🔎 Mercury V-200 EFI (2.5L) Reference Library — Exploded parts diagrams (30 diagrams), specifications, common issues, and maintenance checklist.
The Mercury V-200 EFI (2.5L) is a 2-Stroke EFI, V6 60-degree outboard motor. Designed for large center-consoles, offshore sport-fishing boats, and multi-engine configurations.
Quick Reference Specifications
| Specification |
Value |
| Engine Type |
2-Stroke EFI, V6 60-degree |
| Horsepower |
200 HP |
| Displacement |
2507 cc (2.5L / 153 CID) |
| Bore x Stroke |
89 mm x 67 mm (3.501 in. x 2.650 in.) |
| Spark Plug (Type & Gap) |
NGK BPZ8HS-10 |
| Engine Oil Capacity |
— |
| Recommended Engine Oil |
Mercury 2-Stroke Outboard Oil (TCW-3) |
| Gear Case Oil Capacity |
802 mL (27.1 oz) |
| Idle Speed (in gear) |
650–700 RPM (in gear) |
| Full Throttle RPM Range |
5000-5600 |
| 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 V-200 EFI (2.5L):
-
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 V-200 EFI (2.5L).
▶Accessories (1 parts)
| Ref |
OEM Part # |
Part Name |
| - |
10-677552 |
SCREW, (.500-20 x 6.500), Mounting Comment: (6-1/2 Inch)(Optional) |
▶Air Handler (15 parts)
| Ref |
OEM Part # |
Part Name |
| - |
883600T04 |
POWERHEAD ASSEMBLY Comment: (200) SN# 0T980000 & Up |
| 1 |
880194T05 |
COVER ASSEMBLY |
| 2 |
25-840525 |
GROMMET |
| 3 |
25-20116 |
GROMMET |
| 4 |
25-855613 |
GROMMET Comment: (200) |
| 5 |
25-882840 |
GROMMET Comment: (150) |
| 6 |
8M0082988 |
SENSOR |
| 7 |
10-40011107 |
SCREW, (M5 x 16) Stainless Steel |
| 8 |
8215832 |
PIN, Special |
| 9 |
8261151 |
CLAMP, Connector |
| 10 |
54-883080 |
J CLIP |
| 11 |
10-817504 |
SCREW, (.250-20 x 1.500) Stainless Steel |
| 12 |
54-8M0024808 |
J CLIP |
| 13 |
37-881865 |
DECAL, Caution-Start in Gear Comment: (Start In Gear) |
| 14 |
880131T08 |
AIR HANDLER ASSEMBLY Comment: SN# 0T945785 & Up |
▶Air Handler Components (48 parts)
| Ref |
OEM Part # |
Part Name |
| - |
883600T04 |
POWERHEAD ASSEMBLY Comment: (200) SN# 0T980000 & Up |
| 1 |
883955T1 |
ADAPTOR PLATE KIT |
| 2 |
27-146974 |
GASKET |
| 3 |
27-8500581 |
GASKET |
| 4 |
855952T3 |
REED BLOCK ASSEMBLY |
| 5 |
10-55715 |
SCREW, (.250-20 x .880) |
| 6 |
8M0185615 |
PUMP ASSEMBLY |
| 7 |
23-855364 |
BUSHING |
| 8 |
25-855362001 |
GROMMET Comment: SN# 0T45785 & Up |
| 9 |
12-817274 |
WASHER, (.344 x 1.00 x .063) Stainless Steel |
| 10 |
10-81893430 |
SCREW, (M8 x 30) |
| 11 |
883954T1 |
PLENUM KIT, Air |
| 12 |
8M0148668 |
SENSOR ASSEMBLY |
| 13 |
25-896699 |
O-RING, (.351 x .072) |
| 14 |
22-884588 |
FITTING |
| 15 |
56762 |
TIE STRAP, (4.00 Inches) |
| 16 |
32-8M0054213 |
HOSE, (40.00 Inches Bulk) (Cut to 34 Inches) Comment: SN# 0T945785 & Up |
| 17 |
883956T1 |
THROTTLE BODY KIT |
| 18 |
25-855423 |
O-RING |
| 19 |
10-82130040 |
SCREW, (M6 x 40) |
| 20 |
854445 |
SENSOR, MAP |
| 21 |
884522 |
BRACKET, MAP Sensor |
| 22 |
10-1993716 |
SCREW, (M6 x 16) |
| 23 |
10-82130025 |
SCREW, (M6 x 25) |
| 24 |
12-8M0214930 |
WASHER |
| 25 |
10-883942 |
SCREW, (M4 x 16) |
| 26 |
54-883941 |
CLAMP |
| 27 |
883926 |
BRACKET |
| 28 |
25-8M0190980 |
GROMMET |
| 29 |
23-822003 |
BUSHING |
| 30 |
883953T1 |
FUEL RAIL |
| 31 |
10-840118 |
SCREW, (#8-32 x .380) |
| 32 |
840422A1 |
PLATE KIT |
| 33 |
25-627021 |
O-RING, (.301 x .070) |
| 34 |
840481T01 |
INJECTOR ASSEMBLY |
| 35 |
NSS |
NOT SOLD SEPARATE, O Ring |
| 36 |
8833821 |
RETAINER |
| 37 |
8832151 |
TUBE |
| 38 |
25-883355 |
O-RING |
| 39 |
84-840482A3 |
HARNESS ASSEMBLY, Injector |
| 40 |
22-883940 |
FITTING |
| 41 |
25-20385 |
O-RING, (.239 x .070) |
| 42 |
883382 |
RETAINER |
| 43 |
10-883376 |
SCREW, (#10-24 x .375) |
| 44 |
10-81893435 |
SCREW, (M8 x 35) |
| 45 |
23-855364 |
BUSHING |
| 46 |
25-855362001 |
GROMMET Comment: SN# 0T980000 & Up |
| 47 |
12-817274 |
WASHER, (.344 x 1.00 x .063) Stainless Steel |
▶Bottom Cowl (34 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
4022-828044A1 |
BOTTOM COWL, Black (PORT) |
| 2 |
4022-828045A1 |
BOTTOM COWL, Black (STARBOARD) |
| 3 |
8M0109217 |
SEAL, Cowl (41.00 Inches) |
| 4 |
875266A2 |
RIGGING KIT |
| 5 |
859435T |
INSERT (BOTTOM) |
| 6 |
859434T |
INSERT (TOP) |
| 7 |
859343 |
FOAM |
| 8 |
10-92799 |
SCREW, (#10-16 x 1.12) |
| 9 |
54-816311T |
TIE STRAP, (8.00 Inches) |
| 10 |
10-82130040 |
SCREW, (M6 x 40) |
| 11 |
831209 |
RETAINER |
| 12 |
19-821908 |
PLUG |
| 13 |
12-821915 |
WASHER |
| 14 |
8219631 |
CHECK VALVE |
| 15 |
25-30641 |
O-RING, (.299 x .103) |
| 16 |
22-821952 |
FITTING |
| 17 |
54-816311T |
TIE STRAP, (8.00 Inches) |
| 18 |
32-8M0039077 |
HOSE |
| 19 |
54-850896 |
CLAMP, (28.6) |
| 20 |
22-8320763 |
FITTING |
| 21 |
22-8M0077650 |
FITTING, Tell-Tale |
| 22 |
889847 |
BOOT, Idle Exhaust |
| 23 |
