🔎 Mercury XR-6 Reference Library — Exploded parts diagrams (35 diagrams), specifications, common issues, and maintenance checklist.
The Mercury XR-6 is a 2-Stroke, V6 60-degree outboard motor. Powers center-console boats, larger pontoons, and offshore-capable fishing craft.
Quick Reference Specifications
| Specification |
Value |
| Engine Type |
2-Stroke, V6 60-degree |
| Horsepower |
135 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 BU8H |
| Engine Oil Capacity |
— |
| Recommended Engine Oil |
Mercury 2-Stroke Outboard Oil (TCW-3) |
| Gear Case Oil Capacity |
— |
| 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 XR-6:
-
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 XR-6.
▶Accessories (1 parts)
| Ref |
OEM Part # |
Part Name |
| 0 |
17334A2 |
VISUAL WARNING SYSTEM Comment: (LOW OIL/OVERHEAT) |
▶Attenuator Plate and Throttle Levers (16 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-815791A00 |
GASKET SET, Engine, Cylinder head o-rings and seal not included |
| 1 |
817495A1 |
PLATE ASSEMBLY, Sound Attenuator |
| 2 |
27-892211 |
GASKET |
| 3 |
10-884891 |
SCREW, (.250-28 x 2.500) With Nylon Patch - Stainless Steel |
| 4 |
12-69057 |
WASHER, (.281 x .734 x .063) |
| 5 |
19-815784 |
CAP |
| 6 |
828277A1 |
LINKAGE KIT |
| 7 |
NSS |
NOT SOLD SEPARATE, Throttle Lever |
| 8 |
NSS |
NOT SOLD SEPARATE, Throttle Lever |
| 9 |
NSS |
NOT SOLD SEPARATE, Throttle Link |
| 10 |
18178 |
ROLLER |
| 11 |
10-15124 |
SCREW, (#10-32 x .750) |
| 12 |
12-89302 |
WASHER, (.203 x .406 x .040) |
| 13 |
10,13-69432 |
LOCKWASHER, External |
| 14 |
37-804669A05 |
DECAL, EPA Label Information Comment: (2005) |
| 15 |
NSS |
NOT SOLD SEPARATE, Decal-Caution Airbox |
▶Bleed System (11 parts)
| Ref |
OEM Part # |
Part Name |
| - |
813043T00 |
POWERHEAD ASSEMBLY Comment: (200) |
| 1 |
32-892024122 |
TUBING, (240.00 Inches Bulk) (Cut to 9 Inches) Comment: SN# 0T801000 & Up |
| 2 |
32-892024122 |
TUBING, (240.00 Inches Bulk) (Cut to 12-1/2 Inches) Comment: SN# 0T801000 & Up |
| 3 |
32-892024122 |
TUBING, (240.00 Inches Bulk) (Cut to 14 Inches) Comment: SN# 0T801000 & Up |
| 4 |
32-892024122 |
TUBING, (240.00 Inches Bulk) (Cut to 19 Inches) Comment: SN# 0T801000 & Up |
| 5 |
32-892024122 |
TUBING, (240.00 Inches Bulk) (Cut to 24 Inches) Comment: SN# 0T801000 & Up |
| 6 |
32-892024122 |
TUBING, (240.00 Inches Bulk) (Cut to 27 Inches) Comment: SN# 0T801000 & Up |
| 7 |
21-426982 |
CHECK VALVE |
| 8 |
22-822715 |
FITTING, Elbow |
| 9 |
22-56759 |
FITTING, Barbed |
| 10 |
21-426233 |
CHECK VALVE |
▶Bottom Cowl (33 parts)
| Ref |
OEM Part # |
Part Name |
| - |
813043T00 |
POWERHEAD ASSEMBLY Comment: (200) |
| 1 |
