IDLE
22	27-23180	GASKET, IDLE TUBE
23	10-20858	SCREW AND LOCKWASHER, THROTTLE SHUTTER
24	1399-3037	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	1399-1461	JET, MAIN FUEL (.061)
30	27-28409	GASKET, MAIN FUEL JET
31	1399-2785	NOZZLE, MAIN
32	10-23178	SCREW, PLUG - MAIN NOZZLE
33	24-20869	SPRING, THROTTLE SHAFT RETURN (UPPER CARBURETOR)
34	10-28845	SCREW, PLUG - BODY CHANNEL
35	19-20011	WELCH PLUG, BODY CHANNEL
36	27-757911	GASKET, CARBURETOR FLANGE
37	11-29250	NUT, CARBURETOR MOUNTING STUD

▶CARBURETOR LINKAGE AND CHOKE SOLENOID (32 parts)

Ref	OEM Part #	Part Name
1	45068	CHOKE SOLENOID, TOP COWL
2	30050	TERMINAL, CHOKE SOLENOID LEAD
3	10-26066	SCREW, CHOKE SOLENOID TO FRONT BRACKET
4	13-8M0204647	LOCKWASHER, CHOKE SOLENOID SCREW
5	11-22053	NUT, CHOKE SOLENOID SCREW
6	54-25231	CLIP, CHOKE SOLENOID LEAD
7	10-8M0113176	SCREW, CHOKE SOLENOID CLIP ATTACHING
8	8M0084613	"D" WASHER, CHOKE SOLENOID CLIP SCREW
9	48315A4	PLUNGER AND LINK ASSEMBLY, CHOKE SOLENOID
10	12-30164	WASHER, PLUNGER AND LINK
11	18-26953	COTTER PIN, LINK TO UPPER CHOKE SHUTTER
12	90242A1	KNOB, CHOKE ROD
13	25-20116	GROMMET, CHOKE KNOB
14	46303	"U" LINK, CHOKE ROD TO CHOKE KNOB
15	10-69022	SCREW, "U" LINK TO CHOKE KNOB
16	13-26996	LOCKWASHER, "U" LINK SCREW
17	18-210711	COTTER PIN, "U" LINK TO CHOKE ROD
18	46304	ROD, CHOKE (NOT AS SHOWN)
19	17-25391	RIVET, CHOKE SHUTTER TO CHOKE ROD
20	38604	SHUTTER, CHOKE - CARBURETOR
21	23-30438	BUSHING, NYLON - UPPER CHOKE SHUTTER
22	16-30172	STUD, CARBURETOR - CHOKE SHUTTER PIVOT
23	12-30164	WASHER, CHOKE SHUTTER CARBURETOR STUD
24	11-20110	NUT, CHOKE SHUTTER TO CARBURETOR STUD
25	1333-3015	CARBURETOR ASSEMBLY, COMPLETE
26	24-28965	SPRING, TENSION - CHOKE ROD TO CARBURETOR
27	10-28713	SCREW, TENSION SPRING TO CARBURETOR
28	27711	RETAINER, SPRING
29	53719A2	THROTTLE PICK-UP BRACKET ASSEMBLY
30	10-29239	SCREW, THROTTLE PICK-UP BRACKET MOUNTING
31	27917	CLUSTER, THROTTLE LEVER (UPPER CARBURETOR)
32	1395-6027	SCREW, CLUSTER TO THROTTLE LEVER

▶CLAMP AND SWIVEL BRACKET ASSEMBLY (43 parts)

Ref	OEM Part #	Part Name
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-.020)
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 BRACKET
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	1442-2502A1	SWIVEL BRACKET ASSEMBLY (LONG SHAFT)
19	26-32911	OIL SEAL, SWIVEL BRACKET
20	22-69059	FITTING, GREASE - SWIVEL BRACKET
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	13-20846	WASHER, WAVE - RETAINING SCREW (PORT SIDE)
28	15-37711	SHIM, RETAINING SCREW (.020) - PORT SIDE
29	13-36076	WASHER, WAVE - RETAINING SCREW (PORT SIDE)
30	11-8M0207775	NUT, ANCHOR AND RETAINING SCREW
31	12-26837	WASHER, SWIVEL PIN TO BOTTOM YOKE (.065)
32	77416T1	YOKE, BOTTOM
33	17-28419A5	SWIVEL PIN AND STEERING ARM ASSY (LONG SHAFT)
34	10-31830	SCREW, STEERING ARM TO RIDE GUIDE KIT
35	11-8M0204726	NUT, STEERING ARM SCREW
36	10-33986	BOLT, UPPER MOUNT TO SWIVEL PIN
37	30711	BUMPER, STEERING ARM
38	11-71956	NUT, RETAINING - SWIVEL PIN
39	38-56267	SERIAL PLATE
40	10-25612	SCREW, DRIVE - SERIAL PLATE TO SWIVEL BRACKET
41	10-68298	BOLT, CLAMP BRACKET TO BOAT TRANSOM
42	12-68410	WASHER, CLAMP BRACKET TRANSOM BOLT
43	11-82670912	NUT, CLAMP BRACKET TRANSOM BOLT

▶COWLING AND FRONT COVER (18 parts)

Ref	OEM Part #	Part Name
--	92-86166Q1	GLUE (BLANKET ADHESIVE)
1	2182-7927A5	COWL FRONT COVER ASSEMBLY
2	56848	KNOB, COWL FRONT COVER FASTENING
3	12-30771	WASHER, COVER FASTENING KNOB
4	12-27129	WASHER, COVER FASTENING KNOB
5	24-30772	SPRING, TENSION - COVER FASTENING KNOB
6	17-29077	PIN, ROLL - TENSION SPRING TO KNOB
7	38674	BLANKET, SOUND ABSORBING
8	31095	SEAL, SOUND - LOWER SECTION
9	38133	SEAL, SOUND - UPPER SECTION
10	2118-3247A3	WRAP AROUND COWL ASSEMBLY
11	46785A1	HANDLE, COWL LATCH EARLY STYLE
12	17-21057	PIN, HINGE - COWL LATCH EARLY STYLE
13	53-21058	"E" RING, COWL LATCH HINGE PIN EARLY STYLE
14	46785A1	SWIVEL, COWL LATCH EARLY STYLE
15	46785A1	COWL LATCH ASSEMBLY (LATE STYLE)
16	30413	HOOK, COWL LATCH FASTENING
17	37794	BLANKET, SOUND ABSORBING