21-817519A1 |
CHECK VALVE ASSEMBLY, Drain |
| 24 |
87-8M0235191 |
SWITCH, Trim |
| 25 |
889740A02 |
HANDLE KIT Comment: (Plastic Handle) |
| 26 |
10-824868 |
SCREW, (M6 x 75) Comment: (Use W/Cast Handle) |
| 27 |
23-335891 |
BUSHING |
| 28 |
25-48462 |
O-RING, (.614 x .070) |
| 29 |
8219423 |
PAWL, Front Handle |
| 30 |
12-69057 |
WASHER, (.281 x .734 x .063) |
| 31 |
11-401366 |
NUT, (M6) Stainless Steel |
| 32 |
10-8214281 |
SCREW, (#10-16 x .625) |
| 33 |
54-822873 |
CLIP |
| 34 |
32-8M0108355 |
HOSE, (57.00 Inches Bulk) (Cut to 8 Inches) To Telltale |
▶Coil Plate Assembly (23 parts)
| Ref |
OEM Part # |
Part Name |
| - |
879346A51 |
HARNESS ASSEMBLY, 5 Pin |
| 1 |
880188F1 |
PLATE, Coil |
| 2 |
23-8502341 |
BUSHING |
| 3 |
25-833155 |
GROMMET |
| 4 |
12-49436 |
WASHER |
| 5 |
84-858414A1 |
CABLE ASSEMBLY, Braided |
| 6 |
12-8M0042642 |
WASHER, (.323 x .563 x .063) Stainless Steel |
| 7 |
10-60411 |
SCREW, (.312-18 x 1.250) |
| 8 |
12-8M0204649 |
WASHER, (.281 x .500 x .060) Stainless Steel |
| 9 |
10-82129110 |
SCREW, (M6 x 10) |
| 10 |
300-8M0077471 |
COIL KIT |
| 11 |
10-82129130 |
SCREW, (M6 x 30) |
| 12 |
10-82129114 |
SCREW, (M6 x 14) |
| 13 |
84-882757T1 |
HARNESS ASSEMBLY, Coil |
| 14 |
33-938 |
SPARK PLUG, (NGK # BPZ8HS-10) |
| 15 |
84-881908T |
CABLE SET |
| 16 |
54-883066 |
CLIP, (.865) |
| 17 |
71-8M0157742 |
SENSOR KIT, (0-50 PSI), Tan |
| 18 |
881879A2 |
SENSOR KIT, (100 PSI) |
| 19 |
22-8M0207782 |
FITTING Comment: SN# 0T980000 & Up |
| 20 |
32-85944975 |
TUBING, (72.00 Inches Bulk) (Cut to 14-1/2 Inches) |
| 21 |
22-8M0214971 |
COUPLER |
| 22 |
32-85944975 |
TUBING, (72.00 Inches Bulk) (Cut to 52 Inches) |
▶Crankshaft, Pistons and Connecting Rods (18 parts)
| Ref |
OEM Part # |
Part Name |
| - |
883600T04 |
POWERHEAD ASSEMBLY Comment: (200) SN# 0T980000 & Up |
| 1 |
455-850690T2 |
CRANKSHAFT ASSEMBLY |
| 2 |
78662 |
WEAR SLEEVE |
| 3 |
30-67923T |
BEARING, Ball (LOWER) |
| 4 |
53-67446 |
RING, Retaining |
| 5 |
54196A6 |
CARRIER ASSEMBLY |
| 6 |
65800 |
PACKING |
| 7 |
39-67377T |
RING, Sealing, Sealing |
| 8 |
31-16756A6 |
BEARING KIT |
| 9 |
NSS |
NOT SOLD SEPARATE, Race |
| 10 |
785-883063T2 |
PISTON Comment: (STARBOARD - .015 O/S) |
| 11 |
39-822321A1 |
RING KIT, Piston - .015 Oversize, Piston Comment: (.015 O/S)(Qty. of 8 rings in set) |
| 12 |
53-857196 |
LOCK RING |
| 13 |
644-818141A13 |
CONNECTING ROD KIT |
| 14 |
10-763491 |
SCREW, (.312-24 x .875) |
| 15 |
12-8M0012298 |
WASHER |
| 16 |
8M0234886 |
BEARING KIT |
| 17 |
29-8M0204691 |
BEARING, Needle |
▶Cylinder Block and End Caps (43 parts)
| Ref |
OEM Part # |
Part Name |
| - |
883600T04 |
POWERHEAD ASSEMBLY Comment: (200) SN# 0T980000 & Up |
| 1 |
884-858961A23 |
CYLINDER BLOCK ASSEMBLY Comment: (200) |
| 2 |
16-8M0034455 |
STUD, (1.750 Inches) |
| 3 |
16-8M0034454 |
STUD, (.375-16/.375-24 x 6.870) Comment: .375 x 6.87 |
| 4 |
17-43044 |
PIN, Dowel - Without Hole (.375 x .625) |
| 5 |
17-8M0036405 |
PIN (BEARING RACE) |
| 6 |
8M0111325 |
BRACKET |
| 7 |
10-828213 |
SCREW, (.312-18 x 1.500) Hex Flange |
| 8 |
76867 |
COVER (BOTTOM) |
| 9 |
10-828214 |
SCREW, (.312-18 x 2.00) Hex Flange |
| 10 |
22-887801 |
FITTING, Elbow 90 Degree (.0625-27) |
| 11 |
10-66717 |
SCREW, (.375-16 x 3.250) |
| 12 |
10-74824 |
SCREW, (.312-18 x 1.250) |
| 13 |
26852 |
CAP, Nylon |
| 14 |
10-856832 |
SCREW, (.250-20 x 1.750) |
| 15 |
11-64015 |
NUT, (.250-20) |
| 16 |
8215832 |
PIN, Special |
| 17 |
1159-832760T1 |
END CAP ASSEMBLY |
| 18 |
25-54029 |
O-RING, (2.800 x .103) |
| 19 |
31-16756A4 |
BEARING KIT |
| 20 |
NSS |
NOT SOLD SEPARATE, Bearing Race |
| 21 |
26-41953 |
SEAL |
| 22 |
10-881190 |
SCREW, (.312-18 x 1.00) |
| 23 |
1156-7809T1 |
END CAP ASSEMBLY |
| 24 |
25-62700 |
O-RING, (3.237 x .103) |
| 25 |
26-41953 |
SEAL |
| 26 |
10-28636 |
SCREW, (.250-20 x .750) |
| 27 |
13-26992 |
LOCKWASHER, (.250) Stainless Steel |
| 28 |
10-81893414 |
SCREW, (M8 x 14) |
| 29 |
84-88439A46 |
CABLE ASSEMBLY, Battery - Positive Comment: (POSITIVE)(W/Boot) |
| 30 |
8538821 |
BRACKET, Throttle Position Indicator Mount |
| 31 |
8519371 |
LEVER, Throttle Position Indicator |
| 32 |
10-82130025 |
SCREW, (M6 x 25) |
| 33 |
23-856954 |
BUSHING |
| 34 |
12-65567 |
WASHER, (.265 x .750 x .048) Stainless Steel |
| 35 |
25-8M0190980 |
GROMMET |
| 36 |
8M6005165 |
INDICATOR, Throttle Position |
| 37 |
8582261 |
COVER |
| 38 |
10-8508281 |
SCREW, (#10-32 x 2.00) |
| 39 |
8M0084738 |
LINK ASSEMBLY |
| 40 |
54-28700 |
CLAMP Comment: SN# 0T945785 & Up |
| 41 |
10-8248324 |
SCREW, (M6 x 16) |
| 42 |
54-859172 |
CLAMP Comment: SN# 0T945785 & Up |
▶Cylinder Head (27 parts)
| Ref |
OEM Part # |
Part Name |
| - |
883600T04 |