4022-828044A1 |
BOTTOM COWL, Black Comment: (BLACK-PORT) |
| 2 |
4022-828045A1 |
BOTTOM COWL, Black Comment: (BLACK-STARBOARD) |
| 3 |
8M0109217 |
SEAL, Cowl (41.00 Inches) |
| 4 |
859435T |
INSERT |
| 5 |
859434T |
INSERT |
| 6 |
859343 |
FOAM |
| 7 |
10-92799 |
SCREW, (#10-16 x 1.12) |
| 8 |
10-82130040 |
SCREW, (M6 x 40) |
| 9 |
831209 |
RETAINER |
| 10 |
19-821908 |
PLUG |
| 11 |
12-821915 |
WASHER |
| 12 |
8219631 |
CHECK VALVE |
| 13 |
25-30641 |
O-RING, (.299 x .103) |
| 14 |
22-821952 |
FITTING |
| 15 |
54-816311T |
TIE STRAP, (8.00 Inches) |
| 16 |
32-8M0039077 |
HOSE |
| 17 |
54-850896 |
CLAMP, (28.6) |
| 18 |
22-8320761 |
FITTING, Check Valve |
| 19 |
22-8M0077650 |
FITTING, Tell-Tale |
| 20 |
32-8M0108355 |
HOSE, (57.00 Inches Bulk) (Cut to 8 Inches) |
| 21 |
889847 |
BOOT, Idle Exhaust Comment: SN# 0T801000 & Up |
| 22 |
21-817519A1 |
CHECK VALVE ASSEMBLY, Drain |
| 23 |
87-8M0042301 |
SWITCH ASSEMBLY |
| 24 |
889740A02 |
HANDLE KIT Comment: Plastic Handle |
| 25 |
10-824868 |
SCREW, (M6 x 75) Comment: (Use W/Cast Handle) |
| 26 |
23-335891 |
BUSHING |
| 27 |
25-48462 |
O-RING, (.614 x .070) |
| 28 |
8219423 |
PAWL, Front Handle |
| 29 |
12-69057 |
WASHER, (.281 x .734 x .063) |
| 30 |
11-401366 |
NUT, (M6) Stainless Steel |
| 31 |
10-8214281 |
SCREW, (#10-16 x .625) |
| 32 |
54-822873 |
CLIP |
▶CDM Mounting (21 parts)
| Ref |
OEM Part # |
Part Name |
| - |
85-857074A1 |
BOOT/TERMINAL KIT |
| 1 |
84-858425T2 |
HARNESS ASSEMBLY |
| 2 |
NSS |
NOT SOLD SEPARATE, Cover |
| 3 |
88-832969T20 |
FUSE, Mini - Yellow - 20 Ampere Comment: (20 AMP)(YELLOW) |
| 4 |
54-816311T |
TIE STRAP, (8.00 Inches) |
| 5 |
54-828991T |
CLIP |
| 6 |
8571621 |
PLATE, CDM Mounting |
| 7 |
10-60411 |
SCREW, (.312-18 x 1.250) |
| 8 |
12-8M0042642 |
WASHER, (.323 x .563 x .063) Stainless Steel |
| 9 |
12-49436 |
WASHER |
| 10 |
25-833155 |
GROMMET |
| 11 |
23-8502341 |
BUSHING |
| 12 |
10-82129116 |
SCREW, (M6 x 16) |
| 13 |
84-856583A3 |
CABLE ASSEMBLY |
| 14 |
827509T7 |
CDM MODULE ASSEMBLY |
| 15 |
33-938 |
SPARK PLUG, (NGK # BPZ8HS-10) |
| 16 |
84-857163T1 |
HARNESS ASSEMBLY, CDM |
| 17 |
84-858414A1 |
CABLE ASSEMBLY, Braided |
| 18 |
828791 |
CLIP |
| 19 |
84-857166T1 |
HARNESS ASSEMBLY, Engine Wiring |
| 20 |
13541 |
PLUG, Male |
▶Carburetor (27 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-815791A00 |
GASKET SET, Engine, Cylinder head o-rings and seal not included |
| 1 |
3326-828272T75 |
CARBURETOR, Bottom Comment: (200 - WMV-18-3) |
| 2 |
1395-809743 |
COVER |
| 3 |
1395-809758 |
GASKET |
| 4 |
1395-8087391 |
SCREW |
| 5 |
27-828292 |
GASKET |
| 6 |
1399-3252 |
JET, (.032), Idle Air Vent Comment: (BOTTOM)(200)(PORT) |