▶CRANKSHAFT, PISTON AND CONNECTING ROD (29 parts)

Ref	OEM Part #	Part Name
1	11-8M0214915	NUT, FLYWHEEL
2	12-33001	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 CLAPING
11	10-28666	SCREW, CENTER MAIN BEARING CLAMPING
12	17-20379	DOWEL PIN, (STEPPED)
13	534-3267T25	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
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
29	12-28121	WASHER, NEEDLE LOCATING

▶CYLINDER BLOCK AND CRANKCASE ASSEMBLY (58 parts)

Ref	OEM Part #	Part Name
1	1100-2988A1	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 CYL. BLOCK AND CRANKCASE (.002-3-5-10
6	10-29198	SCREW, UPPER END CAP MOUNTING
7	831-5347A3	CYLINDER BLOCK AND CRANKCASE ASSEMBLY
8	90435	MOUNT, RUBBER - CRANKCASE
9	11-8M0207775	NUT, CRANKCASE RUBBER MOUNT
10	17-20032	DOWEL PIN, CYLINDER BLOCK TO MAIN BEARING
11	17-20323	DOWEL PIN, CYLINDER BLOCK TO CENTER MAIN BEARING
12	22-328022	PLUG, PIPE - WATER PRESSURE AND BALANCE TUBE HOLES
13	16-64936	STUD, CARBURETOR MOUNTING
14	16-33111	STUD, CRANKCASE TO DRIVE SHAFT HOUSING (1 9/16")
15	17-43044	DOWEL PIN, CRANKCASE TO CYLINDER BLOCK
16	16-8M0034463	STUD, CYLIDNER BLOCK TO DRIVE SHAFT HOUSING (3 7/16")
17	16-34378	STUD, CYLINDER BLOCK TO DRIVE SHAFT HOUSING (2 5/16")
18	16-29989	STUD, CYLINDER BLOCK TO DRIVE SHAFT HOUSING (1 15/16")
19	22-291112	CONNECTOR, WATER TELL TALE HOLE - CYLINDER BLOCK
20	10-69091	SCREW, CRANKCASE TO CYLINDER BLOCK (1 5/8")
21	10-22039	SCREW, CRANKCASE TO CYLINDER BLOCK (2 3/4")
22	12-20084	WASHER, CRANKCASE SCREW
23	11-29250	NUT, CRANKCASE SCREW
24	10-98260	SCREW, MAIN BEARING LOCKING
25	14-20091	TAB WASHER, BEARING LOCKING SCREW
26	10-20359	SCREW, CENTER MAIN BEARING LOCKING
27	1102-4181A3	END CAP ASSEMBLY, LOWER
28	21-28481A1	CHECK VALVE ASSEMBLY, LOWER END CAP
29	26-29478	OIL SEAL, LOWER
30	26-41953	OIL SEAL, UPPER
31	25-20081	"O" RING, LOWER END CAP
32	30-63742T	BALL BEARING, LOWER END CAP
33	15-20085A1	SHIM, LOWER END CAP TO CRANKCASE AND CYL. BLOCK (.002-3-5-10
34	10-29198	SCREW, LOWER END CAP MOUNTING
35	32-8M0108355	TUBE, BALANCE - MAIN BEARING
36	22-291112	CONNECTOR, BALANCE TUBE TO CYLINDER BLOCK
37	54-20386	CLAMP, BALANCE TUBE TO CONNECTORS
38	27-854913	GASKET, CYLINDER BLOCK TO BAFFLE PLATE
39	90421T01	PLATE, BAFFLE - EXHAUST MANIFOLD
40	27-854924	GASKET, BAFFLE PLATE TO EXHAUST COVER
41	46112A3	COVER, EXHAUST MANIFOLD
42	10-37562	SCREW, MANIFOLD COVER TO CYLINDER BLOCK (1")
43	10-39661	SCREW, MANIFOLD COVER TO CYLINDER BLOCK - HIGH TENSION CLIP
44	54-52905	CLIP, HIGH TENSION LEAD
45	1017-7054A1	COVER, CYLINDER BLOCK
46	27-85487	GAKSET, CYLINDER BLOCK COVER
47	10-20653	SCREW, CYLINDER BLOCK COVER MOUNTING
48	11-8M0207775	NUT, COVER MOUNTING SCREW
49	90435	MOUNT, RUBBER - CYLINDER BLOCK COVER
50	11-8267089	NUT, CYLINDER BLOCK COVER RUBBER MOUNT
51	27935	COVER, TRANSFER PORT
52	27-279361	GASKET, TRANSFER PORT COVER
53	10-28635	SCREW, TRANSFER PORT COVER MOUNTING (CAP HEAD)
54	22-62365A1	CHECK VALVE ASSEMBLY, BLEED HOSE (UPPER
55	21-28481A1	CHECK VALVE ASSEMBLY, BLEED HOSE VALVE
56	32-9912688	HOSE, CYLINDER BLEED (6 1/2")
57	22-67902	CONNECTOR, CYLINDER BLEED HOSE (LOWER)
58	54-20387	CLAMP, BLEED HOSE TO CHECK VALVE AND CONNECTOR

▶DISTRIBUTOR ADAPTOR AND PILOT ASSEMBLY (57 parts)

