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Mercury 90 (4-STROKE) (0G960500 THRU 0T800999) Parts & Diagrams
🔎 Mercury 90 (4-STROKE) Reference Library — Exploded parts diagrams (34 diagrams), specifications, common issues, and maintenance checklist.
The Mercury 90 (4-STROKE) is a 4-Stroke, Inline 4-Cylinder, EFI, SOHC outboard motor. Suited for bay boats, pontoons, and center-console fishing boats requiring reliable mid-range power.
Quick Reference Specifications
| Specification | Value |
|---|---|
| Engine Type | 4-Stroke, Inline 4-Cylinder, EFI, SOHC |
| Horsepower | 90 HP |
| Displacement | 2100 cc |
| Bore x Stroke | 90 mm x 81 mm |
| Spark Plug (Type & Gap) | NGK IZFR6F-11 |
| Engine Oil Capacity | 5.2 L (5.5 quart) |
| Recommended Engine Oil | Mercury FourStroke Oil 10W-30 |
| Gear Case Oil Capacity | 710 mL (24 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 90 (4-STROKE):
- 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 90 (4-STROKE).
▶Accessories (1 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| - | 816366A32 | STEERING HANDLE KIT Comment: (2004 Model Year And Up) |
▶Bottom Cowl (28 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| 1 | 100-878587A1 | BOTTOM COWL ASSEMBLY (Port) |
| 2 | 100-8M0113913 | BOTTOM COWL ASSEMBLY (Starboard) |
| 3 | 8M0109217 | SEAL, Cowl (41.00 Inches) |
| 4 | 878547T | INSERT Comment: (Design II) |
| 5 | 10-82130040 | SCREW, (M6 x 40) |
| 6 | 831209 | RETAINER |
| 7 | 858742 | BOOT, Idle Exhaust |
| 8 | 8M0039078 | GROMMET |
| 9 | 22-827948 | FITTING |
| 10 | 12-855576 | WASHER |
| 11 | 54-816311T | TIE STRAP, (8.00 Inches) |
| 12 | 32-8M0108355 | HOSE, (57.00 Inches Bulk) (Cut to 5 Inches) |
| 13 | 32-8M0108355 | HOSE, (57.00 Inches Bulk) (Cut to 11 Inches) |
| 14 | 32-9912688 | TUBING, (36.00 Inches Bulk) (Cut to 26 Inches) |
| 15 | 22-817518 | TEE |
| 16 | 10-82130020 | SCREW, (M6 x 20) |
| 17 | 25-889724 | GROMMET |
| 18 | 87-8M0042301 | SWITCH ASSEMBLY |
| 19 | 10-824868 | SCREW, (M6 x 75) |
| 20 | 889740A02 | FRONT HANDLE, Black |
| 21 | 23-33589 | BUSHING |
| 22 | 25-48462 | O-RING, (.614 x .070) |
| 23 | 8219423 | PAWL |
| 24 | 12-69057 | WASHER, (.281 x .734 x .063) |
| 25 | 11-401366 | NUT, (M6) Stainless Steel |
| 26 | 13541 | PLUG, Male |
| 27 | 19-824928001 | PLUG, Rubber Comment: (75 Bodensee) |
| 28 | 859184T | COVER Comment: (Design I) |
▶Carburetor (47 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| - | 804346T02 | REPAIR KIT, Carburetor (1 Per Carburetor) |
| 1 | 3319-804708T1 | CARBURETOR Comment: (1/3) (75) |
| 2 | 3319-804708T2 | CARBURETOR Comment: (2) (75) |
| 3 | 3319-804168T7 | CARBURETOR Comment: (4)(75 Bodensee) |
| 4 | 10-83509M | SCREW, (M4 x 10) |
| 5 | 804171 | PLATE |
| 6 | 25-804172 | O-RING |
| 7 | 35-804195 | FILTER ELEMENT |
| 8 | 10-804176 | SCREW Comment: (1/2/3) |
| 9 | 24-804177 | SPRING Comment: (1/2/3) |
| 10 | 24-804170 | SPRING |
| 11 | 25-804181 | O-RING |
| 12 | 10-804169 | SCREW, Pilot |
| 13 | 19-8M0080454 | PLUG |
| 14 | 804188 | PRIMER, Starter Comment: (1/3) |
| 15 | 10-804192 | SCREW, (M4 x 10) Comment: (1/3) |
| 16 | 804189 | LEVER PLATE, Starter Comment: (1/3) |
| 17 | 804187 | HOUSING, Starter Comment: (1/3) |
| 18 | 10-804190 | SCREW, (M5 x 16) Comment: (1/3) |
| 19 | 25-804191 | O-RING Comment: (1/3) |
| 20 | 25-80419130 | O-RING Comment: (1/3) |
| 21 | 25-80419120 | O-RING Comment: (1/3) |
| 22 | 25-80419110 | O-RING Comment: (1/3) |
| 23 | 24-804178 | SPRING Comment: (1/2/3) |
| 24 | 25-97070M | O-RING |
| 25 | 17050M | NEEDLE VALVE SET |
| 26 | 54-82781M | CLIP |
| 27 | 17-92639M | PIN, Float |
| 28 | 45,804871 | JET, Pilot Comment: (75HP) |
| 29 | 22-8M0080455 | CAP |
| 30 | 877865 | MAIN NOZZLE Comment: (75 HP) |
| 31 | 108,885125 | JET, Main Comment: (75 Bodensee) |
| 32 | 804184 | FLOAT |
| 33 | 17-804185 | PIN, Float Arm |
| 34 | 10-82500M | SCREW, (M4 x 8) |
| 35 | 27-804183 | GASKET |
| 36 | 804182 | FLOAT BOWL Comment: (1/3) |
| 37 | 10-11796M | SCREW, (M4 x 14) |
| 38 | 10-81293M | SCREW, Drain |
| 39 | 25-94498M | O-RING |
| 40 | 8041821 | FLOAT BOWL Comment: (2/4) |
| 41 | 10-804179 | SCREW Comment: (4) |
| 42 | 24-82080M | SPRING Comment: (4) |
| 43 | 19233M | COLLAR Comment: (4) |
| 44 | 23-804180 | BUSHING Comment: (4) |
| 45 | 804193 | DIAPHRAGM Comment: (4) |
| 46 | 10-804194 | SCREW, (M6 x 14) Comment: (4) |
▶Crankshaft, Pistons and Connecting Rods (13 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| - | 27-804345A02 | GASKET SET, Powerhead |
| 1 | 2406-804098T | CRANKSHAFT |
| 2 | 26-8040992 | SEAL, Oil |
| 3 | 26-8041002 | SEAL, Oil |
| 4 | 31-804101T20 | BEARING Comment: (Red) |
| 5 | 31-804102T30 | BEARING Comment: (Red) |
| 6 | 31-804103T20 | BEARING Comment: (Red) |
| 7 | 2715-880895T03 | PISTON ASSEMBLY Comment: (.25MM Oversize) |
| 8 | 10-804105 | BOLT |
| 9 | 31-804106T31 | BEARING Comment: (Red) |
| 10 | 39-880898T02 | RING SET, Piston Comment: (.25MM Oversize) |
| 11 | 28-804153 | KEY |
| 12 | 28-8261001 | KEY |
▶Cylinder Block and Crankcase (46 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| - | 27-804345A02 | GASKET SET, Powerhead |
| 1 | 892-804071T3 | CYLINDER BLOCK |
| 2 | 17-82364M | PIN, Dowel |
| 3 | 27-858732002 | GASKET |
| 4 | 10-8M0101617 | BOLT, (M8 x 55) |
| 5 | 10-804072 | BOLT, (M10 x 135) |
| 6 | 25-855690 | GROMMET |
| 7 | 19-825953 | PLUG, (M14 x 12) |