| 7 |
1399-3518 |
JET, (.082), Bowl Vent Comment: (140/150/XR6/MAGNUM III) |
| 8 |
815633028 |
JET, (.028), Idle Air Vent Comment: (CENTER/BOTTOM)(STBD)(200) |
| 9 |
810779 |
CAP, Limiter |
| 10 |
NSS |
NOT SOLD SEPARATE, Idle Mixture Screw/Spring |
| 11 |
1395-8113523 |
LEVER KIT |
| 12 |
1395-6031 |
SPACER |
| 13 |
NSS |
NOT SOLD SEPARATE, Spring |
| 14 |
NSS |
NOT SOLD SEPARATE, Gasket-Fuel Bowl |
| 15 |
810738 |
FLOAT ASSEMBLY |
| 16 |
F10064 |
SHAFT, Float |
| 17 |
1395-5902 |
SCREW, (#6-32 x .187) |
| 18 |
1395-8116901 |
VALVE SEAT KIT |
| 19 |
NSS |
NOT SOLD SEPARATE, Gasket |
| 20 |
1395-8236241 |
BOWL, Fuel Comment: (CENTER/BOTTOM) |
| 21 |
1395-808612 |
SCREW AND WASHER, (#8-32 x .750) |
| 22 |
1395-811694 |
PLUG KIT |
| 23 |
1395-802731 |
SEAL Comment: (CONSISTS OF 4 GASKETS) |
| 24 |
1399-3517 |
JET, (.084), Main Fuel Comment: (200)(STBD-BOTTOM) |
| 25 |
1395-7900 |
TEE FITTING Comment: (TOP/CENTER) |
| 26 |
1395-7901 |
ELBOW Comment: (BOTTOM) |
▶Crankshaft, Pistons and Connecting Rods (22 parts)
| Ref |
OEM Part # |
Part Name |
| - |
813043T00 |
POWERHEAD ASSEMBLY Comment: (200) |
| 1 |
455-850690T2 |
CRANKSHAFT ASSEMBLY |
| 2 |
78662 |
WEAR SLEEVE |
| 3 |
30-67923T |
BEARING, Ball (LOWER) |
| 4 |
53-67446 |
RING |
| 5 |
43-14513A09 |
GEAR SEGMENT KIT, Drive |
| 6 |
10-813073 |
SCREW, (#6-32 x .620) Socket Head |
| 7 |
6-32,11-813134 |
NUT, Special |
| 8 |
54196A6 |
CARRIER ASSEMBLY |
| 9 |
65800 |
PACKING |
| 10 |
39-67377T |
RING, Sealing, CRANKSHAFT |
| 11 |
31-16756A6 |
BEARING KIT |
| 12 |
NSS |
NOT SOLD SEPARATE, Bearing |
| 13 |
785-9737A10 |
PISTON ASSEMBLY, .015 Oversize Comment: (PORT-.015 O.S.)(140/150/XR6/MAGNUM III/200) |
| 14 |
39-822321A1 |
RING KIT, Piston - .015 Oversize Comment: (.015 O.S.)(140/150/XR6/MAGNUM III/200) |
| 15 |
53-857196 |
LOCK RING |
| 16 |
NSS |
NOT SOLD SEPARATE, Piston Pin |
| 17 |
644-818141A13 |
CONNECTING ROD KIT |
| 18 |
10-763491 |
SCREW, (.312-24 x .875) |
| 19 |
12-8M0012298 |
WASHER |
| 20 |
8M0234886 |
BEARING KIT |
| 21 |
29-8M0204691 |
BEARING, Needle |
▶Cylinder Block and End Caps (42 parts)
| Ref |
OEM Part # |
Part Name |
| - |
813043T00 |
POWERHEAD ASSEMBLY Comment: (200) |
| 1 |
884-858257T9 |
CYLINDER BLOCK ASSEMBLY Comment: (200) |
| 2 |
16-8M0034455 |
STUD, (1.750 Inches) |
| 3 |
16-8M0034454 |
STUD, (.375-16/.375-24 x 6.870) (6-3/4 IN.) |
| 4 |
17-43044 |
PIN, Dowel - Without Hole (.375 x .625) |
| 5 |
17-8M0036405 |
PIN (BEARING RACE) |
| 6 |
27-11338 |
GASKET Comment: (USE WHERE APPLICABLE) |
| 7 |
8M0088723 |
COVER, Starter Motor (UPPER) |
| 8 |
10-828213 |
SCREW, (.312-18 x 1.500) Hex Flange |
| 9 |
76867 |