Ref	OEM Part #	Part Name
1	393-2799A20	DISTRIBUTOR ASSEMBLY, COMPLETE (FOR BREAKDOWN, SEE PAGE 11.)
2	45391	SPACER, IGNITION WIRE
3	33-896329827	SPARK PLUG (CHAMPION - L19V)
4	30109	GROUND STRAP, DISTRIBUTOR TO CRANKCASE
5	10-62568	SCREW, GROUND STRAP TO TAB BRACKET
6	53-78201	BRACKET, TAB - CRANKCASE SCREW
7	53-20067	RING, SNAP - BALL BEARING RETAINING
8	30-20066	BEARING, BALL - DISTRIBUTOR PILOT
9	45-46247	DRIVE SHAFT, DISTRIBUTOR
10	46242A1	PILOT ASSEMBLY, DISTRIBUTOR
11	10-455611	SCREW, DISTRIBUTOR PILOT TO DISTRIBUTOR
12	24-27944	SPRING, HORSESHOE
13	17-27962	PIN, SPRING TERMINAL
14	27946A1	ECONOMIZER COLLAR AND PIN ASSEMBLY
15	17-27961	PIN, SPRING RETAINER
16	22-25094	FITTING, GREASE - ECONOMIZER COLLAR
17	38230A1	THROTTLE ACTUATOR ASSEMBLY
18	23-26602	BUSHING, NYLON - THROTTLE ACTUATOR
19	10-46420	SCREW, THROTTLE ACTUATOR TO SECTOR GEAR
20	12-46246	WASHER, DISTRIBUTOR PILOT TO DISTRIBUTOR ADAPTOR
21	66856A1	ADAPTOR, DISTRIBUTOR
22	10-78841	SCREW, ADAPTOR AND PILOT TO CRANKCASE
23	12-20084	WASHER, ADAPTOR AND PILOT TO CRANKCASE SCREW
24	11-22053	NUT, ADAPTOR AND PILOT TO CRANKCASE SCREW
25	22-25094	FITTING, GREASE - DISTRIBUTOR ADAPTOR
26	12-27939	WASHER, THRUST - DISTRIBUTOR ADAPTOR
27	53-46250	RING, SNAP - BALL BEARING RETAINING
28	30-20066	BEARING, BALL - DISTRIBUTOR ADAPTOR
29	14-27960	TAB WASHER, CAP LOCKING
30	13-27959	WASHER, WAVE - TAB WASHER TENSION
31	27955	CAP, ADAPTOR AND PILOT FASTENING
32	23-29909	SPACER, DRIVEN PULLEY
33	29906A1	DRIVEN PULLEY ASSEMBLY
34	17-29908	PIN, DRIVEN PULLEY
35	29907	FLANGE, DRIVEN PULLEY
36	28-29910	KEY, DISTRIBUTOR DRIVING
37	10-41506	SCREW, PULLEY CLAMPING
38	13-26996	LOCKWASHER, PULLEY CLAMPING SCREW
39	20140	BELT, TMING
40	46251	PLATE, THROTTLE STOP
41	10-69035	SCREW, THROTTLE STOP PLATE TO DISTRIBUTOR ADAPTOR
42	10-21504	SCRWE, THROTTLE STOP ADJUSTING (1 1/4")
43	25-46252	GROMMET, THROTTLE STOP ADJUSTING SCREW
44	26852	CAP, NYLON - THROTTLE STOP ADJUSTING SCREW
45	27947	SWIVEL, LINKAGE - ECONOMIZER COLLAR
46	25996A1	SWIVEL AND LINK ROD ASSEMBLY
47	11-25168	NUT, UPPER LINK ROD ADJUSTING
48	37700	ROD, LINK - UPPER
49	27948	SWIVEL, UPPER LINK ROD TO THROTTLE CONTROL LEVER
50	12-8M0204649	WASHER, UPPER SWIEL TO THROTTLE LEVER
51	11-826709109	NUT, UPPER SWIVEL TO THROTTLE LEVER
52	53143A2	LEVER, THROTTLE CONTROL
53	10-98556	SCREW, THROTTLE LEVER TO EXHAUST COVER
54	12-8M0042641	WASHER, THROTTLE LEVER SCREW
55	23-29529	BUSHING, THROTTLE LEVER SCREW
56	24-37934	SPRING, QUICK DISCONNECT - THROTTLE CABLE TO THROTTLE LEVER
57	10-38069	SCREW, ANCHOR - QUICK DISCONNECT SPRING TO THROTTLE LEVER

▶DISTRIBUTOR ASSEMBLY, COMPLETE (33 parts)

Ref	OEM Part #	Part Name
-	393-2799A20	DISTRIBUTOR ASSEMBLY, COMPLETE
--	8M0084600	CONNECTOR, SPARK PLUG LEAD
1	393-2799A21	HOUSING, PRIMARY
2	13-26917	WASHER, WAVE - PRIMARY HOUSING
3	393-2795	SHIM, TRIGGER HOUSING TO PRIMARY HOUSING
4	393-2918A6	TRIGGER HOUSING ASSEMBLY
5	53-45906	RING, RETAINER - ROTOR SHAFT BALL BEARING
6	30-26379	BEARING, BALL - ROTOR SHAFT
7	393-2921A5	ROTOR SHAFT ASSEMBLY
8	17-20032	DOWEL PIN, ADAPTOR TO PRIMARY HOUSING
9	393-3014A2	ADAPTOR ASSEMBLY, HOUSING TO DISTRIBUTOR CAP
10	27-45910	GASKET, ADAPTOR TO PRIMARY HOUSING SEE NOTE BELOW
11	10-32627	SCREW, ADAPTOR TO HOUSING
12	11-46438	NUT, ADAPTOR TO HOUSING SCREW
13	10-38055	SCREW, SHIM AND TRIGGER HOUSING TO PRIMARY HOUSING
14	85-623594	SLEEVE, TRIGGER HOUSING CABLES
15	22-31521A1	ELBOW ASSEMBLY, VENT HOSE - ADAPTOR HOUSING
16	27-36268	GASKET, DISTRIBUTOR CAP TO ADAPTOR
17	393-2955A2	DISTRIBUTOR CAP ASSEMBLY
18	22-31521	ELBOW, VENT HOSE - DISTRIBUTOR CAP
19	393-1293A1	BRUSH AND SPRING ASSEMBLY
20	10-60464	SCREW, DISTRIBURTOR CAP TO ADAPTOR TO HOUSING (2")
21	12-89302	WASHER, DISTRIBUTOR CAP FASTENING SCREW
22	11-46438	NUT, DISTRIBUTOR CAP FASTENING SCREW
23	393-3018A1	HIGH TENSION CABLE ASSEMBLY, DISTRIBUTOR TO COIL
24	332-2854T01	BOOT, HIGH TENSION CABLE TO COIL
25	85-94589	SLEEVE, SPARK PLUG LEAD TO DISTRIBUTOR
26	25-26547	GROMMET, HIGH TENSION CABLE
27	32-46398	SLEEVE, HIGH TENSION CABLE
28	84-813715A1	SPARK PLUG LEAD ASSEMBLY (#1, #2 AND #4) Comment: ORDER 36549A1 FOR REPLACEMENT
29	85-63709A1	PROTECTOR, SPARK PLUG LEAD
30	32-46768	SLEEVE (LEADS 1, 2, 3, 4) - 6"
31	32-46768	SLEEVE, HIGH TENSION LEAD (LEADS 1, 2, 3, 4)