| 8 | 27-81990M | GASKET |
| 9 | 10-804097 | BOLT |
| 10 | 35-8M0162830 | FILTER, Oil |
| 11 | 881600 | CAP, Rubber |
| 12 | 32-804078 | HOSE |
| 13 | 54-816311T | TIE STRAP, (8.00 Inches) |
| 14 | NSS | NOT SOLD SEPARATE, Anode Comment: Order Cover |
| 15 | 25-804086 | GROMMET |
| 16 | 804085 | COVER |
| 17 | 10-827207 | BOLT, (M8 x 25) |
| 18 | 10-8524741 | BOLT, (M6 x 20) |
| 19 | 10-881428 | BOLT, (M6 x 16) |
| 20 | 804083001 | COVER |
| 21 | 27-804084 | GASKET |
| 22 | 24-804081 | SPRING |
| 23 | 804080001 | VALVE, Pressure Control |
| 24 | 25-804082 | GROMMET |
| 25 | 10-881427 | BOLT, (M6 x 30) |
| 26 | 804075T02 | COVER, Outer Exhaust |
| 27 | 27-804076003 | GASKET |
| 28 | 54-804089 | CLIP |
| 29 | 32-804088 | HOSE |
| 30 | 54-816311T | TIE STRAP, (8.00 Inches) |
| 31 | 804073 | LIFTING EYE |
| 32 | 804149 | PLATE, Valve |
| 33 | 10-8257021 | BOLT, (M6 x 20) |
| 34 | 16-8587331 | STUD |
| 35 | 12-8M0214963 | WASHER, (.406 x .750 x .105) Stainless Steel |
| 36 | 11-40140 | NUT, (M10) |
| 37 | 10-81893435 | SCREW, (M8 x 35) |
| 38 | 25-804093 | O-RING Comment: SN# 0T178499 & Below |
| 39 | 804092 | BRACKET Comment: SN# 0T178499 & Below |
| 40 | 10-811188T | BOLT, (M6 x 16) Comment: SN# 0T178499 & Below |
| 41 | 54-816311T | TIE STRAP, (8.00 Inches) Comment: SN# 0T178499 & Below |
| 42 | 32-804094 | BREATHER PIPE Comment: SN# 0T178499 & Below |
| 43 | 54-804095 | CLAMP Comment: SN# 0T178499 & Below |
| 44 | 10-804602 | BOLT, (M6 x 12) Comment: SN# 0T178499 & Below |
| 45 | 54-804096 | CLIP Comment: SN# 0T178499 & Below |
▶Cylinder Head (34 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| - | 27-804345A02 | GASKET SET, Powerhead |
| 1 | 8M0057170 | CYLINDER HEAD Comment: (Use PN 804127-1 Thermostat Cover and PN 855676-1 Thermostat to service this Cylinder Head) |
| 2 | 17-804110 | PIN, Guide |
| 3 | 19-804111 | PLUG |
| 4 | 10-804112 | BOLT, (M7 x 48) |
| 5 | 17-804113 | PIN, Dowel |
| 6 | 10-804114 | BOLT, (M7 x 37) |
| 7 | 10-8248326 | BOLT, (M6 x 25) |
| 8 | 8041271 | THERMOSTAT COVER Comment: (Use with 804109T4 Cylinder Head) SN# 0T178500 & Up |
| 9 | 8556761 | THERMOSTAT, 60°C (140°F) Comment: (Use with 804109T4 Cylinder Head) SN# 0T178500 & Up |
| 10 | 10-881311 | BOLT, (M10 x 145) |
| 11 | 33-859495Q | SPARK PLUG, (NGK-LFR5A-11) |
| 12 | 10-827207 | BOLT, (M8 x 25) |
| 13 | 10-8524741 | BOLT, (M6 x 20) |
| 14 | 804085 | COVER |
| 15 | 25-804086 | GROMMET |
| 16 | NSS | NOT SOLD SEPARATE, Anode Comment: Order Cover |
| 17 | 23-8M0070515 | COLLAR |
| 18 | 27-8041151 | GASKET |
| 19 | 10-83124714 | BOLT |
| 20 | 12-831246 | WASHER, Sealing |
| 21 | 10-881312 | BOLT, (M8 x 55) |
| 22 | 27-804123 | GASKET |
| 23 | 881313T1 | COVER KIT Comment: SN# 0T409000 & Up |
| 24 | 804119 | COVER, Breather |
| 25 | 10-804120 | SCREW, (M4 x 8) |
| 26 | 22-804122 | NIPPLE Comment: SN# 0T178499 & Below |
| 27 | 10-858530 | BOLT, (M6 x 30) |
| 28 | 859578A1 | PLUG ASSEMBLY, Oil |
| 29 | NSS | NOT SOLD SEPARATE, O-Ring |
| 30 | 25-855690 | GROMMET |
| 31 | 858752001 | COVER |
| 32 | 10-1993716 | SCREW, (M6 x 16) |
| 33 | NSS | NOT SOLD SEPARATE, Decal-Bodensee |
▶Driveshaft Housing (22 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| 1 | 1507-858576T2 | HOUSING ASSEMBLY, Driveshaft |
| 2 | 16-9035015 | STUD, (M10 x 227) Comment: (X-Long) |
| 3 | 16-8M0034462 | STUD, (M10 x 190) Comment: (X-Long) |
| 4 | 12-8M0214963 | WASHER, (.406 x .750 x .105) Stainless Steel |
| 5 | 11-40140 | NUT, (M10) |
| 6 | 22-85822A13 | PICK UP ASSEMBLY, Speedometer |
| 7 | 22-433351 | CONNECTOR, 90 Degree (.125-27) Nylon |
| 8 | 22-85822T | CONNECTOR, Straight |
| 9 | 44343T1 | MOUNT |
| 10 | 10-898835001 | BOLT, (M12 x 154) |
| 11 | 12-30119 | WASHER, (.875 Inch Outside Diameter) |
| 12 | 11-8M0204662 | NUT, (M12) |
| 13 | 88238A10 | CABLE ASSEMBLY, Ground |
| 14 | 10-41508 | SCREW, (.250-20 x .500) Stainless Steel |
| 15 | 858916T | CLAMP |
| 16 | 10-4010725 | SCREW, (M8 x 25) |
| 17 | 8M0142713 | CAP |
| 18 | 23-859550 | BUSHING |
| 19 | 17-24873 | PIN, Alignment |
| 20 | 22-855622 | FITTING |
| 21 | 12092A3 | SPACER KIT Comment: (X-Long) |
| 22 | 17-43044 | PIN, Dowel - Without Hole (.375 x .625) Comment: (X-Long) |
▶Electrical Components (44 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| 0 | 891824 | COVER, Fuse - Black |
| 1 | 804288T | COVER |
| 2 | 37-881865 | DECAL, Caution-Start in Gear |
| 3 | 37-8272822 | DECAL, Warning, High Voltage |
| 4 | 804289 | PULLER, Fuse |
| 5 | 84-8042903 | HARNESS ASSEMBLY Comment: SN# 0T599000 & Up |
| 6 | 88-832969T20 | FUSE, 20 Ampere |
| 7 | 88-8M0057159 | FUSE, 30 Ampere |
| 8 | 54-816311T | TIE STRAP, (8.00 Inches) |
| 9 | 804287T | BRACKET |
| 10 | 10-811188T | BOLT, (M6 x 16) |
| 11 | 804286T | BRACKET, Relay |
| 12 | 10-811188T | BOLT, (M6 x 16) |
| 13 | 8M0010250 | BRACKET |
| 14 | 825096T01 | RELAY |
| 15 | 12-827205 | WASHER |
| 16 | 11-827204 | NUT, (M6) |
| 17 | 85-826574 | BOOT |
| 18 | 804281T | RELAY |
| 19 | 12-827205 | WASHER |
| 20 | 11-827204 | NUT, (M6) |
| 21 | 85-804284001 | BOOT |
| 22 | 804282T | RELAY |
| 23 | 84-804285 | CABLE |
| 24 | 84-804283 | CABLE |
| 25 | 12-827205 | WASHER |
| 26 | 11-827204 | NUT, (M6) |
| 27 | 84-858740T4 | HARNESS ASSEMBLY |
| 28 | 92753 | RETAINER |
| 29 | 10-84058M | BOLT, (M6 x 20) |
| 30 | 13-82212M | LOCKWASHER |
| 31 | 12-82214M | WASHER |
| 32 | 804292 | PLATE |