COVER (LOWER) |
| 10 |
10-828214 |
SCREW, (.312-18 x 2.00) Hex Flange |
| 11 |
21-8781051 |
CHECK VALVE |
| 12 |
23-99448 |
BUSHING |
| 13 |
10-74824 |
SCREW, (.312-18 x 1.250) |
| 14 |
26852 |
CAP, Nylon |
| 15 |
10-64022 |
SCREW, (.250-20 x 2.125) |
| 16 |
11-64015 |
NUT, (.250-20) |
| 17 |
NSS |
NOT SOLD SEPARATE, Plug |
| 18 |
1159-858521T1 |
END CAP ASSEMBLY, Upper |
| 19 |
25-54029 |
O-RING, (2.800 x .103) |
| 20 |
31-16756A4 |
BEARING KIT |
| 21 |
NSS |
NOT SOLD SEPARATE, Race |
| 22 |
26-41953 |
SEAL |
| 23 |
10-881190 |
SCREW, (.312-18 x 1.00) |
| 24 |
16-15094 |
STUD, (.190-32 x 1.870) |
| 25 |
54-23567 |
CLIP |
| 26 |
857167 |
BRACKET |
| 27 |
10-68513 |
SCREW, (#10-32 x .375) Stainless Steel |
| 28 |
23-67269 |
SPACER |
| 29 |
12-8M0204663 |
WASHER, (.187 x .500 x .062) Neoprene |
| 30 |
10-32,11-816874 |
WING NUT, |
| 31 |
857185T1 |
CONTROL MODULE |
| 32 |
10-690201 |
SCREW, (#10-32 x .875) |
| 33 |
12-30164 |
WASHER, (.192 x .375 x .0312) Stainless Steel |
| 34 |
422482 |
BRACKET |
| 35 |
10-49668 |
SCREW, (.250-20 x .750) |
| 36 |
16-8M0034435 |
STUD, (#10-32 x 1.00) |
| 37 |
1156-7809T1 |
END CAP ASSEMBLY, Lower |
| 38 |
25-62700 |
O-RING, (3.237 x .103) |
| 39 |
26-41953 |
SEAL |
| 40 |
10-28636 |
SCREW, (.250-20 x .750) |
| 41 |
13-26992 |
LOCKWASHER, (.250) Stainless Steel |
▶Driveshaft Housing and Exhaust Tube (43 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-815791A00 |
GASKET SET, Engine, Cylinder head o-rings and seal not included |
| 1 |
1590-8343A13 |
HOUSING ASSEMBLY, Driveshaft Comment: (BLACK - JET) |
| 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 Comment: (ALL OTHER MODELS) |
| 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# 0T801000 & Up |
| 24 |
18276T |
TUBE, Exhaust |
| 25 |
8M0039076 |
SEAL (UPPER) |
| 26 |
812834A2 |
EXTENSION ASSEMBLY, Exhaust Comment: (135/140/150/XR6/MAGNUM III)(STUD MOUNTING) |
| 27 |
16-56766 |
STUD, (.250 x 1.38) |
| 28 |
12-35044 |
WASHER, (.281 x .625 x .065) Stainless Steel |
| 29 |
11-888500 |
NUT |
| 30 |
879288T71 |
EXTENSION, Exhaust Comment: (200) (JET) |
| 31 |
32-8M0042790 |
TUBE, Water Comment: (X-LONG) |
| 32 |
18233A20 |
PLATE ASSEMBLY, Driveshaft Housing Comment: (WITH TWO HOLES IN THE BACK OF PLATE) |
| 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 |
| 41 |
812834A2 |
EXTENSION, Exhaust Comment: (135/140/150/XR6/MAGNUM III)(SCREW MOUNTING) |
| 42 |
10-90192 |
SCREW, (.250-20 x .750) Stainless Steel |
▶Dual Cable Attaching Kit (12 parts)
| Ref |
OEM Part # |
Part Name |
| - |
92876A8 |
ATTACHING KIT, Steering |
| 1 |
41055A1 |
BRACKET ASSEMBLY |
| 2 |
715651 |
TUBE, Steering Cable |
| 3 |
25-48462 |