▶DRIVE SHAFT HOUSING ASSEMBLY (47 parts)

Ref	OEM Part #	Part Name
1	1564-3913A2	DRIVE SHAFT HOUSING ASSEMBLY (LONG SHAFT)
2	16-8M0022145	STUD, DRIVE SHAFT HOUSING TO GEAR HOUSING (1 3/4")
3	16-57935	STUD, DRIVE SHAFT HOUSING TO GEAR HOUSING (3")
4	19-32298	PLUG, PLASTIC - WATER PICK-UP SCREW HOLE
5	11-8M0204653	NUT, GEAR HOUSING TO DRIVE SHAFT HOUSING STUDS (7/16")
6	45678	ROD, PUSH - REVERSE LOCK (LONG SHAFT)
7	18-25191	COTTER PIN, PUSH ROD TO REVERSE LOCK
8	24-25122	SPRING, TENSION - PUSH ROD
9	17-24887	PIN, REVERSE LOCK LEVER
10	52920	LEVER, REVERSE LOCK
11	22-390721	PLUG, GREASE - REVERSE LOCK HOLE
12	35474T	COVER, LOWER MOUNT CLAMP
13	10-29722	SCREW, COVER TO LOWER MOUNT CLAMP
14	11-35521	NUT, LOWER MOUNT CLAMP COVER
15	69592F1	CLAMP, LOWER MOUNT TO DRIVE SHAFT HOUSING
16	10-29256	SCREW, LOWER MOUNT CLAMP TO DRIVE SHAFT HOUSING
17	24-35522	SPRING, TENSION - LOWER MOUNT CLAMP
18	75304T1	MOUNT, RUBBER - LOWER
19	25067	BUMPER, RUBBER - LOWER MOUNT SCREW
20	10-75284	SCREW, LOWER MOUNT (5 1/2")
21	12-28051	WASHER, LOWER MOUNT SCREW
22	12-28053	WASHER, RUBBER - LOWER MOUNT SCREW
23	12-30119	WASHER, LOWER MOUNT SCREW
24	11-25096	NUT, LOWER MOUNT SCREW
25	75305	MOUNT, RUBBER - UPPER
26	24929	PACKING, "U" CUP - UPPER MOUNT COVERS
27	79680A1	COVER, UPPER MOUNT - OUTSIDE HALF
28	79680A1	COVER, UPPER MOUNT - INSIDE HALF
29	10-28772	SCREW, UPPER MOUNT COVER - REAR (1 1/2")
30	10-37941	SCREW, UPPER MOUNT COVER - FRONT (1 3/4")
31	11-35888	NUT, UPPER MOUNT COVER FASTENING SCREW
32	12-30520	WASHER, UPPER MOUNT BOLT (37/64 ID)
33	12-30521	WASHER, RUBBER - UPPER MOUNT BOLT
34	12-30519	WASHER, UPPER MOUNT BOLT (3/8 ID)
35	11-23161	NUT, UPPER MOUNT BOLT
36	27-385011	GASKET, EXHAUST EXTENSION PLATE TO DRIVE SHAFT HOUSING
37	11-862902	NUT, POWERHEAD TO DRIVE SHAFT HOUSING STUDS (5/16")
38	695441	TUBE, EXHAUST (LONG SHAFT)
39	23-23651	SLEEVE, WATER INLET TUBE
40	32-45679	TUBE, WATER INLET (LONG SHAFT)
41	38157	SEAL, TRIM COVER TO DRIVE SAHFT HOUSING
42	38154	STRIP, RETAINING - TRIM COVER SEAL (SIDE)
43	38158	STRIP, RETAINING - TRI COVER SEAL (REAR)
44	10-37571	SCREW, RETAINING STRIP TO DRIVE SHAFT HOUSING
45	12-30164	WASHER, RETAINING STRIP SCREW
46	37687	COVER, TRIM - DRIVE SHAFT HOUSING
47	10-37571	SCREW, TRIM COVER TO DRIVE SHAFT HOUSING

▶FLYWHEEL ASSEMBLY AND STATOR (17 parts)

Ref	OEM Part #	Part Name
1	11-8M0214915	NUT, FLYWHEEL
2	12-33001	WASHER, FLYWHEEL NUT
3	28-20094	KEY, FLYWHEEL DRIVE
4	223-2403A18	FLYWHEEL ASSEMBLY
5	50-39837	RATCHET, FLYWHEEL - FLEX PLATE
6	10-32417	SCREW, PLATE AND RATCHET TO FLYWHEEL HUB
7	10-98256	SCREW, FLEX PLATE TO FLYWHEEL
8	17-26618	PIN, DOWEL - UPLLEY TO FLYWHEEL
9	29788	FLANGE, FLYWHEEL PULLEY
10	30306	PULLEYF, FLYWHEEL
11	29787	HUB, FLANGE - FLYWHEEL PULLEY
12	398-2996	STATOR, ALTERNATOR - FLYWHEEL
13	10-57021	SCREW, STATOR TO UPPER END CAP
14	54-24836	CLAMP, STATOR LEAD TO CRANKCASE
15	10-41228	SCREW, STATOR LEAD CLAMP FASTENING
16	8M0084613	"D" WASHER, STATOR LEAD CLAMP SCREW
17	54-46379	CLIP, STATOR LEAD TO CRANKCASE