| 33 | 10-804602 | BOLT, (M6 x 12) |
| 34 | 84-88439A33 | CABLE ASSEMBLY, Positive - Battery |
| 35 | 84-88439A4 | CABLE ASSEMBLY, Battery - Negative |
| 36 | 11-401388 | NUT, (M8) Stainless Steel |
| 37 | 10-81893412 | SCREW, (M8 x 12) |
| 38 | 859249T1 | CONNECTOR |
| 39 | 84-858723T1 | HARNESS ASSEMBLY, Adaptor/Trim |
| 40 | 84-858914T1 | HARNESS ASSEMBLY, Trim Motor Adaptor |
| 41 | 11-401386 | NUT, (M6) Stainless Steel |
| 42 | 804293T | COVER Comment: (Use where Applicable) |
| 43 | 10-804126 | SCREW Comment: (Use where Applicable) |
▶Exhaust Plate (33 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| 1 | 858582T | ADAPTOR PLATE ASSEMBLY |
| 2 | 17-23784 | PIN, Dowel |
| 3 | 22-291112 | FITTING |
| 4 | 21-817519A2 | CHECK VALVE ASSEMBLY, Drain |
| 5 | 25-12602002 | GROMMET |
| 6 | 27-8585831 | GASKET |
| 7 | 858572T01 | SUMP, Oil |
| 8 | 858584A1 | TUBE ASSEMBLY, Exhaust |
| 9 | 25-881295 | O-RING |
| 10 | 25-89417004 | GROMMET |
| 11 | 32-8M0026129 | TUBE, Water Comment: (X-Long) |
| 12 | 814080001 | SEAL (Upper) |
| 13 | 858571T | TUBE, Oil Pick Up |
| 14 | 25-859082 | O-RING |
| 15 | 10-8M0204741 | SCREW, (M6 x 20) Stainless Steel |
| 16 | 10-8M0214957 | SCREW, (M6 x 30) |
| 17 | 8596021 | DIPSTICK Comment: SN# 0T178500 & Up |
| 18 | 23-48237 | BUSHING |
| 19 | 858577A3 | SHIFT SHAFT |
| 20 | 859177A3 | SHIFT LINK |
| 21 | NSS | NOT SOLD SEPARATE, Bushing |
| 22 | NSS | NOT SOLD SEPARATE, Roller |
| 23 | 11-401386 | NUT, (M6) Stainless Steel |
| 24 | 23-11289 | SPACER Comment: (X-Long) |
| 25 | 43585 | COUPLING |
| 26 | 18-859746 | COTTER PIN |
| 27 | 8M0039073 | SEAL |
| 28 | 8288181 | PLUG, Drain |
| 29 | 27-8M0204692 | GASKET |
| 30 | 10-82483213 | SCREW, (M6 x 60) |
| 31 | 10-4010750 | SCREW, (M8 x 50) |
| 32 | 22-479452 | PLUG |
| 33 | 22-384073 | PLUG, Pipe (.500-14) |
▶Flywheel (22 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| - | 883548T02 | POWERHEAD ASSEMBLY Comment: SN# 0T178499 & Below |
| 1 | 881343T1 | FLYWHEEL COVER |
| 2 | NSS | NOT SOLD SEPARATE, Decal-Warning-Spinning Flywheel |
| 3 | NSS | NOT SOLD SEPARATE, Decal-Servicing Referral |
| 4 | NSS | NOT SOLD SEPARATE, Decal-Engine Oil/Valve |
| 5 | 37-804656A03 | DECAL, EPA Label Information Comment: (2003) |
| 6 | NSS | NOT SOLD SEPARATE, Decal-Emergency |
| 7 | 10-804348 | BOLT, (M6 x 20) |
| 8 | 825665 | COLLAR |
| 9 | 25-11416T | GROMMET |
| 10 | 11-804265A1 | NUT/WASHER KIT, Hex (36 mm) Comment: SN# 0T599000 & Up |
| 11 | 12-804264 | WASHER Comment: SN# 0T598999 & Below |
| 12 | 280-804261T | FLYWHEEL |
| 13 | NSS | NOT SOLD SEPARATE, Decal-Warning Neutral |
| 14 | 398-804262T | STATOR KIT |
| 15 | 17-825010 | PIN, Dowel |
| 16 | 10-804124 | BOLT |
| 17 | 13-82212M | LOCKWASHER |
| 18 | 12-82214M | WASHER |
| 19 | 10-804267 | SCREW |
| 20 | 804266001 | TIMING PLATE |
| 21 | 804263 | ROTOR |
▶Fuel Pump(Serial Number 0T408999 & Below) (35 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| - | 27-804345A02 | GASKET SET, Powerhead |
| 1 | 804249T1 | PUMP, Fuel |
| 2 | 10-809564 | SCREW, (M5 x 35) |
| 3 | 809565 | COVER |
| 4 | 8095611 | DIAPHRAGM |
| 5 | 10-804253 | SCREW |
| 6 | 21-41888M | CHECK VALVE |
| 7 | 804250 | DIAPHRAGM |
| 8 | 17-804254 | PIN |
| 9 | 24-809562 | SPRING |
| 10 | 11-82388M | NUT, (M5) |
| 11 | 24-804252 | SPRING |
| 12 | 804251 | PLUNGER |
| 13 | 10-804256 | BOLT, (M6 x 30) |
| 14 | 25-8M0050719 | O-RING |
| 15 | 12-84292M | WASHER |
| 16 | 804257 | LEVER, Fuel Change |
| 17 | 17-82738M | PIN |
| 18 | 804258 | SHAFT |
| 19 | 17-804113 | PIN, Dowel |
| 20 | 804260 | BRACKET |
| 21 | 10-804112 | BOLT, (M7 x 48) |
| 22 | 35-877565T1 | FILTER, Fuel |
| 23 | 8775381 | PROTECTIVE SLEEVE |
| 24 | 54-816311T | TIE STRAP, (8.00 Inches) |
| 25 | 32-8M0108349 | TUBING, (.312) (70.00 Inches Bulk) (Cut to 36 Inches) |
| 26 | 22-822769 | CONNECTOR |
| 27 | NSS | NOT SOLD SEPARATE, Cap |
| 28 | 32-8M0108355 | HOSE, (57.00 Inches Bulk) (Cut to 2 Inches) |
| 29 | 22-818993 | CONNECTOR, Tee |
| 30 | 32-8M0108355 | HOSE, (57.00 Inches Bulk) (Cut to 4.75 Inches) |
| 31 | 32-8M0108349 | TUBING, (.312) (70.00 Inches Bulk) (Cut to 13.5 Inches) |
| 32 | 32-828547633 | CONDUIT, (.620 Inside Diameter x 3.00 Feet Bulk) (Cut to 13 Inches) |
| 33 | 32-828547T | CONDUIT, (1.00 Inside Diameter x 3.00 Feet Bulk) (Cut to 3.75 Inches) |
| 34 | 32-828547T | CONDUIT, (1.00 Inside Diameter x 3.00 Feet Bulk) (Cut to 1.25 Inches) |
▶Fuel Pump(Serial Number 0T409000 & Up) (39 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| - | 27-804345A02 | GASKET SET, Powerhead |
| 1 | 880890T1 | PUMP, Fuel |
| 2 | NSS | NOT SOLD SEPARATE, Body |
| 3 | 24-881544 | SPRING |
| 4 | 881545 | PLUNGER |
| 5 | 24-881546 | SPRING |
| 6 | 881547 | DIAPHRAGM |
| 7 | 17-881548 | PIN |
| 8 | NSS | NOT SOLD SEPARATE, Body |
| 9 | NSS | NOT SOLD SEPARATE, Diaphragm |
| 10 | NSS | NOT SOLD SEPARATE, Body |
| 11 | 10-881550 | SCREW |
| 12 | 11-881333 | NUT |
| 13 | 25-8M0050719 | O-RING |
| 14 | 56762 | CLAMP |
| 15 | 10-804256 | BOLT, (M6 x 30) |
| 16 | 32-881543002 | HOSE |
| 17 | 881542 | BRACKET |
| 18 | 10-826957M | BOLT |
| 19 | 11-82382M | NUT |
| 20 | 35-881538T02 | FILTER ASSEMBLY |
| 21 | 35-8M0168897 | ELEMENT |
| 22 | 25-826966T | O-RING |
| 23 | 881541 | FLOAT |
| 24 | 881539 | CUP |
| 25 | 56762 | CLAMP |
| 26 | 804260 | BRACKET |
| 27 | 10-804112 | BOLT, (M7 x 48) |
| 28 | 17-804113 | PIN, Dowel |