O-RING, (.614 x .070) |
| 4 |
13-821203 |
LOCKWASHER |
| 5 |
11-8M0041651 |
NUT, (.875-14) |
| 6 |
10-38601 |
SCREW, (.250-28 x 1.250) |
| 7 |
13-78968 |
LOCKWASHER, Internal (.250) |
| 8 |
850791T |
COUPLER |
| 9 |
10-73732 |
SCREW, (.375-24 x 1.120) |
| 10 |
12-37828 |
WASHER, (.390 x .625 x .062) Stainless Steel |
| 11 |
11-8M0204726 |
NUT, (.375-24) Stainless Steel |
▶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 O.D.) |
| 20 |
10-94319 |
SCREW, (.375-24 x 1.5) |
▶Engine Gasket Set Components (2 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-815791A00 |
GASKET SET, Engine, Cylinder head o-rings and seal not included |
| 0 |
27-167371 |
GASKET Comment: (Not used for this application) |
▶Exhaust Manifold and Exhaust Plate (51 parts)
| Ref |
OEM Part # |
Part Name |
| - |
813043T00 |
POWERHEAD ASSEMBLY Comment: (200) |
| 1 |
27-190506 |
GASKET |
| 2 |
828343T3 |
PLATE, Exhaust Divider |
| 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 |
10-881892 |
SCREW, (.312-18 x 1.750) |
| 7 |
54-814634 |
CLAMP |
| 8 |
22-8144301 |
FITTING, To Block |
| 9 |
22-920071 |
FITTING, (90 Degree) |
| 10 |
32-8M0108355 |
HOSE, (57.00 Inches Bulk) (Cut to 26 Inches) |
| 11 |
54-816311T |
TIE STRAP, (8.00 Inches) |
| 12 |
8M0039767 |
COVER |
| 13 |
10-31984 |
SCREW, (.312-18 x 1.375) |
| 14 |
10-69570 |
SCREW, (#10-16 x .750) |
| 15 |
12-76451 |
WASHER |
| 16 |
144791 |
DIAPHRAGM |
| 17 |
16496 |
DEFLECTOR, Water |
| 18 |
16497A1 |
PLATE |
| 19 |
27-78690002 |
GASKET Comment: SN# 0T801000 & Up |
| 20 |
24-64878 |
SPRING |
| 21 |
12-85303 |
WASHER |
| 22 |
14480 |
POPPET |
| 23 |
25-64872 |
GROMMET |
| 24 |
65848 |
CARRIER |
| 25 |
27-991764 |
GASKET |
| 26 |
18260T2 |
PLATE ASSEMBLY, Exhaust |
| 27 |
22-897722 |
FITTING, Straight |
| 28 |
17-43044 |
PIN, Dowel - Without Hole (.375 x .625) |
| 29 |
8M0043164 |
SEAL |
| 30 |
680101 |
BRACKET |
| 31 |
10-878608 |
SCREW, (#10-16 x .500) |
| 32 |
12-20553 |
WASHER, (.406 x .734 x .063) |
| 33 |
11-69254 |
NUT |
| 34 |
23-27132 |
BUSHING |
| 35 |
25-19565002 |
GROMMET Comment: SN# 0T980000 & Up |
| 36 |
25-12602002 |
GROMMET Comment: SN# 0T980000 & Up |
| 37 |
10-66727 |
SCREW, (.312-18 x 1.250) |
| 38 |
10-68783 |
SCREW, (.312-18 x 2.50) |
| 39 |
10-898833 |
SCREW, (.375-16 x 3.50) |
| 40 |
812905T |
BRACKET ASSEMBLY, Front |
| 41 |
10-8055571 |
SCREW, (.3125-18 x .50) |
| 42 |
12-187031 |
WASHER |
| 43 |
25-18778001 |
GROMMET Comment: SN# 0T980000 & Up |
| 44 |
18578T09 |
BRACKET ASSEMBLY, Rear |
| 45 |
22-881866 |
FITTING Comment: SN# 0T801000 & Up |
| 46 |
32-85978571 |
TUBING, (44.00 Inches Bulk) (44 Inches Required) |
| 47 |
22-8M0214971 |
COUPLER |
| 48 |