POWERHEAD ASSEMBLY Comment: (200) SN# 0T980000 & Up |
| 1 |
858281A10 |
CYLINDER HEAD ASSEMBLY Comment: (200) |
| 2 |
25-8M0149612 |
SEAL |
| 3 |
8597721 |
SEAL |
| 4 |
10-8M0125882 |
SCREW, (.375-16 x 2.750) |
| 5 |
17-63779 |
PIN, Dowel (.250 x .625) |
| 6 |
27-8M0204714 |
GASKET Comment: SN# 0T980000 & Up |
| 7 |
90390A1 |
COVER KIT |
| 8 |
75692 |
THERMOSTAT |
| 9 |
10-40011149 |
SCREW, (M8 x 25) Stainless Steel |
| 10 |
22-687271 |
FITTING, (.250-18) 90 Degree - Brass |
| 11 |
32-77653101 |
HOSE, (48.00 Inches Bulk) (Cut to 12-3/4 Inches) |
| 12 |
22-68728 |
FITTING |
| 13 |
54-816311T |
TIE STRAP, (8.00 Inches) |
| 14 |
32-77653101 |
HOSE, (48.00 Inches Bulk) (Cut to 13-1/2 Inches) |
| 15 |
32-827602002 |
HOSE |
| 16 |
22-815914 |
T-FITTING, To Telltale |
| 17 |
22-897722 |
FITTING, Straight |
| 18 |
8M6003194 |
SENSOR ASSEMBLY, Knock Comment: (200) |
| 19 |
882841 |
ADAPTOR Comment: (200) |
| 20 |
12-4002319 |
WASHER Comment: (200) |
| 21 |
10-87810178 |
SCREW, (M10 x 35) Comment: (200) |
| 22 |
8M0148668 |
SENSOR ASSEMBLY |
| 23 |
25-896699 |
O-RING, (.351 x .072) |
| 24 |
13536A13 |
SENSOR ASSEMBLY, Temperature |
| 25 |
10-81893414 |
SCREW, (M8 x 14) |
| 26 |
137151 |
RETAINER |
▶Driveshaft Housing and Exhaust Tube (41 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-8M0046715 |
GASKET SET |
| 1 |
3503-813563T1 |
HOUSING, Driveshaft - Black - X-Long Comment: (X-LONG) |
| 2 |
16-56295 |
STUD, (.437 x 2.69) |
| 3 |
10-898831 |
SCREW, (.500-20 x 6.00) |
| 4 |
88238A10 |
CABLE ASSEMBLY, Ground |
| 5 |
77327 |
MOUNT, Lower |
| 6 |
12-49339 |
WASHER, (.8125) |
| 7 |
11-898832 |
NUT, (.500-20) |
| 8 |
10-41508 |
SCREW, (.250-20 x .500) Stainless Steel |
| 9 |
12-45176 |
WASHER, (.453 x .812 x .105) Stainless Steel |
| 10 |
11-8M0204653 |
NUT, (.437-20) Stainless Steel |
| 11 |
54-8M0036782 |
CLAMP |
| 12 |
10-66727 |
SCREW, (.312-18 x 1.250) |
| 13 |
100-8M4500752 |
COVER, Black |
| 14 |
10-88417 |
SCREW, (#12-24 x .620) |
| 15 |
11-35521 |
NUT |
| 16 |
12-48926 |
WASHER |
| 17 |
11-8M0204653 |
NUT, (.437-20) Stainless Steel |
| 18 |
12-20553 |
WASHER, (.406 x .734 x .063) |
| 19 |
11-69254 |
NUT |
| 20 |
8M0039081 |
BOOT, Idle Exhaust |
| 21 |
19-64649 |
PLUG |
| 22 |
27-991734 |
GASKET |
| 23 |
66350001 |
SEAL (LOWER) Comment: SN# 0T980000 & Up |
| 24 |
18276T |
TUBE, Exhaust |
| 25 |
8M0039076 |
SEAL (UPPER) |
| 26 |
812834A2 |
EXTENSION ASSEMBLY, Exhaust Comment: (150) |
| 27 |
16-56766 |
STUD |
| 28 |
12-35044 |
WASHER, (.281 x .625 x .065) Stainless Steel |
| 29 |
11-888500 |
NUT |
| 30 |
879288T71 |
EXTENSION, Exhaust Comment: (200) |
| 31 |
32-8M0042790 |
TUBE, Water Comment: (X-LONG) |
| 32 |
18233A20 |
PLATE ASSEMBLY, Driveshaft Housing |
| 33 |
8M0043165 |
SEAL |
| 34 |
68011 |
BRACKET |
| 35 |
10-878608 |
SCREW, (#10-16 x .500) |
| 36 |
17-43044 |
PIN, Dowel - Without Hole (.375 x .625) |
| 37 |
26-38970 |
SEAL |
| 38 |
22-328022 |
PLUG, Pipe (.125-27) Brass |
| 39 |
27-183076 |
GASKET |
| 40 |
NSS |
NOT SOLD SEPARATE, Decal-Counter Rotation |
▶Dual Engine Tie Bar Kit (21 parts)
| Ref |
OEM Part # |
Part Name |
| - |
92876A9 |
EXTENSION KIT, Dual Engine |
| 1 |
71565A2 |
TUBE ASSEMBLY |
| 2 |
25-48462 |
O-RING, (.614 x .070) |
| 3 |
41055 |
MOUNT |
| 4 |
14-42100 |
TAB WASHER |
| 5 |
11-8M0041651 |
NUT, (.875-14) |
| 6 |
88404 |
TAB WASHER |
| 7 |
10-38601 |
SCREW, (.250-28 x 1.250) |
| 8 |
17729A1 |
BRACKET |
| 9 |
10-62055 |
SCREW, (.312-24 x 1.250) |
| 10 |
17728 |
TAB WASHER |
| 11 |
10-140001 |
SCREW, (.375-24 x 1.38) |
| 12 |
11-8M0204726 |
NUT, (.375-24) Stainless Steel |
| 13 |
8M0026167 |
STEERING EYE |
| 14 |
23-23651 |
SLEEVE, (1.625) |
| 15 |
97931 |
TUBING, (4.00 Inches) |
| 16 |
8M0026098 |
COUPLER, (15.00 Inches) |
| 17 |
11-42099 |
NUT, (.562-18) |
| 18 |
22-821169 |
COUPLING |
| 19 |
12-37828 |
WASHER, (.390 x .625 x .062) Stainless Steel Comment: (.625 Outside Diameter) |
| 20 |
10-94319 |
SCREW, (.375-24 x 1.5) |
▶Electrical Plate Assembly (47 parts)
| Ref |
OEM Part # |
Part Name |
| - |
NSS |
NOT SOLD SEPARATE, Electrical Plate Assembly |
| 1 |
833137F1 |
PLATE |
| 2 |
10-82129110 |
SCREW, (M6 x 10) |
| 3 |
54-858755 |
CLIP, (1.00) |
| 4 |
8M0207773 |
RELAY ASSEMBLY |
| 5 |
NSS |
NOT SOLD SEPARATE, Decal-Trim Relay |
| 6 |
828102 |
BRACKET |
| 7 |
23-8M0214955 |
BUSHING |
| 8 |
25-818967 |
GROMMET |
| 9 |
10-82129125 |
SCREW, (M6 x 25) |
| 10 |
23-91912 |
BUSHING |
| 11 |
84-819514T16 |
HARNESS ASSEMBLY, Trim |
| 12 |
84-882830A1 |
CABLE ASSEMBLY, Starter |
| 13 |
84-88807A16 |
CABLE ASSEMBLY, (4.00 Inches) Black (BLACK) |
| 14 |
84-859244A2 |
HARNESS ASSEMBLY, Smartcraft |
| 15 |
85-8500671 |
BOOT, Insulator - Red (Use where Applicable) |