| 29 | 12-84292M | WASHER |
| 30 | 804257 | LEVER, Fuel Change |
| 31 | 881334 | SHAFT |
| 32 | 17-82738M | PIN |
| 33 | 32-8M0108349 | TUBING, (.312) (70.00 Inches Bulk) (Cut to 55 Inches) |
| 34 | 54-816311T | TIE STRAP, (8.00 Inches) |
| 35 | 22-822769 | CONNECTOR |
| 36 | NSS | NOT SOLD SEPARATE, Cap |
| 37 | 32-828547T1 | CONDUIT, (.500 Inside Diameter x 3.00 Feet Bulk) |
| 38 | 12-82214M | WASHER |
▶Fuel/Vent Lines(Serial Number 0T408999 & Below) (31 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| 1 | 804230 | ROD, Choke |
| 2 | 54-816311T | TIE STRAP, (8.00 Inches) |
| 3 | 32-804236 | HOSE |
| 4 | 84-804197 | HARNESS ASSEMBLY |
| 5 | 21-804198 | CHECK VALVE |
| 6 | 32-804229 | HOSE |
| 7 | 22-804231 | CONNECTOR |
| 8 | 32-804229 | HOSE |
| 9 | 54-98974M | CLIP |
| 10 | 32-804237 | HOSE |
| 11 | 32-804236 | HOSE |
| 12 | 32-804236 | HOSE |
| 13 | 54-804239 | CLAMP |
| 14 | 54-8556961 | CLAMP |
| 15 | 10-804602 | BOLT, (M6 x 12) |
| 16 | 22-97083M | TEE FITTING |
| 17 | 32-804236 | HOSE |
| 18 | 32-804236 | HOSE |
| 19 | 22-804238 | CONNECTOR |
| 20 | 32-804236 | HOSE |
| 21 | 54-814967M | CLIP |
| 22 | 32-804229 | HOSE |
| 23 | 32-804229 | HOSE |
| 24 | 32-804229 | HOSE |
| 25 | 32-804229 | HOSE |
| 26 | 32-804229 | HOSE |
| 27 | 32-9912688 | TUBING, (36.00 Inches Bulk) (Cut to 1.75 Inches) |
| 28 | 22-875268 | TEE FITTING |
| 29 | 54-816311T | TIE STRAP, (8.00 Inches) |
| 30 | 32-8M0108349 | TUBING, (.312) (70.00 Inches Bulk) (Cut to 22 Inches) |
| 31 | 32-8752481 | TUBE, Carburetor Vent |
▶Fuel/Vent Lines(Serial Number 0T409000 & Up) (29 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| 1 | 804230 | ROD, Choke |
| 2 | 54-816311T | TIE STRAP, (8.00 Inches) |
| 3 | 32-804236 | HOSE |
| 4 | 84-804197 | HARNESS ASSEMBLY |
| 5 | 21-804198 | CHECK VALVE |
| 6 | 32-804229 | HOSE |
| 7 | 22-804231 | CONNECTOR |
| 8 | 32-804229 | HOSE |
| 9 | 54-8M0099240 | CLIP |
| 10 | 32-804237 | HOSE |
| 11 | 32-804236 | HOSE |
| 12 | 32-804236 | HOSE |
| 13 | 54-804239 | CLAMP |
| 14 | 54-8556961 | CLAMP |
| 15 | 10-804602 | BOLT, (M6 x 12) |
| 16 | 22-97083M | TEE FITTING |
| 17 | 32-804236 | HOSE |
| 18 | 32-885197 | HOSE |
| 19 | 32-885198 | PIPE |
| 20 | 32-804229 | HOSE |
| 21 | 32-804229 | HOSE |
| 22 | 32-804229 | HOSE |
| 23 | 32-804229 | HOSE |
| 24 | 32-804229 | HOSE |
| 25 | 32-9912688 | TUBING, (36.00 Inches Bulk) (Cut to 1.75 Inches) |
| 26 | 22-875268 | TEE FITTING |
| 27 | 54-816311T | TIE STRAP, (8.00 Inches) |
| 28 | 32-8M0108349 | TUBING, (.312) (70.00 Inches Bulk) (Cut to 22 Inches) |
| 29 | 32-8752481 | TUBE, Carburetor Vent |
▶Gear Hsg Drive 2.07:1-S/N-0T598999 & Below (43 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| - | 47-8M0100526 | REPAIR KIT, Water Pump Impeller |
| 1 | 1667-9011G59 | GEAR HOUSING ASSEMBLY, Basic |
| 2 | 17-8M0084244 | PIN, Dowel - With Hole (.375 x .625) (Front) |
| 3 | 43046 | TUBE, Oiler |
| 4 | 10-79953Q04 | SCREW KIT, (.375-16 x .250) Drain |
| 5 | 12-191833 | WASHER |
| 6 | 17-43044 | PIN, Dowel - Without Hole (.375 x .625) (Rear) |
| 7 | 31640T07 | TRIM TAB |
| 8 | 10-825427 | SCREW, (.437-14 x 1.250) Stainless Steel |
| 9 | 12-451761 | WASHER, (.453 x .812 x .105) Black Oxide |
| 10 | 43040T1 | CARRIER ASSEMBLY |
| 11 | NSS | NOT SOLD SEPARATE, Needle Bearing |
| 12 | 97-826134Q | ANODE |
| 13 | 11-401386 | NUT, (M6) Stainless Steel |
| 14 | 10-4000333 | SCREW, (M6 x 40) |
| 15 | NSS | NOT SOLD SEPARATE, Pinion Gear (Part of 43-881260A5) Comment: SN# 0T575480 THRU 0T598999 |
| 16 | 11-35921 | NUT, (.625-18) |
| 17 | 850307 | CAM, Shift Control |
| 18 | 31-883047A1 | BEARING ASSEMBLY, Tapered Roller Comment: (Use With Pinion stamped 43-881259) SN# 0T575480 THRU 0T598999 |
| 19 | 15-44492A1 | SHIM SET |
| 20 | 45-878575T1 | DRIVESHAFT ASSEMBLY Comment: (X-Long) |
| 21 | 42461A1 | SLEEVE/RING KIT |
| 22 | NSS | NOT SOLD SEPARATE, Seal Ring |
| 23 | 43055A4 | COVER ASSEMBLY, Water Pump |
| 24 | 27-430331 | GASKET |
| 25 | 27-8M0214931 | GASKET |
| 26 | 26-43036 | SEAL, Oil (Lower) |
| 27 | 26-43035 | SEAL, Oil (Upper) |
| 28 | 27-8172771 | GASKET |
| 29 | 817275A2 | HOUSING KIT, Upper Water Pump |
| 30 | 8M0204709 | FACEPLATE |
| 31 | 10-82684430 | SCREW, (M6 x 30) |
| 32 | 430232 | SEAL |
| 33 | 28-8M0204723 | KEY |
| 34 | 47-43026T2 | IMPELLER |
| 35 | 10-82684425 | SCREW, (M6 x 25) |
| 36 | 853908A1 | SHIFT SHAFT ASSEMBLY Comment: (X-Long) |
| 37 | 53-29641 | E RING |
| 38 | 23-43052A4 | BUSHING ASSEMBLY |
| 39 | 25-8M0204681 | O-RING, (1.424 x .103) |
| 40 | 26-8M0204708 | SEAL, Oil |
| 41 | 10-82684425 | SCREW, (M6 x 25) |
| 42 | 26-861415 | FACE SEAL |
▶Gear Hsg Prop 2.07:1-S/N-0T598999 & Below (30 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| - | 43-881260A5 | GEAR ASSEMBLY, Forward (With Forward Bearing |
| 1 | 1667-9011G59 | GEAR HOUSING ASSEMBLY, Basic |
| 2 | 31-30894A1 | BEARING SET, Cup And Cone |
| 3 | NSS | NOT SOLD SEPARATE, Cup |
| 4 | 43-881260A5 | GEAR ASSEMBLY, Pinion/Forward (29 Teeth) Comment: SN# 0T545480 THRU 0T598999 |
| 5 | 31-30895T | BEARING, Needle |
| 6 | 53-856823 | RING, Retaining |
| 7 | 850315A1 | FOLLOWER KIT, Cam |
| 8 | 30-44530 | BALL |
| 9 | NSS | NOT SOLD SEPARATE, Slide |
| 10 | 24-850327 | SPRING |
| 11 | 17-8M0100263 | PIN, Cross |
| 12 | 24-30893 | SPRING |
| 13 | 52-850048T | CLUTCH |
| 14 | 44-8M0140445 | PROPELLER SHAFT |