▶FUEL PUMP ASSEMBLY (24 parts)

Ref	OEM Part #	Part Name
1	30269A2	FUEL PUMP ASSEMBLY
2	21-30430A1	CHECK VALVE ASSEMBLY
3	23014A1	DIAPHRAGM KIT
7	23004	RETAINER, CHECK VALVE
8	10-43725	SCREW, RETAINER TO HOUSING
9	23008	COVER, FUEL PUMP
10	10-30274	SCREW, FUEL PUMP MOUNTING (1 3/4")
11	10-29878	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	32-32094	FUEL LINE, PUMP TO LOWER AND UPPER 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	22-37682	CONNECTOR, FUEL LINE TO ADAPTOR
21	30186	ADAPTTOR, CHECK UNIT (FUEL LINE)
22	30187	STEM, CHECK UNIT ADAPTOR
23	25-16524	"O" RING, ADAPTOR STEM
24	24-30189	SPRING, ADAPTOR STEM
25	30188	CUP WASHER, ADAPTOR
26	10-21937	SCREW, ADAPTOR TO BOTTOM COWL (2")
27	11-8M0207775	NUT, ADAPTOR SCREW

▶GEAR HOUSING ASSEMBLY, COMPLETE (PAGE 1) (49 parts)

Ref	OEM Part #	Part Name
-	1626-3927A8	GEAR HOUSING ASSEMBLY, COMPLETE (LONG SHAFT) SEE NOTE BEL
1	1626-2470A16	GEAR HOUSING ASSEMBLY
2	31-62091T	BEARING, ROLLER - DRIVE SHAFT
3	16-57934	STUD, WATER PUMP BODY AND BASE TO GEAR HOUSING
4	16-8M0034453	STUD, GEAR HOUSING TO DRIVE SHAFT HOUSING
5	12-45176	WASHER, GEAR HOUSING STUD
6	92815	PLATE, SUPPORT - EXHAUST TUBE SEAL
7	37721001	SEAL, EXHAUST TUBE
8	43-20834	GEAR, PINION - DRIVE SHAFT
9	14-29163	TAB WASHER, PINION GEAR SCREW
10	10-20925	SCREW, PINION GEAR TO DRIVE SHAFT
11	56622A1	SHAFT, SHIFT - LOWER
12	53-29641	CLIP, RETAINING - SHIFT SHAFT
13	25-25439	"O" RING, SHIFT SHAFT BUSHING
14	23-46284A1	BUSHING ASSEMBLY, SHIFT SHAFT
15	26-892361	OIL SEAL, SHIFT SHAFT BUSHING
16	12-31266	WASHER, RUBBER - SHIFT SHAFT BUSHING
17	52918	CAM, LOWER - REVERSE LOCKING
18	52919	CAM, UPPER - REVERSE LOCKING
19	45-46394	DRIVE SHAFT (LONG SHAFT)
20	15-20929A1	SHIM, BEARING TO GEAR HOUSING (.002-3-5-10)
21	30-72961	BEARING, BALL - DRIVE SHAFT
22	53-29116	RING, SNAP - BALL BEARING RETAINING
23	15-20929A1	SHIM, BEARING TO WATER PUMP BASE (.002-3-5-10)
24	27-32771	GASKET, WATER PUMP BASE TO GEAR HOUSING
25	25-26855	"O" RING, WATER PUMP BASE
26	46-39531A1	WATER PUMP BASE ASSEMBLY
27	26-79831	OIL SEAL, WATER PUMP BASE
28	26-90562	OIL SEAL, WATER PUMP BASE
29	17-35973	DOWEL PIN, WATER PUMP BASE TO WATER PUMP BODY
30	27-19553	GASKET, LOWER - WATER PUMP BASE TO FACE PLATE
31	32768	PLATE, FACE - WATER PUMP BASE TO WATER PUMP BODY
32	27-19551	GASKET, UPPER - FACE PLATE TO WATER PUMP BODY
33	47-89983T	IMPELLER, WATER PUMP
34	28-8M0032837	PIN, IMPELLER DRIVE
35	26-38452	SEAL, WATER PUMP BODY TO WATER TUBE
36	12-38453	WASHER, CUPPED - WATER TUBE SEAL
37	46-60366Q1	WATER PUMP BODY ASSEMBLY
38	32001	INSERT, WATER PUMP BODY
39	26-32121	OIL SEAL, WATER PUMP BODY
40	13-26992	LOCKWASHER, WATER PUMP BODY AND BASE STUDS
41	11-29598	NUT, WATER PUMP BODY AND BASE STUDS
42	25-20273	RING, RUBBER - CENTRIFUGAL SLINGER
43	25-29619	"O" RING, UPPER - DRIVE SHAFT
44	10-29608	SCREW, GEAR HOUSING FLUSHING HOLE
45	27-8M0214916	GASKET, GEAR HOUSING FLUSHING HOLE SCREW
46	26-8M0214917	SEAL, GEAR HOUSING FLUSHING HOLE SCREW
47	10-79953Q04	SCREW, GREASER FILLER AND VENT HOLE
48	12-191833	WASHER, GREASE FILLER AND VENT HOLE SCREW

▶GEAR HOUSING ASSEMBLY, COMPLETE (PAGE 2) (36 parts)