| 16 |
89-817109A2 |
SOLENOID ASSEMBLY, (#10-32 / .3125-18 Terminals) |
| 17 |
25-822179 |
GROMMET |
| 18 |
23-8M0214955 |
BUSHING |
| 19 |
10-32,11-813938 |
CAP NUT, |
| 20 |
10-32,11-45076 |
NUT, Brass |
| 21 |
13-53166 |
LOCKWASHER, (.312) |
| 22 |
11-8M0204668 |
NUT, (.312-18) |
| 23 |
12-8M0204649 |
WASHER, (.281 x .500 x .060) Stainless Steel |
| 24 |
10-82129135 |
SCREW, (M6 x 35) |
| 25 |
84-880186T3 |
HARNESS ASSEMBLY, Engine Wiring |
| 26 |
858754 |
COVER, Fuse |
| 27 |
54-828991T |
CLIP |
| 28 |
879346A50 |
HARNESS ASSEMBLY (FUEL INJECTOR) |
| 29 |
879346A41 |
HARNESS ASSEMBLY (TPS) |
| 30 |
88-832969T15 |
FUSE, Mini - Blue - 15 Ampere Comment: (15 AMP) |
| 31 |
54-816311T |
TIE STRAP, (8.00 Inches) |
| 32 |
10-82130012 |
SCREW, (M6 x 12) |
| 33 |
89790617T |
PCM, Propulsion Control Module Comment: (200) SN# 0T980000 & Up |
| 34 |
10-82130025 |
SCREW, (M6 x 25) |
| 35 |
23-856954 |
BUSHING |
| 36 |
25-8M0190980 |
GROMMET |
| 37 |
12-65567 |
WASHER, (.265 x .750 x .048) Stainless Steel |
| 38 |
858953 |
BRACKET |
| 39 |
10-82129114 |
SCREW, (M6 x 14) |
| 40 |
13540 |
CAP, Female |
| 41 |
84-882815A1 |
HARNESS ASSEMBLY, Knock Sensor Comment: (200) |
| 42 |
832948A1 |
CONNECTOR ASSEMBLY |
| 43 |
881065A1 |
CONNECTOR, 6 Pin Plug |
| 44 |
84-878231A6 |
HARNESS ASSEMBLY, Fuse - 100 Ampere |
| 45 |
881175A1 |
CAP ASSEMBLY, Connector Comment: (COUNTER ROTATION) |
| 46 |
881176A1 |
CAP ASSEMBLY, Connector Comment: (COUNTER ROTATION) |
▶Engine Gasket Set Components (2 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-8M0046715 |
GASKET SET |
| 0 |
25-8M0214920 |
O-RING, Bearing Carrier |
▶Exhaust Manifold and Exhaust Plate (38 parts)
| Ref |
OEM Part # |
Part Name |
| - |
883600T04 |
POWERHEAD ASSEMBLY Comment: (200) SN# 0T980000 & Up |
| 1 |
27-190506 |
GASKET |
| 2 |
828343A05 |
PLATE KIT, Exhaust Divider, Exhasut |
| 3 |
26-814754 |
SEAL, (12.50 Inches) |
| 4 |
10-8263561 |
SCREW AND WASHER, (.312-18 x 1.500) |
| 5 |
10-881190 |
SCREW, (.312-18 x 1.00) |
| 6 |
8M0039767 |
COVER, Relief Valve |
| 7 |
10-31984 |
SCREW, (.312-18 x 1.375) |
| 8 |
10-69570 |
SCREW, (#10-16 x .750) |
| 9 |
12-76451 |
WASHER |
| 10 |
144791 |
DIAPHRAGM |
| 11 |
16496 |
DEFLECTOR, Water |
| 12 |
16497A1 |
PLATE |
| 13 |
27-78690002 |
GASKET |
| 14 |
24-42996 |
SPRING |
| 15 |
14480 |
POPPET |
| 16 |
25-64872 |
GROMMET |
| 17 |
65848 |
CARRIER |
| 18 |
27-991764 |
GASKET |
| 19 |
18260T2 |
PLATE ASSEMBLY, Exhaust |
| 20 |
17-43044 |
PIN, Dowel - Without Hole (.375 x .625) |
| 21 |
8M0043164 |
SEAL |
| 22 |
680101 |
BRACKET |
| 23 |
10-878608 |
SCREW, (#10-16 x .500) |
| 24 |
25-19565002 |
GROMMET Comment: SN# 0T980000 & Up |
| 25 |
12-20553 |
WASHER, (.406 x .734 x .063) |
| 26 |
11-69254 |
NUT |
| 27 |
23-27132 |
BUSHING |
| 28 |
10-66727 |
SCREW, (.312-18 x 1.250) |
| 29 |
10-68783 |
SCREW, (.312-18 x 2.50) |
| 30 |
10-898833 |
SCREW, (.375-16 x 3.50) |
| 31 |
812905T |
BRACKET ASSEMBLY, Front |
| 32 |
10-8055571 |
SCREW, (.3125-18 x .50) |
| 33 |
12-187031 |
WASHER |
| 34 |
25-18778001 |
GROMMET Comment: SN# 0T980000 & Up |
| 35 |
18578T09 |
BRACKET ASSEMBLY, Rear |
| 36 |
25-12602002 |
GROMMET Comment: SN# 0T980000 & Up |
| 37 |
10-881892 |
SCREW, (.312-18 x 1.750) |
▶Flywheel/Alternator (28 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
8M0064021 |
ALTERNATOR |
| 2 |
10-8M0012503 |
SCREW, (M10 x 100) Hex Flange - Stainless Steel |
| 3 |
10-40108120 |
SCREW, (M10 x 120) Hex Flange - Stainless Steel |
| 4 |
12-8M0042641 |
WASHER, (.390 x 1.00 x .06) |
| 5 |
23-856975 |
MOUNT |
| 6 |
858391T01 |
BRACKET |
| 7 |
12-845998 |
WASHER, (.406 x 1.250 x .089) |
| 8 |
858393T01 |
BRACKET |
| 9 |
11-826292 |
NUT, (M10) Brass/Nickel Plated |
| 10 |
10-82446155 |
SCREW, (M10 x 55) |
| 11 |
84-856583T2 |
CABLE ASSEMBLY |
| 12 |
12-4002319 |
WASHER |
| 13 |
857142T |
BRACKET |
| 14 |
10-812618 |
SCREW, (.312-18 x 1.00) Stainless Steel With Nylon Patch |
| 15 |
24-855798001 |
SPRING |
| 16 |
856815T2 |
ARM TENSIONER ASSEMBLY |
| 17 |
16-8M0034457 |
STUD, (M10 x 85) |
| 18 |
11-826292 |
NUT, (M10) Brass/Nickel Plated |
| 19 |
23-8568941 |
BUSHING |
| 20 |
12-4002320 |
WASHER |
| 21 |
883471T |
PULLEY |
| 22 |
10-4010835 |
SCREW, (M10 x 35) Hex Flange - Stainless Steel |
| 23 |
57-828507Q11 |
BELT |
| 24 |
281-859734T1 |
FLYWHEEL |
| 25 |
11-52901 |
NUT, (.625-18) |
| 26 |
12-33001 |
WASHER, (.641 x 1.250 x .190) |
| 27 |
19-45907 |
PLUG, Yellow |
| 28 |
11-401386 |
NUT, (M6) Stainless Steel |
▶Fuel System (31 parts)
| Ref |
OEM Part # |
Part Name |
| - |
883600T04 |
POWERHEAD ASSEMBLY Comment: (200) SN# 0T980000 & Up |
| 1 |
NSS |
NOT SOLD SEPARATE, Body-Fuel Pump |
| 2 |
21-857005A1 |