| 15 | 43-850036T | GEAR, Reverse - 29 Teeth |
| 16 | 8M0168901 | CARRIER ASSEMBLY, Bearing |
| 17 | 25-8M0214974 | O-RING, (3.609 x .139) |
| 18 | 31-30956T | BEARING, Needle |
| 19 | 26-8M0205728 | SEAL, Oil (Inner) |
| 20 | 26-8M0205729 | SEAL, Oil (Outer) |
| 21 | 31-12578T | BEARING, Roller |
| 22 | 12-12577 | THRUST WASHER |
| 23 | 31-12576 | BEARING, Thrust |
| 24 | 16-8M0034456 | STUD, (M8 x 48) |
| 25 | 12-855941 | WASHER, (.323 x .590 x .112) Stainless Steel |
| 26 | 11-401378 | NUT, (M8) |
| 27 | 15-44491A1 | SHIM SET |
| 28 | 8227731 | INSERT, Threaded |
| 29 | NSS | NOT SOLD SEPARATE, Decal-Pinion Identification |
▶Gear Hsg(Drive-2.33:1)(S/N-0T599000 & Up) (43 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| - | 47-8M0100526 | REPAIR KIT, Water Pump Impeller |
| 1 | 1667-9011G59 | GEAR HOUSING ASSEMBLY, Basic |
| 2 | 17-8M0084244 | PIN, Dowel - With Hole (.375 x .625) (Front) |
| 3 | 43046 | TUBE, Oiler |
| 4 | 10-79953Q04 | SCREW KIT, (.375-16 x .250) Drain |
| 5 | 12-191833 | WASHER |
| 6 | 17-43044 | PIN, Dowel - Without Hole (.375 x .625) (Rear) |
| 7 | 31640T07 | TRIM TAB |
| 8 | 10-825427 | SCREW, (.437-14 x 1.250) Stainless Steel |
| 9 | 12-451761 | WASHER, (.453 x .812 x .105) Black Oxide |
| 10 | 43040T1 | CARRIER ASSEMBLY |
| 11 | NSS | NOT SOLD SEPARATE, Needle Bearing |
| 12 | 97-826134Q | ANODE |
| 13 | 11-401386 | NUT, (M6) Stainless Steel |
| 14 | 10-4000333 | SCREW, (M6 x 40) |
| 15 | NSS | NOT SOLD SEPARATE, Pinion Gear (12 Teeth) Comment: (Part of 43-882813A3) |
| 16 | 11-35921 | NUT, (.625-18) |
| 17 | 850307 | CAM, Shift Control |
| 18 | 31-883047A1 | BEARING ASSEMBLY, Tapered Roller |
| 19 | 15-44492A1 | SHIM SET |
| 20 | 45-878575T1 | DRIVESHAFT ASSEMBLY Comment: (X-Long) |
| 21 | 42461A1 | SLEEVE/RING KIT |
| 22 | NSS | NOT SOLD SEPARATE, Seal Ring |
| 23 | 43055A4 | COVER ASSEMBLY, Water Pump |
| 24 | 27-430331 | GASKET |
| 25 | 27-8M0214931 | GASKET |
| 26 | 26-43036 | SEAL, Oil (Lower) |
| 27 | 26-43035 | SEAL, Oil (Upper) |
| 28 | 27-8172771 | GASKET |
| 29 | 817275A2 | HOUSING KIT, Upper Water Pump |
| 30 | 8M0204709 | FACEPLATE |
| 31 | 10-82684430 | SCREW, (M6 x 30) |
| 32 | 430232 | SEAL |
| 33 | 28-8M0204723 | KEY |
| 34 | 47-43026T2 | IMPELLER |
| 35 | 10-82684425 | SCREW, (M6 x 25) |
| 36 | 853908A1 | SHIFT SHAFT ASSEMBLY Comment: (X-Long) |
| 37 | 53-29641 | E RING |
| 38 | 23-43052A4 | BUSHING ASSEMBLY |
| 39 | 25-8M0204681 | O-RING, (1.424 x .103) |
| 40 | 26-8M0204708 | SEAL, Oil |
| 41 | 10-82684425 | SCREW, (M6 x 25) |
| 42 | 26-861415 | FACE SEAL |
▶Gear Hsg(Prop-2.33:1)(S/N-0T599000 & Up) (30 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| - | 52-803489T1 | REPAIR KIT, Clutch/Cam |
| 1 | 1667-9011G59 | GEAR HOUSING ASSEMBLY, Basic |
| 2 | 31-30894A1 | BEARING SET, Cup And Cone |
| 3 | NSS | NOT SOLD SEPARATE, Cup |
| 4 | 43-882813A3 | GEAR KIT, Forward And Pinion 28 Teeth |
| 5 | 31-30895T | BEARING, Needle |
| 6 | 53-856823 | RING, Retaining |
| 7 | 850315A1 | FOLLOWER KIT, Cam |
| 8 | 30-44530 | BALL |
| 9 | NSS | NOT SOLD SEPARATE, Slide |
| 10 | 24-850327 | SPRING |
| 11 | 52-850048T | CLUTCH |
| 12 | 17-8M0100263 | PIN, Cross |
| 13 | 24-30893 | SPRING |
| 14 | 44-8M0140445 | PROPELLER SHAFT |
| 15 | 43-882814T | GEAR, Reverse - 28 Teeth |
| 16 | 8M0168901 | CARRIER ASSEMBLY, Bearing |
| 17 | 25-8M0214974 | O-RING, (3.609 x .139) |
| 18 | 31-30956T | BEARING, Needle |
| 19 | 26-8M0205728 | SEAL, Oil (Inner) |
| 20 | 26-8M0205729 | SEAL, Oil (Outer) |
| 21 | 31-12578T | BEARING, Roller |
| 22 | 12-12577 | THRUST WASHER |
| 23 | 31-12576 | BEARING, Thrust |
| 24 | 16-8M0034456 | STUD, (M8 x 48) |
| 25 | 12-855941 | WASHER, (.323 x .590 x .112) Stainless Steel |
| 26 | 11-401378 | NUT, (M8) |
| 27 | 15-44491A1 | SHIM SET |
| 28 | 8227731 | INSERT, Threaded |
| 29 | NSS | NOT SOLD SEPARATE, Decal-Pinion Identification |
▶Ignition Components (20 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| NS | NSS | NOT SOLD SEPARATE, CLAMP |
| 1 | 804278T11 | RECTIFIER/REGULATOR Comment: (Design I) SN# 0T408999 & Below |
| 2 | 804279 | COVER |
| 3 | 10-853536 | BOLT, (M6 x 25) |
| 4 | 10-804604 | BOLT, (M6 x 20) |
| 5 | 804269T2 | CDI UNIT Comment: SN# 0T599000 & Up |
| 6 | 10-804270 | BOLT, (M6 x 28) |
| 7 | 25-881304 | GROMMET |
| 8 | 23-804344003 | BUSHING |
| 9 | 339-804271T | COIL, Ignition |
| 10 | 10-804603 | BOLT, (M6 x 30) |
| 11 | 54-83577M | CLAMP |
| 12 | 10-804602 | BOLT, (M6 x 12) |
| 13 | 10-804604 | BOLT, (M6 x 20) |
| 14 | 84-804272A1 | CABLE SET, Hi Tension |
| 15 | 54-804276 | CLAMP |
| 16 | 54-804277 | CLAMP |
| 17 | 804278A12 | RECTIFIER/REGULATOR Comment: (Design II) |
| 18 | 84-8042903 | HARNESS ASSEMBLY |
| 19 | 804278T12 | REGULATOR, Voltage |
▶Intake (24 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| - | 27-804345A02 | GASKET SET, Powerhead |
| 1 | 804164T | SILENCER, Intake |
| 2 | 10-804167 | BOLT, M8 x 60 |
| 3 | 10-804165 | BOLT, (M6 x 16) |
| 4 | 804154 | PLATE |
| 5 | 25-84054M | O-RING |
| 6 | 25-804166 | O-RING |
| 7 | 10-804155 | BOLT, (M6 x 115) |
| 8 | 804157 | INSULATOR |
| 9 | 26-804156 | SEAL |
| 10 | 804158T | MANIFOLD |
| 11 | 17-804160 | PIN |
| 12 | 27-804161 | GASKET |
| 13 | 10-804159 | BOLT, (M8 x 35) |
| 14 | 10-84088M | SCREW, (M6 x 10) |
| 15 | 27-827610 | GASKET |
| 16 | 32-804162 | BREATHER PIPE |
| 17 | 54-816311T | TIE STRAP, (8.00 Inches) |