Ref	OEM Part #	Part Name
-	1626-3927A8	GEAR HOUSING ASSEMBLY, COMPLETE (LONG SHAFT SEE NOTE BEL
1	1626-2470A16	GEAR HOUSING ASSEMBLY (SEE PAGE 31 FOR BREAKDOWN)
49	97-31640Q4	TRIM TAB, GEAR HOUSING
50	10-32470	SCREW, TRIM TAB TO GEAR HOUSING
51	760394	CAM, SHIFT
52	38441	FOLLOWER, CAM
53	20843	SLIDE, CROSS PIN
54	24-39845	SPRING, COMPRESSION - CAM FOLLOWER
55	15-31154A1	SHIM, BEARING CUP TO GEAR HOUSING (.002-3-5-10)
56	43-39941A2	FORWARD GEAR ASSEMBLY
57	31-20249	BEARING, ROLLER - FORWARD GEAR
58	31-31215A1	TAPERED ROLLER BEARING ASSEMBLY
59	31-31216	CUP, TAPERED ROLLER BEARING
60	52-92911T	RATCHET, SLIDING CLUTCH
61	17-8M0020942	PIN, CROSS - RATCHET TO PROPELLER SHAFT
62	24-38114	SPRING, RETAINING - CROSS PIN
63	44-38127	SHAFT, PROPELLER
64	43-39942	REVERSE GEAR ASSEMBLY
65	12-32004	WASHER, THRUST - REVERSE GEAR
66	30-20839T	BEARING, BALL - REVERSE GEAR
67	15-20927A1	SHIM, THRUST WASHER TO GEAR HOUSING (.002-3-5-10)
68	25-31986	"O" RING, BEARING CARRIER
69	53014T1	BEARING CARRIER ASSEMBLY
70	31-20249	BEARING, ROLLER - BEARING CARRIER
71	26-23517	OIL SEAL, BEARING CARRIER
72	28-30281	KEY, LOCATING - BEARING CARRIER
73	12-31993	WASHER, GAER HOUSING COVER
74	11-87763	COVER, GEAR HOUSING
75	12-8M0214963	WASHER, DRIVE SHAFT HOUSING STUD (3/8")
76	11-8M0204726	NUT, DRIVE SHAFT HOUSING TO GEAR HOUSING (3/8")
77	12-45176	WASHER, DRIVE SHAFT HOUSING STUD (7/16")
78	11-8M0204653	NUT, DRIVE SHAFT HOUSING TO GEAR HOUSING (7/16)
79	38859A1	THRUST HUB AND WASHER ASSEMBLY
80	12-31992	WASHER, CUPPED - THRUST HUB
81	12-32007	WASHER, SPLINED - PROPELLER SHAFT
82	11-82671120	NUT, PROPELLER

▶MAGNETO ADAPTOR AND PILOT ASSEMBLY (59 parts)

Ref	OEM Part #	Part Name
1	394-2271A2	MAGNETO ASSEMBLY, COMPLETE (4D-4)
2	45-27951	SHAFT, MAGNETO DRIVE
3	39560A1	MAGNETO PILOT ASSEMBLY
4	30-20066	BALL BEARING, 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	ECONOMIZER COLLAR AND PIN ASSEMBLY
9	17-27961	PIN, ECONOMIZER COLLAR - SPRING RETAINER
10	22-25094	FITTING, GREASE - ECONOMIZER COLLAR
11	38230A1	THROTTLE ACTUATOR ASSEMBLY
12	23-26602	BUSHING, NYLON - THROTTLE ACTUATOR
13	10-46420	SCRW, THROTTLE ACTUATOR TO ECONOMIZER COLLAR
14	66856A1	ADAPTOR, MAGNETO
15	22-25094	FITTING, GREASE - MAGNETO ADAPTOR
16	12-27939	WASHER, MAGNETO PILOT
17	14-27960	TAB WASHER, ADAPTOR CAP FASTENING
18	13-27959	WASHER, WAVE - MAGNETO BALL BEARING TENSION
19	27955	CAP, MAGNETO ADAPTOR AND PILOT FASTENING
20	27947	SWIVEL, LINKAGE - ECONOMIZER COLLAR
21	25996A1	SWIVEL AND LINK ROD ASSEMBLY
22	11-25168	NUT, UPPER LINK ROD ADJUSTING
23	37700	ROD, LINK - UPPER
24	27948	SWIVEL, UPPER LINK ROD TO THROTTLE CONTROL LEVER
25	53143A2	LEVER, THROTTLE CONTROL
26	10-98556	SCREW, THROTTLE LEVER TO EXHAUST COVER
27	12-8M0042641	WASHER, THROTTLE LEVER SCREW
28	23-29529	BUSHING, THROTTLE LEVER SCREW
29	24-37934	SPRING, QUICK DISCONNECT - THROTTLE CABLE TO THROTTLE LEVER
30	10-38069	SCREW, ANCHOR - QUICK DISCONNECT SPRING TO THROTTLE LEVER
31	10-30110	SCREW, ADAPTOR AND PILOT TO MAGNETO
32	10-78841	SCREW, ADAPTOR AND PILOT TO CRANKCASE
33	12-20084	WASHER, ADAPTOR AND PILOT TO CRANKCASE SCREW
34	11-22053	NUT, ADAPTOR AND PILOT TO CRANKCASE SCREW
35	28-28657	KEY, MAGNETO DRIVING
36	29784	HUB, DRIVEN PULLEY
37	29783A1	DRIVEN PULLEY ASSEMBLY
38	17-24873	PIN, ROLL - FLANGE LOCATING
39	29785	FLANGE, DRIVEN PULLEY
40	12-20138	WASHER, PULLEY CLAMPING SCREW
41	10-32228	SCREW, PULLEY CLAMPING
42	20140	BELT, TIMING
43	53458	PLATE, THROTTLE STOP
44	10-20012	SCREW, THROTTLE STOP ADJUSTING (1 5/8")
45	11-20013	NUT, THROTTLE STOP ADJUSTING SCREW
46	26852	CAP, NYLON - ADJUSTING SCREW
47	10-69035	SCREW, THROTTLE STOP PLATE TO ADAPTOR
48	37996	GROUND STRAP, THROTTLE STOP PLATE SCREW
49	12-8M0204649	WASHER, UPPER SWIVEL TO THROTTLE LEVER
50	11-826709109	NUT, UPPER SWIVEL TO THROTTLE LEVER
51	33-8M0114739	SPARK PLUG
52	85-63709A1	PROTECTOR, SPARK PLUG
53	84-821945A46	CABLE, HIGH TENSION LEAD - SPARK PLUG
54	25-25429	"O" RING, HIGH TENSION LEAD CABLE TO END CAP COVER
55	54-25231	CLIP, HARNESS LEADS TO MAGNETO
56	10-20401	SCREW, LEAD CLIP TO MAGNETO
57	8M0084613	"D" WASHER, CLIP FASTENING SCREW
58	394-1134A1	GROUND STRAP ASSEMBLY, MAGNETO TO CRANKCASE
59	32-46768	SLEEVE, HIGH TENSION LEAD (3")