DIAPHRAGM KIT |
| 3 |
NSS |
NOT SOLD SEPARATE, Check Valve |
| 4 |
NSS |
NOT SOLD SEPARATE, Retainer |
| 5 |
NSS |
NOT SOLD SEPARATE, Spring |
| 6 |
NSS |
NOT SOLD SEPARATE, Cap |
| 7 |
NSS |
NOT SOLD SEPARATE, Spring |
| 8 |
NSS |
NOT SOLD SEPARATE, Cap |
| 9 |
NSS |
NOT SOLD SEPARATE, Diaphragm |
| 10 |
NSS |
NOT SOLD SEPARATE, Gasket-Boost |
| 11 |
NSS |
NOT SOLD SEPARATE, Gasket-Pulse |
| 12 |
27-8M0204705 |
GASKET |
| 13 |
987752 |
PLATE |
| 14 |
22-996642 |
FITTING, Elbow 90 Degree (.125-27 x .250) Nylon |
| 15 |
10-82104540 |
SCREW, (M5 x 40), Fuel Pump |
| 16 |
10-82130050 |
SCREW, (M6 x 50), Pump to Crankcase |
| 17 |
144303 |
BASE |
| 18 |
22-291112 |
FITTING |
| 19 |
22-782792 |
FITTING, Elbow 45 Degree (1.25) |
| 20 |
54-816311T |
TIE STRAP, (8.00 Inches) |
| 21 |
32-8M0108349 |
TUBING, (.312) (70.00 Inches Bulk) (Cut to 6 Inches) |
| 22 |
22-996642 |
FITTING, Elbow 90 Degree (.125-27 x .250) Nylon, To Block |
| 23 |
32-8M0043979 |
HOSE AND SLEEVE ASSEMBLY, (18.00 Inches) |
| 24 |
22-822769 |
CONNECTOR |
| 25 |
32-8M0064784 |
TUBING |
| 26 |
32-8M0108355 |
HOSE, (57.00 Inches Bulk) (Cut to 7-1/2 Inches) |
| 27 |
22-858955 |
CONNECTOR, To Flywheel Cover |
| 28 |
54-8M0214964 |
CLAMP, Hose (15.3) |
| 29 |
32-883363 |
HOSE |
| 30 |
32-883352 |
CONDUIT |
▶Gear Housing(Driveshaft)(Standard/Counter Rotation) (49 parts)
| Ref |
OEM Part # |
Part Name |
| - |
43-803613T1 |
GEAR ASSEMBLY, Pinion/Forward Comment: (Counter Rotation)(2:1) |
| 0 |
1647-9148T83 |
GEAR HOUSING ASSEMBLY, Complete (4.75 Inch/120.65 mm Torpedo Diameter) Comment: (Counter Rotation)(2:1) |
| 1 |
1647-9148T93 |
GEAR HOUSING ASSEMBLY, Basic |
| 2 |
17-43044 |
PIN, Dowel - Without Hole (.375 x .625) |
| 3 |
16-8M0034464 |
STUD, (.438 x 3.82 Inches) Comment: (X-LONG) |
| 4 |
16-8M0133358 |
STUD, (.437-14/.437-20 x 2.060) |
| 5 |
16-8M0034463 |
STUD, (.312-18/.324-24 x 3.380) |
| 6 |
16-306671 |
STUD, (.250-20/.250-28 x 3.125) |
| 7 |
8M0039169 |
FILLER BLOCK |
| 8 |
31-42647A1 |
BEARING ASSEMBLY, Roller |
| 9 |
97-826134Q |
ANODE |
| 10 |
10-4000333 |
SCREW, (M6 x 40) |
| 11 |
11-401386 |
NUT, (M6) Stainless Steel |
| 12 |
22-881866 |
FITTING |
| 13 |
23-29804T |
SLEEVE |
| 14 |
43-44101T3 |
GEAR, Pinion Comment: (2:1 - 14 Teeth) |
| 15 |
12-92721 |
WASHER |
| 16 |
11-35921 |
NUT, (.625-18) |
| 17 |
15-42637A1 |
SHIM SET (006 THRU 048) |
| 18 |
10-79953Q04 |
SCREW KIT, (.375-16 x .250) Drain |
| 19 |
12-191833 |
SEAL |
| 20 |
789022 |
SHIFT SHAFT |
| 21 |
25-25439 |
O-RING, (.862 x .103) |
| 22 |
23-77631A2 |
BUSHING ASSEMBLY |
| 23 |
26-8M0204708 |
SEAL, Oil |
| 24 |
12-77674 |
WASHER |
| 25 |
45-897625T |
DRIVESHAFT Comment: (X-LONG) |
| 26 |
31-8M0146566 |
BEARING, Roller |
| 27 |
NSS |
NOT SOLD SEPARATE, Cup |
| 28 |
8245191 |
RETAINER |
| 29 |
46-8M0077147 |
BASE ASSEMBLY, Water Pump |
| 30 |
NSS |
NOT SOLD SEPARATE, Retainer |
| 31 |
27-8M0204678 |
GASKET |
| 32 |
25-8M0142854 |
O-RING, (2.175 x .175) |
| 33 |
26-89238 |
SEAL, Oil |
| 34 |
26-16977 |
SEAL, Oil |
| 35 |
27-8M0090319 |
GASKET, Lower |
| 36 |
27-858524 |
GASKET |
| 37 |
8M0204677 |
FACE PLATE |
| 38 |
46-96148T1 |
BODY ASSEMBLY, Water Pump |
| 39 |
48752T |
INSERT |
| 40 |
26-38970 |
SEAL |
| 41 |
47-89984T3 |
IMPELLER |
| 42 |
28-8M0214992 |
KEY |
| 43 |
10-8M0215009 |
SCREW, (#14-8 x 2.25) |
| 44 |
12-8M0204649 |
WASHER, (.281 x .500 x .060) Stainless Steel |
| 45 |
11-8267119 |
NUT, (.250-28) |
| 46 |
12-36001 |
WASHER |
| 47 |
11-13436 |
NUT |
▶Gear Housing, Propeller Shaft - Counter Rotation (41 parts)
| Ref |
OEM Part # |
Part Name |
| - |
43-803613T1 |
GEAR ASSEMBLY, Pinion/Forward Comment: (2:1) |
| 1 |
1647-9148T93 |
GEAR HOUSING ASSEMBLY, Basic |
| 2 |
89594A1 |
FOLLOWER ASSEMBLY |
| 3 |
789562 |
SHIFT CAM |
| 4 |
828287 |
ROD |
| 5 |
15-44491A1 |
SHIM SET |
| 6 |
828830A2 |
ADAPTOR ASSEMBLY, Bearing |
| 7 |
31-814653T |
BEARING ASSEMBLY, Needle Rollers |
| 8 |
12-815481 |
THRUST WASHER |
| 9 |
31-815480 |
BEARING, Thrust |
| 10 |
43-828704A2 |
GEAR ASSEMBLY, Reverse - 14/28 Comment: (2:1 Gear Ratio) |
| 11 |
31-15844 |
BEARING ASSEMBLY, Roller |
| 12 |
24-30893 |
SPRING |
| 13 |
52-859340T |
CLUTCH |
| 14 |
17-8M0100263 |
PIN, Cross |
| 15 |
17-828356 |
PIN, Detent |
| 16 |
44-828951 |
PROPELLER SHAFT |
| 17 |
43-828703A1 |
GEAR ASSEMBLY, Forward - 14/28 Comment: (2:1 Gear Ratio) |
| 18 |
23-1761526 |
SPACER SHIM, (.230) |
| 19 |
31-815480 |
BEARING, Thrust |
| 20 |
12-815481 |
THRUST WASHER |
| 21 |
828831A3 |
ADAPTOR ASSEMBLY, Bearing |
| 22 |
31-814653T |
BEARING ASSEMBLY, Needle Rollers |
| 23 |
12-18448 |
THRUST WASHER |
| 24 |
31-15842 |
BEARING, Thrust |
| 25 |
8182911 |
RACE, Thrust |
| 26 |
814605 |
KEEPER |
| 27 |