| 18 | 54-804163 | CLAMP |
| 19 | 10-804602 | BOLT, (M6 x 12) |
| 20 | 54-804089 | CLIP |
| 21 | 892849 | INDUCTION SILENCER |
| 22 | 881268 | BRACKET |
| 23 | 10-8M0204741 | SCREW, (M6 x 20) Stainless Steel |
▶Intake/Exhsust Valves (24 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| - | 27-804345A02 | GASKET SET, Powerhead |
| 1 | 804128T | VALVE, Intake |
| 2 | 804129T | VALVE, Exhaust |
| 3 | 804130 | SEAT |
| 4 | 26-804136 | SEAL |
| 5 | 26-804137 | SEAL |
| 6 | 24-804131 | SPRING, Valve |
| 7 | 804132 | RETAINER |
| 8 | 28-804135 | COTTER VALVE |
| 9 | 804138T | LIFTER, Valve |
| 10 | 15-80460880 | SHIM Comment: (2.975) |
| 11 | 2407-804139T | CAMSHAFT |
| 12 | 17-804141 | PIN, Dowel |
| 13 | 2407-8M0057172 | CAMSHAFT |
| 14 | 26-804144001 | SEAL, Oil |
| 15 | 43-804142T | GEAR, Driven |
| 16 | 10-804143001 | BOLT, (M10 x 35) |
| 17 | 57-804145 | V BELT |
| 18 | 804146 | TENSIONER |
| 19 | 24-804147 | SPRING |
| 20 | 32-804148 | HOSE |
| 21 | 10-804150 | BOLT, (M10 x 45) |
| 22 | 11-881314003 | NUT, (M40) |
| 23 | 43-804151T | GEAR, Drive |
▶Key Chart, Ignition Switch (1 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| - | 8949112 | KEY, Ignition (2F) |
▶Oil Pump (20 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| 1 | 25-62705001 | O-RING |
| 2 | 17-41275M | PIN, Dowel |
| 3 | 881900T03 | MOUNT |
| 4 | 10-898487 | BOLT, (M12 x 175) |
| 5 | 12-32834 | WASHER, Neoprene |
| 6 | 12-8M0204648 | WASHER, (1.5 x 3.05 x 0.13) Stainless Steel |
| 7 | 11-896963 | NUT, (M12) |
| 8 | 10-4010750 | SCREW, (M8 x 50) |
| 9 | 858579T3 | PUMP, Oil |
| 10 | 10-8M0052670 | BOLT, (M6 x 45) |
| 11 | 26-804349 | SEAL |
| 12 | 858793T10 | BRACKET, Shift Linkage |
| 13 | 10-42975 | DRIVE SCREW |
| 14 | 10-82130020 | SCREW, (M6 x 20) |
| 15 | 8591761 | RETAINER |
| 16 | 98889 | LATCH |
| 17 | 87-8M0052927 | SWITCH |
| 18 | 10-88075020 | SCREW, (M3 x 20) |
| 19 | 84-878178A1 | HARNESS ASSEMBLY, Shift Interrupt |
| 20 | 8M0043168 | SEAL |
▶Power Trim Components (22 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| - | 25-893914A02 | O-RING KIT (Complete Trim) |
| 1 | 8M0171821 | SHOCK ROD KIT |
| 2 | 25-8M0171819 | O-RING KIT, Rebuild |
| 3 | 8M0171822 | PISTON ASSEMBLY, Memory |
| 4 | 893916A01 | CYLINDER ASSEMBLY |
| 5 | 893905A02 | VALVE KIT, Trim Limit |
| 6 | 893906A02 | PUMP ASSEMBLY |
| 7 | 893907A02 | MOTOR KIT |
| 8 | 22-8134351 | PLUG |
| 9 | 893929A01 | MANUAL RELEASE ASSEMBLY |
| 10 | 893909A02 | MANIFOLD KIT |
| 11 | 10-809876A1 | SCREW KIT (Motor) |
| 12 | 88238A18 | CABLE ASSEMBLY |
| 13 | 809877A1 | DRIVESHAFT/SEAL KIT |
| 14 | 35-893912A02 | FILTER KIT |
| 15 | 893913A02 | POPPET KIT |
| 16 | 17-821539 | PIN, Trilobe |
| 17 | 17-818898 | PIN, Anchor |
| 18 | 99625002 | SHAFT |
| 19 | 54-22740 | CLIP |
| 20 | 10-878609 | SCREW, (#10-16 x .600) |
| 21 | 8M0084613 | C WASHER |
▶Sensors (24 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| - | 27-804345A02 | GASKET SET, Powerhead |
| 1 | 8042941 | PLATE |
| 2 | 10-811188T | BOLT, (M6 x 16) |
| 3 | 804295T | THERMOSENSOR |
| 4 | 804296 | RETAINER |
| 5 | 27-8042971 | GASKET Comment: SN# 0T178500 & Up |
| 6 | 10-811188T | BOLT, (M6 x 16) |
| 7 | 87-8043071 | SWITCH, Oil Pressure Comment: SN# 0T178500 & Up |
| 8 | 54-804300 | CLAMP |
| 9 | 54-804300 | CLAMP |
| 10 | 54-816311T | TIE STRAP, (8.00 Inches) |
| 11 | 10-827160M | SCREW, (M5 x 10) |
| 12 | 804298T | SENSOR, Throttle |
| 13 | 804301 | LEVER |
| 14 | 10-804306 | SCREW, (M5 x 25) |
| 15 | 12-804305 | WASHER |
| 16 | 804302 | BRACKET |
| 17 | 25-804304 | GROMMET |
| 18 | 23-804303 | COLLAR |
| 19 | 54-816311T | TIE STRAP, (8.00 Inches) |
| 20 | 84-859295T1 | HARNESS ASSEMBLY |
| 21 | 54-83577M | CLAMP |
| 22 | 10-84088M | SCREW, (M6 x 10) |
| 23 | 56762 | CLAMP |
▶Service/Support Material (1 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| - | 37-804656A03 | DECAL, EPA Label Information Comment: (2003) |
▶Starter Motor (27 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| - | 50-8M0065220 | STARTER MOTOR ASSEMBLY |
| 1 | 804320 | STOP SET, Pinion |
| 2 | 804319 | PINION |
| 3 | 804331T | COVER |
| 4 | 10-804336 | BOLT, (M6 x 52) |
| 5 | 804332 | LEVER KIT |
| 6 | 804333T | RELAY, Starter |
| 7 | 804334 | COVER |
| 8 | 804321T1 | GEAR KIT |
| 9 | 804322 | CLUTCH |
| 10 | 12-804330 | WASHER KIT |
| 11 | 804324 | BRACKET |
| 12 | 804326 | RING GEAR |
| 13 | 27-804327 | GASKET |
| 14 | 31-804325 | BEARING |
| 15 | 804323 | SHAFT, Pinion |
| 16 | 43-804329001 | IDLER GEAR |
| 17 | 804328 | BRACKET |
| 18 | 804314T | STATOR |
| 19 | 804313T | ARMATURE |
| 20 | 804315T1 | HOLDER KIT, Brush |
| 21 | 804316 | BRUSH SET |
| 22 | 24-804317 | SPRING |
| 23 | 804318T | BRACKET |
| 24 | 10-804337 | SCREW, (M4 x 16) |
| 25 | 10-804335 | THRU BOLT, (M6 x 120) |
| 26 | 10-804605 | BOLT, (M8 x 45) |
▶Steering Handle Kit (39 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| - | 816366A32 | STEERING HANDLE KIT Comment: (2004 Model Year and Up) |
| NS | 22-8M0169589 | FITTING, Grease |
| 1 | 12020A3 | HANDLE ASSEMBLY, Steering Arm |
| 2 | 23-42992T02 | BUSHING |
| 3 | 48414 | HOUSING |
| 4 | 48519 | PLATE |
| 5 | 27-48518 | GASKET |
| 6 | 10-878609 | SCREW, (#10-16 x .600) |
| 7 | 10-878608 | SCREW, (#10-16 x .500) |
| 8 | 54-889729 | CLAMP |
| 9 | 10-40007112 | SCREW, (M5 x 40) |
| 10 | 10-32,11-816874 | WING NUT, |