▶MAGNETO ASSEMBLY (INTERNAL PARTS) (44 parts)

Ref	OEM Part #	Part Name
-	394-2271A2	MAGNETO ASSEMBLY, COMPLETE
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, SUPPOR5T TO FRAME
9	84-60466A13	WIRE ASSEMBLY, PRIMARY GROUND LEAD
10	10,10-29182	SCREW, PRIMARY GROUND
11	12-30267	WASHER, PRIMARY GROUND TERMINAL
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
25	11-29236	NUT, PRIMARY LEAD FASTENING
26	394-1106A1	HOLDER AND CAM WICK ASSEMBLY
27	53-21058	"E" RING, BREAKER TO PIVOT PIN
28	10-20597	SCREW, BREAKER HOLDER TO HOUSING
29	394-1130A1	CONDENSER
30	10-25509	SCRWE AND LOCKWASHER, CONDENSER FASTENING
31	27-29166	GASKET, MAGNETO COVER
32	394-1577A2	COVER, MAGNETO
33	10-29418	SCREW, COVER TO FRAME
34	14-38359	TAB WASHER, COVER FASTENING SCREW
35	394-2602A1	MAGNETO ROTOR ASSEMBLY
36	394-1110	CLIP, SPRING
37	27-25725	GASKET, END CAP COVER
38	394-1561A2	END CAP COVER ASSEMBLY
39	394-1056A1	BRUSH AND SPRING ASSEMBLY
40	10-25517	SCREW, HIGH TENSION CABLE FASTENING
41	10-29418	SCREW, END CAP COVER TO MAGNETO COVER
42	14-38359	TAB WASHER, COVER FASTENING SCREW
43	22-996642	ELBOW, PLASTIC - MAGNETO COVER VENT

▶MISCELLANEOUS PARTS/ACCESSORIES (1 parts)

Ref	OEM Part #	Part Name
-	79-73370A3	TACHOMETER ASSEMBLY (MERC 500E-6-SS)

▶OVERSIZE PISTON AND RING (1 parts)

Ref	OEM Part #	Part Name
--	39-28616A12	RING, PISTON (.015 OVERSIZE)

▶STARTER MOTOR, STARTER SOLENOID, RECTIFIER & WIRING HARNESS (54 parts)

Ref	OEM Part #	Part Name
--	11-20890	NUT, GROUND WIRE SCREW
1	332-2986A27	SWITCH BOX ASSEMBLY, COMPLETE
2	12-45075	WASHER, SWITCH BOX TERMINAL
3	11-45076	NUT, SWITCH BOX TERMINAL
4	10-22485	SCREW, SWITCH BOX TO FRONT SUPPORT BRACKET (3/4")
5	11-8M0207775	NUT, SWITCH BOX TO FRONT SUPPORT BRACKET SCREW
6	78614A1	RECTIFIER ASSEMBLY, COMPLETE
7	12-45075	WASHER, RECTIFIER TERMINAL
8	11-45076	NUT, RECTIFIER TERMINAL
9	46286	JUMPER WIRE, RECTIFIER TO SWITCH BOX Comment: SERIAL 00000000-02167843
10	10-22485	SCREW, RECTIFIER TO FRONT SUPPORT BRACKET (3/4")
11	11-8M0207775	NUT, RECTIFIER TO FRONT SUPPORT BRACKET SCREW
12	59757	BRACKET, RETAINER - HIGH TENSION LEAD
13	10-21722	SCREW, RETAINER BRACKET TO FRONT SUPPORT BRAKCET (5/8")
14	11-8M0207775	NUT, RETAINER BRACKET SCREW
15	50-55601A2	STARTER MOTOR ASSEMBLY
16	10-22698	SCREW, STARTER MOTOR TO CRANKCASE FLANGE
17	13-8M0204647	LOCKWASHER, STARTER MOTOR SCREW
18	84-93389A12	WIRE, STARTER MOTOR TO STARTER SOLENOID AND TOP MOUNT
19	10-69035	SCREW, GROUND WIRE TO STARTER MOTOR
20	13-26992	LOCKWASHER, GROUND WIRE FASTENING SCREW
21	46715	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 TERMINAL (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	38072	WIRING HARNESS (INTERNAL) - USE ON STARTER ENGINES ONLY
30	24-28975	SPRING, GARTER - INTERNAL WIRING HARNESS
31	26079A2	PLATE, BACKING - WIRING HARNESS
32	10-45893	SCREW, BACKING PLATE TO BOTTOM COWL
33	10-98256	SCREW, WIRING HARNESS LEAD TO BOTTO COWL (1/2")
34	13-24669	LOCKWASHER, WIRING HARNESS LEAD SCREW
35	54-26550	CLIP, WIRING HARNESS LEAD
36	10-29072	SCREW, WIRING HARNESS LEAD CLIP ATTACHING (5/8")
37	18-27789	"D" WASHER, WIRING HARNESS LEAD CLIP ATTACHING SCREW
38	11-24656	NUT, WIRING HARNESS LEAD CLIP ATTACHING SCREW
39	332-4895A6	IGNITION COIL ASSEMBLY, COMPLETE
40	10-46367	SCREW, IGNITION COIL CLAMPING - CLIP ATTACHING (2 1/2")
41	11-68219	NUT, IGNITION COIL CLAMPING SCREW
42	12-8M0204666	WASHER, IGNITION COIL CLAMPING SCREW
43	54-22740	CLIP, LEAD WIRE TO IGNITION COIL
44	8M0084613	"D" WASHER, IGNITION COIL CLAMPING SCREW
45	11-8267086	NUT, IGNITION COIL CLAMPING SCREW
46	10-36137	SCREW, IGNITION COIL TO BOTTOM COWL (1")
47	13-26992	LOCKWASHER, IGNITION COIL SCREW
48	10-45218	SCREW, IGNITION COIL WIRE TO SWITCH BOX (3/8")
49	30212	TERMINAL BLOCK USE ON STARTER ENGINES
50	10-72169	SCREW, TERMINAL BLOCK ATTACHING USE ON STARTER ENGINES
51	10-62568	SCREW, HARNESS LEADS TO TERMINAL BLOCK USE ON START ENGINE
52	54-22783	"S" CLIP, WIRING HARNESS TO BOTTOM COWL USE ON START ENGINE
53	46715	CABLE, STARTER SOLENOID TO TOP MOUNT USE ON STARTER ENGINES