25-8M0214920 |
O-RING |
| 28 |
818290A4 |
CARRIER ASSEMBLY, Bearing |
| 29 |
31-30956T |
BEARING, Needle |
| 30 |
26-14077 |
SEAL, Oil Comment: (INSIDE) |
| 31 |
26-8M0204670 |
SEAL Comment: (OUTSIDE) |
| 32 |
14-183231 |
TAB WASHER |
| 33 |
28-30281 |
KEY |
| 34 |
8M2011027 |
RETAINER |
| 35 |
97-76214Q5 |
ANODE Comment: Aluminum |
| 36 |
10-8M0204686 |
SCREW, (.437-14 x 1.750) |
| 37 |
10-65210 |
SCREW, (.375-16 x 1.00) |
| 38 |
12-45176 |
WASHER, (.453 x .812 x .105) Stainless Steel |
| 39 |
11-8M0204653 |
NUT, (.437-20) Stainless Steel |
| 40 |
NSS |
NOT SOLD SEPARATE, Decal-Counter Rotation |
▶Gear Housing, Propeller Shaft - Standard Rotation (34 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-8M0046715 |
GASKET SET |
| 1 |
1647-9148T93 |
GEAR HOUSING ASSEMBLY, Basic |
| 2 |
89594A1 |
FOLLOWER ASSEMBLY |
| 3 |
789562 |
SHIFT CAM |
| 4 |
828287 |
ROD |
| 5 |
43-803612T2 |
GEAR ASSEMBLY, Pinion/Forward Comment: (2:1 Gear Ratio) SN# 0T980000 & Up |
| 6 |
15-44491A1 |
SHIM SET |
| 7 |
31-30894A1 |
BEARING SET, Cup And Cone |
| 8 |
NSS |
NOT SOLD SEPARATE, Cup |
| 9 |
31-30895T |
BEARING, Needle |
| 10 |
53-856823 |
RING, Retaining |
| 11 |
52-859340T |
CLUTCH |
| 12 |
17-8M0100263 |
PIN, Cross |
| 13 |
17-828356 |
PIN, Detent |
| 14 |
24-30893 |
SPRING |
| 15 |
44-94148 |
PROPELLER SHAFT |
| 16 |
43-828177A1 |
GEAR ASSEMBLY, Reverse - 14/28 Comment: (2:1 Gear Ratio) |
| 17 |
23-824108 |
SPACER |
| 18 |
681001 |
RING, Thrust |
| 19 |
30-88957T |
BEARING, Ball |
| 20 |
25-8M0214920 |
O-RING |
| 21 |
43567T1 |
CARRIER ASSEMBLY, Bearing |
| 22 |
31-30956T |
BEARING, Needle |
| 23 |
26-14077 |
SEAL, Oil (INSIDE) |
| 24 |
26-8M0204670 |
SEAL (OUTSIDE) |
| 25 |
28-30281 |
KEY |
| 26 |
14-79447 |
TAB WASHER |
| 27 |
8M2011027 |
RETAINER |
| 28 |
31640T07 |
TRIM TAB |
| 29 |
97-76214Q5 |
ANODE KIT |
| 30 |
10-8M0204686 |
SCREW, (.437-14 x 1.750) |
| 31 |
10-65210 |
SCREW, (.375-16 x 1.00) |
| 32 |
12-45176 |
WASHER, (.453 x .812 x .105) Stainless Steel |
| 33 |
11-8M0204653 |
NUT, (.437-20) Stainless Steel |
▶Oil Lines (17 parts)
| Ref |
OEM Part # |
Part Name |
| - |
883600T04 |
POWERHEAD ASSEMBLY Comment: (200) SN# 0T980000 & Up |
| 1 |
22-887801 |
FITTING, Elbow 90 Degree (.0625-27) |
| 2 |
32-8M0054152 |
TUBING, (38.00 Inches Bulk) (Cut to 22 Inches) |
| 3 |
22-59169003 |
FITTING, Tee |
| 4 |
32-8M0054152 |
TUBING, (38.00 Inches Bulk) (Cut to 1-1/2 Inches) |
| 5 |
32-8M0054152 |
TUBING, (38.00 Inches Bulk) (Cut to 4-3/4 Inches) |
| 6 |
32-8M0054152 |
TUBING, (38.00 Inches Bulk) (Cut to 3-1/2 Inches) |
| 7 |
21-426233 |
CHECK VALVE |
| 8 |
21-426982 |
CHECK VALVE |
| 9 |
21-8282182 |
CHECK VALVE |
| 10 |
21-8348041 |
CHECK VALVE |
| 11 |
56762 |
TIE STRAP, (4.00 Inches) |
| 12 |
32-8M0054152 |
TUBING, (38.00 Inches Bulk) (Cut to 4-1/2 Inches) |
| 13 |
32-8M0054152 |
TUBING, (38.00 Inches Bulk) (Cut to 16-1/2 Inches) Comment: SN# 0T945785 & Up |
| 14 |
32-8M0054152 |
TUBING, (38.00 Inches Bulk) (Cut to 7 Inches) |
| 15 |
32-8M0054152 |
TUBING, (38.00 Inches Bulk) (Cut to 4-3/4 Inches) |
| 16 |
32-8M0054152 |
TUBING, (38.00 Inches Bulk) (Cut to 5-1/4 Inches) |
▶Oil Tank (22 parts)
| Ref |
OEM Part # |
Part Name |
| - |
883600T04 |
POWERHEAD ASSEMBLY Comment: (200) SN# 0T980000 & Up |
| 1 |
NSS |
NOT SOLD SEPARATE, Oil Reservoir |
| 2 |
NSS |
NOT SOLD SEPARATE, Decal-Reservoir |
| 3 |
25-855362001 |
GROMMET Comment: SN# 0T980000 & Up |
| 4 |
12-49436 |
WASHER |
| 5 |
10-60411 |
SCREW, (.312-18 x 1.250) |
| 6 |
23-855364 |
BUSHING |
| 7 |
87-856156T02 |
SWITCH ASSEMBLY |
| 8 |
10-58376 |
SCREW, (.164-18 x .375) |
| 9 |
12-72761 |
WASHER, (.203 x .562 x .060) Stainless Steel |
| 10 |
21-8781051 |
CHECK VALVE, To Block |
| 11 |
22-8M0207780 |
FITTING |
| 12 |
32-8M0108355 |
HOSE, (57.00 Inches Bulk) (Cut to 6 Inches) |
| 13 |
32-875289 |
HOSE |
| 14 |
22-858955 |
CONNECTOR |
| 15 |
35-875284T01 |
FILTER, Oil - In Line |
| 16 |
32-875283 |
HOSE, (2.00 Inches) |
| 17 |
54-415825 |
CLAMP, Nylon |
| 18 |
54-816311T |
TIE STRAP, (8.00 Inches) |
| 19 |
32-892830053 |
HOSE, (24.00 Inches Braided) |
| 20 |
32-883354 |
HOSE |
| 21 |
32-883357 |
CONDUIT |
▶Power Trim Components (38 parts)
| Ref |
OEM Part # |
Part Name |
| - |
855998A11 |
POWER TRIM, Complete |
| 1 |
878265A4 |
TRIM MOTOR |
| 2 |
NSS |
NOT SOLD SEPARATE, Armature |
| 3 |
NSS |
NOT SOLD SEPARATE, End Frame |
| 4 |
10-82494830 |
SCREW, (M6 x 30) |
| 5 |
13-400256 |
LOCKWASHER, (M6) |
| 6 |
8782451 |
DRIVESHAFT |
| 7 |
878410A1 |
PO CHECK KIT |
| 8 |
893929A01 |
MANUAL RELEASE ASSEMBLY Comment: (Incls. Ref. #26) |
| 9 |
8M0142997 |
SHAFT KIT |
| 10 |
17-878267 |
PIN |
| 11 |
878235A03 |
TILT CYLINDER ASSEMBLY |
| 12 |