| 11 | 87-823609A15 | SWITCH KIT, Stop - Throttle Handle |
| 12 | 87-8M0104612 | SWITCH ASSEMBLY, Stop |
| 13 | NSS | NOT SOLD SEPARATE, Insulator |
| 14 | 12018A4 | TUBE ASSEMBLY, Throttle |
| 15 | NSS | NOT SOLD SEPARATE, Drive Wheel |
| 16 | NSS | NOT SOLD SEPARATE, Roll Pin |
| 17 | 10-62568 | SCREW, (#10-16 x .375) |
| 18 | 8M0221732 | GRIP |
| 19 | 54-648552 | CLIP |
| 20 | 11-40140 | NUT, (M10) |
| 21 | 8885241 | CONDUIT, (9.03 Inches) Comment: (Black Vinyl Coverd) |
| 22 | 895665 | GUIDE TUBE |
| 23 | 89578 | BARREL, Throttle Actuator |
| 24 | 10-32,10-824081 | SET SCREW, |
| 25 | 12019003 | CABLE ASSEMBLY |
| 26 | 8M0204660 | GUIDE, Cable |
| 27 | 20007 | ANCHOR, Cable End |
| 28 | 8-32,10-8M0204644 | SET SCREW, |
| 29 | 10-823567105 | SCREW, (M10 x 105) Hex Flange - Stainless Steel |
| 30 | 48416 | CAP |
| 31 | 12-4002319 | WASHER |
| 32 | 12-12024 | WASHER, (.402 x .787 x .039 Bellevi) |
| 33 | 23-146011 | SPACER |
| 34 | 54-816311T | TIE STRAP, (8.00 Inches) |
| 35 | NSS | NOT SOLD SEPARATE, Decal-Throttle |
| 36 | 881240 | GROMMET, Hose Cable Comment: (Use W/ Stainless Steel Mesh Covered Conduit - Ref. #21) |
| 37 | 25-889724 | GROMMET, Hose Cable Comment: (Use W/ Black Vinyl Coverd Conduit - Ref. #21) |
▶Steering Handle Kit Components (50 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| - | 816366T10 | HANDLE Comment: (2004 Model Year and Up) |
| 1 | 816366T10 | HANDLE, Bracket Comment: (2004 Model Year and Up) |
| 2 | 10-881261 | SCREW, (.313-24 x 3.50) |
| 3 | 14-42981 | TAB WASHER |
| 4 | 822263 | SPACER |
| 5 | 84-12649A4 | HARNESS ASSEMBLY |
| 6 | 87-88107A5 | SWITCH KIT, Key Comment: (For Replacement Key - Order 89491--1 Thru 89491-12)(See Key Chart - Ignition Switch Section) |
| 7 | 11-879755 | NUT, Special - Black Nylon Comment: (Black Nylon) |
| 8 | 13541 | PLUG, Male |
| 9 | 121051 | GROMMET |
| 10 | 19-889730 | PLUG |
| 11 | 8M0032846 | RETAINER, Brass |
| 12 | 8158041 | COVER |
| 13 | 10-878608 | SCREW, (#10-16 x .500) |
| 14 | 87-11083A4 | SWITCH ASSEMBLY, Stop |
| 15 | 15920Q54 | LANYARD ASSEMBLY |
| 16 | 84-11149A3 | CABLE ASSEMBLY |
| 17 | 889528T01 | HORN ASSEMBLY Comment: (Use W/ Black Vinyl Coverd Conduit) |
| 18 | 87-18286A19 | SWITCH KIT, Trim (25.00 Feet) Comment: (Use W/ Black Vinyl Coverd Conduit) |
| 19 | 87-8M0052927 | SWITCH |
| 20 | 10-12110 | SCREW, (#6-32 x .750) |
| 21 | 54-648551 | CLAMP |
| 22 | 10-878608 | SCREW, (#10-16 x .500) |
| 23 | 10-849838 | SCREW, (.375-24 x 1.250) |
| 24 | 11-8M0204726 | NUT, (.375-24) Stainless Steel |
| 25 | 48419T01 | ROD END Comment: (2004 Model Year and Up) |
| 26 | 495637 | ROD, Shift |
| 27 | 23-26856 | BUSHING |
| 28 | 12-35950 | WASHER, (.273 x .437 x .031) Stainless Steel |
| 29 | 18-25191 | COTTER PIN, Cotter |
| 30 | 8163677 | LEVER, Shift, Shift |
| 31 | 16-8M0034452 | STUD, (.375-24 x 1.125) |
| 32 | 98530 | KNOB |
| 33 | 12016A2 | DETENT/SPRING KIT |
| 34 | 23-8159831 | BUSHING |
| 35 | 12-823970 | WASHER |
| 36 | 12-824610 | WASHER, Plastic |
| 37 | 12-814803 | WASHER |
| 38 | 14-8158051 | TAB WASHER |
| 39 | 10-4000357 | SCREW, (M8 x 45) |
| 40 | 56-52148A08 | CO PILOT ASSEMBLY Comment: (Use W/ Black Vinyl Coverd Conduit) |
| 41 | 52148002 | PILOT ROD, (15.00 Inches) Comment: (Use W/ Black Vinyl Coverd Conduit)(15 IN.) |
| 42 | 11-52155A1 | NUT ASSEMBLY |
| 43 | 10-36137 | SCREW, (.250-28 x 1.00) |
| 44 | 821621 | KNOB, Prong |
| 45 | 873491 | ROD, Link |
| 46 | 23-26841 | BUSHING Comment: (Use W/ Black Vinyl Coverd Conduit)(Flanged) |
| 47 | 12-8M0042642 | WASHER, (.323 x .563 x .063) Stainless Steel |
| 48 | 11-826709111 | NUT, (.312-24) Stainless Steel |
| 49 | 11-64015 | NUT, (.250-20) |
▶Swivel Bracket and Steering Arm (18 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| 1 | 1400-8M0220957 | SWIVEL BRACKET |
| 2 | 26-87735 | SEAL, Oil (Lower) |
| 3 | 23-818764 | BUSHING |
| 4 | 25-8M0214926 | O-RING |
| 5 | 23-816039 | SPACER |
| 6 | 22-8M0169589 | FITTING, Grease |
| 7 | 23-821207 | BUSHING |
| 8 | 10-64014 | SCREW, (.250-28 x .500) |
| 9 | 99661A35 | SWIVEL PIN ASSEMBLY |
| 10 | 92876A12 | LINK ROD ASSEMBLY |
| 11 | 10-849838 | SCREW, (.375-24 x 1.250) |
| 12 | 11-8M0204726 | NUT, (.375-24) Stainless Steel |
| 13 | 12-37828 | WASHER, (.390 x .625 x .062) Stainless Steel |
| 14 | 42961A06 | YOKE ASSEMBLY, Bottom |
| 15 | 53-67684 | RING, Retaining |
| 16 | 12-816432 | THRUST WASHER |
| 17 | NSS | NOT SOLD SEPARATE, Decal-Serial Overlaminate |
| 18 | 11288001 | BUMPER, Bottom Yoke Comment: (X-Long) |
▶Throttle Lever and Linkage (22 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| 1 | 10-804602 | BOLT, (M6 x 12) |
| 2 | 12-81794M | WASHER |
| 3 | 13-83457M | WAVE WASHER |
| 4 | 12-82221M | PLATE |
| 5 | 23-81949M | BUSHING |
| 6 | 804340 | BRACKET |
| 7 | 10-8248326 | SCREW, (M6 x 25 MM) |
| 8 | 804338 | LEVER, Throttle Control |
| 9 | 17-82149M | PIN, (18.5 mm) |
| 10 | 23-804344 | COLLAR |
| 11 | 24-804343 | SPRING |
| 12 | 8043421 | CAM |
| 13 | 12-84974M | WASHER |
| 14 | 13-81868M | WAVE WASHER |
| 15 | 12-94524M | WASHER |
| 16 | 10-826958M | BOLT, (M6 x 35) |
| 17 | 8587951 | BRACKET, Throttle Lever |
| 18 | 10-85593912 | SCREW, (M6 x 12) |
| 19 | 8587961 | LINK, Throttle |
| 20 | 12-71055 | WASHER |
| 21 | 12-35459 | WASHER |
| 22 | 18-859746 | COTTER PIN |
▶Tools, Special (60 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| 1 | 91-802653Q02 | WRENCH, Oil Filter |