▶TOP COWL ASSEMBLY (63 parts)

Ref	OEM Part #	Part Name
1	2117-2959A2	TOP COWL ASSEMBLY
2	16-21550	STUD, REAR - TOP COWL TO REAR SUPPORT BRACKET
3	16-21553	STUD, FRONT - TOP COWL TO FRONT SUPPORT BRACKET
4	25-20116	GROMMET, CHOKE KNOKB - FRONT SUPPORT BRACKET OR TOP COWL
5	37690	SHIELD, REAR - TOP COWL
6	10-37370	SCREW, REAR SHIELD TO TOP COWL
7	13-37371	LOCKWASHER, REAR SHIELD SCREW
8	12-69056	WASHER, REAR SHIELD SCREW
9	13-35048	LOCKWASHER, TOP COWL STUD (3/8") - USED ON EARLY MODELS ONLY
10	11-23161	NUT, TOP COWL STUD (3/8-24)
11	12-20084	WASHER, TOP COWL STUD (5/16")
12	11-826709111	NUT, TOP COWL STUD (5/16-24)
13	46144	BRACKET, TOP COWL LATCH
14	10-21091	SCREW, LATCH BRACKET TO TOP COWL
15	12-8M0204649	WASHER, LATCH BRACKET SCREW (1/16" THICK)
16	12-37998	WASHER, LATCH BRACKET SCREW (1/32" THICK)
17	46142A1	RETAINER ASSEMBLY, TOP COWL
18	35496	PAD, BUMPER - TOP COWL HANDLE
19	10-35386	SCREW, RETAINER TO TOP COWL
20	13-39107	LOCKWASHER, RETAINER TO TOP COWL SCREW
21	52899	BRACKET, REAR COWL SUPPORT
22	37640	MOUNT, RUBBER - REAR SUPPORT BRACKET
23	13-8M0204647	LOCKWASHER, REAR SUPPORT BRACKET RUBBER MOUNT
24	12-26825	WASHER, REAR SUPPORT BRACKET RUBBER MOUNT
25	11-22053	NUT, REAR SUPPORT BRACKET RUBBER MOUNT
26	37412	LEVER, CLAMPING - TOP COWL
27	23-26819	BUSHING, TOP COWL CLAMPING LEVER (NYLON)
28	23-31293	BUSHING, TOP COWL CLAMPING LEVER (RUBBER)
29	11-30428	FASTENER, TOP COWL CLAMPING LEVER
30	17-29077	PIN, ROLL - TOP COWL CLAMPING LEVER
31	11-20166	NUT, SHEAVE SHAFT (LEFT HAND THREAD)
32	14-20165	TAB WASHER, SHEAVE SHAFT NUT
33	37685	HOUSING, STARTER
34	10-90073	SCREW, STARTER HOUSING TO CRANKCASE AND CYLINDER BLOCK (1")
35	13-20202	LOCKWASHER, STARTER HOUSING SCREW
36	37691	PLATE, CABLE GUIDE
37	10-358811	SCREW, DRIVE - CABLE GUIDE PLATE TO STARTER HOUSING
38	39835	RETAINER, STARTER SPRING
39	24-39502T02	SPRING, STARTER REWIND
40	23-28912	BUSHING, SPRING GUIDE
41	76053A1	SHEAVE ASSEMBLY
42	30596	PAWL, STARTER
43	13-36206	WASHER, WAVE - STARTER PAWL
44	23-28919	BUSHING, NYLON - SHEAVE SHAFT SPACER
45	23-61005	SPACER, SHEAVE SHAFT
46	39840	RETAINER, WAVE WASHER
47	12-35559	WASHER, WAVE WASHER RETAINER
48	13-20160	WASHER, WAVE - RETAINER TENSION
49	24-26068	SPRING, RETAINER PLATE TO STARTER SHEAVE
50	66845	PLATE, RETAINER - STARTER PAWL
51	45477A1	SHAFT, SHEAVE
52	47341A11	STARTER CABLE (FOR MANUAL STARTING ONLY)
53	28747	HANDLE, STARTER CABLE
54	79470A1	RETAINER, STARTER CABLE AND HANDLE
55	47904A2	BRACKET ASSEMBLY, FRONT SUPPORT (NOT AS SHOWN)
56	37921	FLANGE, RUBBER - FRONT SUPPORT BRACKET
57	32-8M0108355	TUBE, DRAIN - FRONT SUPPORT BRACKET TO BOTTOM COWL
58	10-35386	SCREW, FRONT SUPPORT BRACKET TO BOTTOM COWL (1")
59	37-46397	DECAL, TIMING - FRONT SUPPORT BRACKET
60	31014	MOUNT, RUBBER - FRONT SUPPORT BRACKET
61	13-26992	LOCKWASHER, FRONT SUPPORT BRACKET RUBBER MOUNT
62	12-69057	WASHER, FRONT SUPPORT BRACKET RUBBER MOUNT
63	11-20088	NUT, FRONT SUPPORT BRACKET RUBBER MOUNT

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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