878239A02 |
GUIDE KIT Comment: (Incls. Ref. #26) |
| 13 |
8M0142999 |
O-RING KIT Comment: (Incls. Ref. #26) |
| 14 |
8M0168219 |
SHOCK ROD KIT Comment: (Incls. Ref. #26) |
| 15 |
8M0143000 |
PISTON ASSEMBLY, Memory |
| 16 |
878406A02 |
REPAIR KIT, Check Valve Comment: (Incls. Ref. #26) |
| 17 |
878414T01 |
PISTON ASSEMBLY |
| 18 |
878413A1 |
PISTON ASSEMBLY |
| 19 |
1100-8M0021648 |
GUIDE ASSEMBLY |
| 20 |
878264A1 |
RESERVOIR KIT |
| 21 |
19-811613 |
PLUG ASSEMBLY |
| 22 |
10-4000327 |
SCREW, (M6 x 14) |
| 23 |
12-4002315 |
WASHER |
| 24 |
892251A01 |
PUMP KIT |
| 25 |
878408A1 |
REPAIR KIT, Power Trim |
| 26 |
17-821539 |
PIN, Trilobe |
| 27 |
10-858771 |
SCREW, (M10 x 30) |
| 28 |
12-4002319 |
WASHER |
| 29 |
97-818298Q1 |
ANODE KIT |
| 30 |
10-8M0204707 |
SCREW, (M6 x 25) |
| 31 |
12-8M0204649 |
WASHER, (.281 x .500 x .060) Stainless Steel |
| 32 |
99625002 |
SHAFT Comment: SN# 0T980000 & Up |
| 33 |
8M0084613 |
C WASHER |
| 34 |
54-26550 |
CLAMP |
| 35 |
10-878609 |
SCREW, (#10-16 x .600) |
| 36 |
32-828547353 |
CONDUIT, (.350 Inside Diameter x 3.00 Feet Bulk) (Cut to 12 Inches) |
| 37 |
54-816311T |
TIE STRAP, (8.00 Inches) |
▶Service/Support Material (1 parts)
| Ref |
OEM Part # |
Part Name |
| 0 |
37-804669A05 |
DECAL, EPA Label Information Comment: (2005) |
▶Starter Motor (13 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
50-892339T01 |
STARTER MOTOR ASSEMBLY Comment: SN# 0T960099 & Up |
| 2 |
10-803005 |
THRU BOLT |
| 3 |
43-880805A1 |
GEAR KIT |
| 4 |
809463A1 |
SOLENOID KIT |
| 5 |
10-69035 |
SCREW AND LOCKWASHER, (.250-20 x .625) Stainless Steel |
| 6 |
84-93388A1 |
CABLE ASSEMBLY, (6.00 Inches) Black |
| 7 |
37-8272822 |
DECAL, Warning, High Voltage |
| 8 |
13-400255 |
LOCKWASHER, (M5) |
| 9 |
11-400211 |
NUT, (M5) Stainless Steel |
| 10 |
13-8M0204647 |
LOCKWASHER, (.312) |
| 11 |
11-400213 |
NUT, (M8) Stainless Steel |
| 12 |
23-8M0034918 |
COLLAR |
| 13 |
8M0043276 |
STOP |
▶Swivel Bracket and Steering Arm (31 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
1499-8M0102865 |
SWIVEL BRACKET ASSEMBLY, Black |
| 2 |
25-8M0214926 |
O-RING |
| 3 |
23-818764 |
BUSHING |
| 4 |
23-816039 |
SPACER |
| 5 |
26-87735 |
SEAL, Oil (LOWER) |
| 6 |
22-8M0169589 |
FITTING, Grease |
| 7 |
23-821207 |
BUSHING |
| 8 |
12-816432 |
THRUST WASHER |
| 9 |
878182T01 |
YOKE, Bottom - Stainless Steel Comment: (STAINLESS STEEL) |
| 10 |
53-67684 |
RING, Retaining |
| 11 |
8M0045383 |
STRIKER PLATE |
| 12 |
13-58643 |
LOCKWASHER, (.375) |
| 13 |
11-46335 |
NUT, (.375-24) |
| 14 |
10-64014 |
SCREW, (.250-28 x .500) |
| 15 |
NSS |
NOT SOLD SEPARATE, Decal-Serial Overlaminate |
| 16 |
8M0074846 |
SENDER ASSEMBLY, Trim Comment: (TRACKER) |
| 17 |
10-852368 |
SCREW, (#10-24 x .750) |
| 18 |
10,13-26996 |
LOCKWASHER, Stainless Steel |
| 19 |
12-89302 |
WASHER, (.203 x .406 x .040) |
| 20 |
17-8M0132731 |
SWIVEL PIN ASSEMBLY, Steering Arm - Stainless Steel Comment: (STAINLESS STEEL) |
| 21 |
10-8M0176309 |
SCREW, (.437-20 x 7.50) |
| 22 |
8M0000516 |
BUMPER |
| 23 |
77326 |
MOUNT |
| 24 |
12-66921 |
WASHER |
| 25 |
12-78688 |
WASHER |
| 26 |
11-8M0204653 |
NUT, (.437-20) Stainless Steel |
| 27 |
92876A12 |
LINK ROD ASSEMBLY |
| 28 |
10-849838 |
SCREW, (.375-24 x 1.250) |
| 29 |
11-8M0204726 |
NUT, (.375-24) Stainless Steel |
| 30 |
12-37828 |
WASHER, (.390 x .625 x .062) Stainless Steel |
| 31 |
54-816311T |
TIE STRAP, (8.00 Inches) |
▶Throttle Lever and Shift Shaft (47 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
8M0040990 |
LEVER, Throttle Control |
| 2 |
10-818165 |
SCREW, (.375-16 x 1.75) |
| 3 |
23-55164 |
BUSHING |
| 4 |
23-858959 |
SPACER |
| 5 |
10-64022 |
SCREW, (.250-20 x 2.125) |
| 6 |
11-64015 |
NUT, (.250-20) |
| 7 |
26852 |
CAP, Nylon |
| 8 |
42927 |
INSERT |
| 9 |
12-35459 |
WASHER |
| 10 |
11-401386 |
NUT, (M6) Stainless Steel |
| 11 |
814283T6 |
BRACKET ASSEMBLY, Anchor, Anchor |
| 12 |
98889 |
LATCH |
| 13 |
10-42975 |
DRIVE SCREW |
| 14 |
39519 |
CUP |
| 15 |
52100 |
WEAR PLATE |
| 16 |
8M0036768 |
LATCH |
| 17 |
12-35462 |
WASHER, (.2656 x .625 x .0625) Stainless Steel |
| 18 |
11-826709109 |
NUT, (.250-28) Stainless Steel |
| 19 |
10-28782 |
SCREW, (.312-18 x .880) Stainless Steel |
| 20 |
814284 |
GUIDE BLOCK |
| 21 |
24-20099 |
SPRING |
| 22 |
67073A1 |
LINK ROD ASSEMBLY |
| 23 |
79932A17 |
SHIFT SHAFT ASSEMBLY Comment: (X-LONG) |
| 24 |
NSS |
NOT SOLD SEPARATE, Roll Pin |
| 25 |
NSS |
NOT SOLD SEPARATE, Shift Shaft Lever-Upper |
| 26 |
23-26856 |
BUSHING |
| 27 |
13-29720 |
WAVE WASHER |
| 28 |
12-35462 |
WASHER, (.2656 x .625 x .0625) Stainless Steel |
| 29 |
11-826709109 |
NUT, (.250-28) Stainless Steel |
| 30 |
87-889514T02 |
SWITCH |