| 2 | 91-8M0161873 | HOLDER TOOL, Flywheel |
| 3 | 91-83164M | FLYWHEEL PULLER |
| 4 | FT2997 | COMPRESSOR TOOL, Piston Ring |
| 5 | 44357Q2 | FLUSHING ATTACHMENT |
| 6 | 90265A5 | PUMP ASSEMBLY, Crankcase Oil |
| 7 | NSS | NOT SOLD SEPARATE Comment: (Snap-On MT26J) (Snap-On MT26J300) |
| 8 | 22-86306A01 | ADAPTOR |
| 9 | 22-89772 | CONNECTOR, (.125-27) |
| 10 | 91-79250A2 | GAUGE KIT |
| 11 | 91-36392 | GAUGE TOOL, Carburetor |
| 12 | 91-37241 | PULLER PLATE, Universal |
| 13 | 91-99379 | TIMING LIGHT |
| 14 | NSS | NOT SOLD SEPARATE, Valve Seat Cutter Kit (Obtain Locally) |
| 15 | 91-890451 | ADAPTOR TOOL, Direct Voltage |
| 16 | 91-34569A1 | PULLER ASSEMBLY, Slide Hammer |
| 17 | 91-850439T1 | TESTER |
| 18 | 91-854009A3 | TACH MULTI METER, DMT 2000 Digital |
| 19 | 91-804771 | HARNESS ASSEMBLY, Pick Up Test |
| 20 | 91-804772 | HARNESS ASSEMBLY, Charge Coil Test |
| 21 | 91-804773 | HARNESS ASSEMBLY, Throttle Position Test |
| 22 | 91-875216 | HOLDER TOOL, Brush |
| 23 | 91-875215A1 | INSTALLER TOOL, Driveshaft Bushing |
| 24 | 91-804774001 | REMOVER/INSTALLER TOOL, Valve Guide |
| 25 | 91-804775 | REAMER TOOL, Valve Guide |
| 26 | 91-809494A1 | COMPRESSOR TOOL, Valve Spring |
| 27 | 91-24697 | EXPANDER TOOL, Piston Ring |
| 28 | 91-804770A1 | HOLDER TOOL, Crankshaft |
| 30 | 91-74951 | SPANNER WRENCH |
| 31 | NSS | NOT SOLD SEPARATE, Lock-Ring Pliers (Snap-On SRP-4) |
| 32 | NSS | NOT SOLD SEPARATE, Expanding Rod (Snap-On CG 41-11) |
| 33 | NSS | NOT SOLD SEPARATE, Collet (Snap-On CG 41-12) |
| 34 | 91-63209 | HEAT LAMP |
| 35 | 91-12349A05 | LOCATION TOOL, Pinion |
| 36 | 91-13945 | INSTALLATION TOOL, Bearing |
| 37 | 91-13949 | DRIVER TOOL, Oil Seal |
| 38 | 91-14308T02 | TOOL KIT, Bearing Race |
| 39 | 91-14309T02 | INSTALLATION TOOL, Bearing |
| 40 | 91-14310T1 | WEAR SLEEVE INSTALLATION TOOL |
| 41 | 91-14311A04 | PRE LOAD TOOL, Bearing |
| 42 | 91-15755T | MANDREL |
| 43 | 91-196601 | INDICATOR TOOL, Backlash |
| 44 | 91-31106T | MANDREL, Bearing Driver Cup |
| 45 | 91-31108T | DRIVER, Oil Seal |
| 46 | 91-36569T | DRIVE HEAD TOOL |
| 47 | 91-804776A1 | HOLDING TOOL, Driveshaft |
| 48 | 91-31229 | SHAFT |
| 49 | 91-34569A1 | PULLER ASSEMBLY, Slide Hammer |
| 50 | 91-37323 | DRIVER ROD TOOL, Needle Bearings |
| 51 | 91-37241 | PULLER PLATE, Universal |
| 52 | 91-37350T | MANDREL |
| 53 | 91-46086A1 | PULLER JAW ASSEMBLY |
| 54 | 91-58222A1 | DIAL INDICATOR TOOL |
| 55 | 91-8M0053505 | INDICATOR TOOL, Backlash |
| 56 | 91-85716 | PULLER BOLT TOOL, Bearing Carrier |
| 57 | 91-83155 | ADAPTER KIT, Dial Indicator |
| 58 | 91-83165T | PULLER ASSEMBLY |
| 59 | 91-856875A1 | INSTALLATION TOOL, Bearing |
| 60 | 91-877321A1 | INSTALLATION TOOL, Bearing |
| 62 | 91-880177 | SCRENCH TOOL, (10 mm) |
▶Top Cowl (26 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| 1 | 4021-827328T10 | TOP COWL ASSEMBLY Comment: (SILVER) |
| 2 | 821256T2 | INLET, Air - Silver Comment: (SILVER) |
| 3 | 10-82130016 | SCREW, (M6 x 16) |
| 4 | 859356A02 | SOUND BLANKET KIT |
| 5 | NSS | NOT SOLD SEPARATE, Sound Blanket-Port |
| 6 | NSS | NOT SOLD SEPARATE, Sound Blanket-Starboard |
| 7 | NSS | NOT SOLD SEPARATE, Sound Blanket-Back |
| 8 | 19-823865 | CAP PLUG |
| 9 | 831207A16 | HANDLE |
| 10 | 23-812707 | BUSHING |
| 11 | 23-831214 | SPACER |
| 12 | 13-12134 | WASHER, Wave |
| 13 | 8M0001081 | CAM, Latch Shaft |
| 14 | 12-8M0214930 | WASHER |
| 15 | 10-1993716 | SCREW, (M6 x 16) |
| 16 | 8M0036792 | BRACKET, Front |
| 17 | 815477 | BUMPER, Latch |
| 18 | 12-8M0204649 | WASHER, (.281 x .500 x .060) Stainless Steel |
| 19 | 11-401366 | NUT, (M6) Stainless Steel |
| 20 | 53-8237951 | RING, Retaining |
| 21 | 8M0207770 | ROLLER |
| 22 | 8155381 | PIN, Roll |
| 23 | 12-8M0204649 | WASHER, (.281 x .500 x .060) Stainless Steel |
| 24 | 11-401366 | NUT, (M6) Stainless Steel |
| 25 | 47341A11 | ROPE AND HANDLE KIT, Manual Starting |
| 26 | 50-12066Q10 | ROPE |
▶Transom Bracket (26 parts)
| Ref | OEM Part # | Part Name |
|---|---|---|
| 1 | 3426-828334T02 | BRACKET, Transom (Starboard) |
| 2 | 3425-828333T07 | BRACKET ASSEMBLY, Transom (Port) |
| 3 | 22-8M0169588 | FITTING, Grease (Port) |
| 4 | 826125A1 | TILT TUBE Comment: (Saltwater) |
| 5 | 11-826135 | NUT, (1.00-14) Nylon Insert Comment: (Saltwater) |
| 6 | 25-45711 | O-RING, (.612 x .103) |
| 7 | 13-88750 | WASHER |
| 8 | 11-826164 | NUT, (.875-14) Comment: (Saltwater) |
| 9 | 10-8M0149747 | SCREW, (.500-20 x 4.500) |
| 10 | 12-8M0204665 | WASHER, (.530 x .870 x .105) Stainless Steel |
| 11 | 12-8M0204648 | WASHER, (1.5 x 3.05 x 0.13) Stainless Steel |
| 12 | 11-82671117 | NUT, (.500-20) |
| 13 | 24-830899 | SPRING, Tension |
| 14 | 8M0109798 | LEVER ASSEMBLY, Tilt Lock |
| 15 | 23-65830 | NYLINER |
| 16 | 24-830900 | SPRING, Compression |
| 17 | 99633 | KNOB |
| 18 | 17-99615 | PIN, Groove |
| 19 | 17-893709 | PIN |
| 20 | 8M0086406 | BRACKET, Anchor |
| 21 | 10-858771 | SCREW, (M10 x 30) |
| 22 | 12-4002319 | WASHER |
| 23 | 11-40114 | NUT, (M10 x 1.5) |
| 24 | 97-818298Q1 | ANODE KIT |
| 25 | 10-8M0204707 | SCREW, (M6 x 25) |
| 26 | 12-8M0204649 | WASHER, (.281 x .500 x .060) Stainless Steel |
100-Hour / Annual Service Checklist
Regular maintenance keeps your Mercury 90 (4-STROKE) 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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