| 31 |
10-77478 |
SCREW, (#6-32 x .875) |
| 32 |
12-27882 |
WASHER |
| 33 |
23-8M0215006 |
BUSHING, Swivel |
| 34 |
8508152 |
ROD |
| 35 |
858847A2 |
CAM |
| 36 |
8235694 |
BALL, Threaded |
| 37 |
23-8M0215006 |
BUSHING |
| 38 |
10-81893440 |
SCREW, (M8 x 40) |
| 39 |
23-856895 |
BUSHING |
| 40 |
850286A03 |
LEVER/ROLLER KIT, Throttle |
| 41 |
8M0072162 |
ROLLER |
| 42 |
12-8M0204666 |
WASHER, (.203 x .500 x .032) |
| 43 |
8-32,11-826709104 |
NUT, Stainless Steel |
| 44 |
10-889354 |
SCREW, Special |
| 45 |
12-881991 |
WASHER, Cupped |
| 46 |
12-881992 |
WASHER, Spool |
| 47 |
10,13-69432 |
LOCKWASHER, External |
▶Tools (1 parts)
| Ref |
OEM Part # |
Part Name |
| 0 |
91-66274 |
TORQUE WRENCH, (0-150 lb-in) |
▶Top Cowl (24 parts)
| Ref |
OEM Part # |
Part Name |
| 0 |
37-808621A96 |
DECAL SET Comment: (TRACKER 200) |
| 1 |
4021-827328T8 |
TOP COWL ASSEMBLY, Silver Comment: (SILVER) |
| 2 |
821256T2 |
INLET, Air - Silver Comment: (SILVER |
| 3 |
10-82130016 |
SCREW, (M6 x 16) |
| 4 |
828344A1 |
SOUND BLANKET KIT |
| 5 |
NSS |
NOT SOLD SEPARATE, Sound Blanket-Top |
| 6 |
19-823865 |
CAP PLUG |
| 7 |
831207A15 |
HANDLE ASSEMBLY, Silver Comment: (SILVER) |
| 8 |
23-812707 |
BUSHING |
| 9 |
23-831214 |
SPACER |
| 10 |
13-12134 |
WASHER, Wave |
| 11 |
8M0001081 |
CAM Comment: SN# 0T980000 & Up |
| 12 |
12-8M0214930 |
WASHER |
| 13 |
10-1993716 |
SCREW, (M6 x 16) |
| 14 |
8M0036792 |
BRACKET, Front |
| 15 |
815477 |
BUMPER, Latch |
| 16 |
12-8M0204649 |
WASHER, (.281 x .500 x .060) Stainless Steel |
| 17 |
11-401366 |
NUT, (M6) Stainless Steel |
| 18 |
53-8237951 |
RING, Retaining |
| 19 |
8M0207770 |
ROLLER |
| 20 |
8155381 |
PIN, Roll |
| 21 |
12-8M0204649 |
WASHER, (.281 x .500 x .060) Stainless Steel |
| 22 |
11-401366 |
NUT, (M6) Stainless Steel |
| 23 |
NSS |
NOT SOLD SEPARATE, Decal-Starting Procedure |
▶Transom Brackets (19 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
3426-828334T03 |
BRACKET ASSEMBLY, Transom-Starboard |
| 2 |
3425-828333T08 |
BRACKET ASSEMBLY, Transom-Port |
| 3 |
22-8M0169588 |
FITTING, Grease (PORT) |
| 4 |
826125A1 |
TILT TUBE |
| 5 |
11-826135 |
NUT, (1.00-14) Brass/Nickel Plate |
| 6 |
25-45711 |
O-RING, (.612 x .103) |
| 7 |
13-88750 |
WASHER |
| 8 |
11-826164 |
NUT, (.875-14) |
| 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 |
8M0115104 |
LEVER ASSEMBLY, Tilt Lock |
| 14 |
24-830899 |
SPRING, Tension |
| 15 |
23-65830 |
NYLINER |
| 16 |
24-830900 |
SPRING, Compression |
| 17 |
99633 |
KNOB |
| 18 |
17-99615 |
PIN, Groove |
| 19 |
17-893709 |
PIN |
▶Vapor Separator Components (35 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
883245T04 |
COVER KIT |
| 2 |
22-881740 |
FITTING, Straight |
| 3 |
22-883249 |
FITTING |
| 4 |
NSS |
NOT SOLD SEPARATE, Elbow |
| 5 |
22-885186A1 |
FITTING KIT Comment: (Use with Filter) |
| 6 |
25-831985 |
O-RING, (.468 x .078) Comment: (Use with Filter) |
| 7 |
35-885188 |
FILTER |
| 8 |
883219 |
VALVE |
| 9 |
25-8M0062785 |
O-RING |
| 10 |
883220 |
CAP |
| 11 |
19-883208 |
PLUG |
| 12 |
26-883248 |
SEAL |
| 13 |
27-883252 |
GASKET |
| 14 |
883257T1 |
REGULATOR |
| 15 |
25-883593A1 |
O-RING KIT |
| 16 |
12-883258 |
WASHER |
| 17 |
10-883261 |
SCREW, (M5 x .8) |
| 18 |
10-883261 |
SCREW, (M5 x .8) |
| 19 |
84-881831 |
WIRE ASSEMBLY |
| 20 |
1395-808612 |
SCREW AND WASHER, (#8-32 x .750) |
| 21 |
883253A1 |
FLOAT KIT |
| 22 |
F10064 |
SHAFT |
| 23 |
883247A1 |
VALVE/SEAT KIT, Inlet |
| 24 |
10-883223 |
SCREW, (M6 x 16) |
| 25 |
35-18458Q4 |
FILTER KIT |
| 26 |
8M0204710 |
PROBE |
| 27 |
889318002 |
BAFFLE |
| 28 |
10-883223 |
SCREW, (M6 x 16) |
| 29 |
881705T1 |
PUMP KIT |
| 30 |
8M6000589 |
SLEEVE |
| 31 |
883256T1 |
BOWL KIT |
| 32 |
26-883248 |
SEAL |
| 33 |
19-855435A1 |
PLUG KIT |
| 34 |
25-8M0062785 |
O-RING |
| 35 |
10-16955 |
SCREW, (M6 x 8) |
▶Water Hoses (13 parts)
| Ref |
OEM Part # |
Part Name |
| - |
883600T04 |
POWERHEAD ASSEMBLY Comment: (200) SN# 0T980000 & Up |
| 1 |
22-850805 |
FITTING |
| 2 |
54-816311T |
TIE STRAP, (8.00 Inches) |
| 3 |
32-77653101 |
HOSE, (48.00 Inches Bulk) (Cut to 20 Inches) |
| 4 |
22-687271 |
FITTING, (.250-18) 90 Degree - Brass |
| 5 |
22-881866 |
FITTING |
| 6 |
32-85978571 |
TUBING, (52.00 Inches Bulk) (Cut to 12 Inches) |
| 7 |
22-8M0207782 |
FITTING Comment: SN# 0T980000 & Up |
| 8 |
22-875207 |
TEE, Fitting |
| 9 |
32-85978571 |
TUBING, (52.00 Inches Bulk) (Cut to 44 Inches) |
| 10 |
22-8M0214971 |
COUPLER |
| 11 |
22-859732 |
PLUG |
| 12 |
32-85978571 |
TUBING, (52.00 Inches Bulk) (Cut to 1-1/2 Inches) |
100-Hour / Annual Service Checklist
Regular maintenance keeps your Mercury V-200 EFI (2.5L) 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.