22-859732 |
PLUG |
| 49 |
22-8M0214970 |
FITTING, Adapter |
| 50 |
22-185981 |
PLUG, Pipe (.375-18) Comment: (Use where Applicable) |
▶Flywheel/Starter Motor (26 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
18896A1 |
COVER KIT |
| 2 |
79022 |
MARKER |
| 3 |
10-37572 |
SCREW, (.190-32 x .380) |
| 4 |
12-72761 |
WASHER, (.203 x .562 x .060) Stainless Steel |
| 5 |
19-45907 |
PLUG, Yellow |
| 6 |
11-52901 |
NUT, (.625-18) |
| 7 |
12-33001 |
WASHER, (.641 x 1.250 x .190) |
| 8 |
271-859238T17 |
FLYWHEEL Comment: SN# 0T801000 & Up |
| 9 |
398-858404T4 |
STATOR ASSEMBLY Comment: SN# 0T598999 & Below |
| 10 |
10-90045 |
SCREW, (#10-32 x 1.375) |
| 11 |
10,13-26996 |
LOCKWASHER, Stainless Steel |
| 12 |
96455T18 |
TRIGGER ASSEMBLY |
| 13 |
74897T |
PIVOT |
| 14 |
10-32,11-45076 |
NUT, Brass |
| 15 |
76035 |
ROD |
| 16 |
62459T |
BALL JOINT ASSEMBLY |
| 17 |
50-893893 |
STARTER MOTOR ASSEMBLY Comment: SN# 0T408999 & Below |
| 18 |
23-8M0034918 |
COLLAR |
| 19 |
8M0043376 |
STOP, Rubber, Rubber |
| 20 |
10-69035 |
SCREW AND LOCKWASHER, (.250-20 x .625) Stainless Steel |
| 21 |
84-93388A1 |
CABLE ASSEMBLY, (6.00 Inches) Black |
| 22 |
13-26992 |
LOCKWASHER, (.250) Stainless Steel |
| 23 |
11-94330 |
NUT, (.250-20) Brass |
| 24 |
NSS |
NOT SOLD SEPARATE, Decal-In-Gear Idle |
| 25 |
37-8272822 |
DECAL, Warning, High Voltage |
| 26 |
37-881865 |
DECAL, Caution-Start in Gear Comment: (Start In Gear) |
▶Fuel Lines (27 parts)
| Ref |
OEM Part # |
Part Name |
| - |
813043T00 |
POWERHEAD ASSEMBLY Comment: (200) |
| 1 |
32-82381335 |
TUBING, (15.00 Inches Bulk) (Cut to 4-1/2 Inches) |
| 2 |
54-816311T |
TIE STRAP, (8.00 Inches) |
| 3 |
22-818993 |
CONNECTOR, Tee |
| 4 |
32-830760 |
HOSE |
| 5 |
22-8189941 |
CHECK VALVE |
| 6 |
32-8M0108349 |
TUBING, (.312) (70.00 Inches Bulk) (Cut to 2 Inches)- To Oil Pump |
| 7 |
32-830762 |
HOSE |
| 8 |
35-816296Q2 |
FILTER, Fuel |
| 9 |
32-8M0108355 |
HOSE, (57.00 Inches Bulk) (Cut to 11 Inches) |
| 10 |
32-8M0108355 |
HOSE, (57.00 Inches Bulk) (Cut to 4-1/2 Inches) |
| 11 |
27-828292 |
GASKET |
| 12 |
16-270372 |
STUD, (.250-28 x 1.125) |
| 13 |
13-26992 |
LOCKWASHER, (.250) Stainless Steel |
| 14 |
11-8267089 |
NUT, (.250-28) |
| 15 |
10-55715 |
SCREW, (.250-20 x .880) |
| 16 |
32-892024122 |
TUBING, (240.00 Inches Bulk) (Cut to 9 Inches) Comment: SN# 0T801000 & Up |
| 17 |
32-9912878 |
HOSE, (.187) (26.00 Inches Bulk) (Cut to 4-1/4 Inches) |
| 18 |
32-9912878 |
HOSE, (.187) (26.00 Inches Bulk) (26 Inches RequiredI)- To Cylinder Head |
| 19 |
89-819503A4 |
SOLENOID KIT, Enrichner Valve |
| 20 |
54-633003 |
CLAMP |
| 21 |
10-73286 |
SCREW, (.250-20 x .500) Stainless Steel |
| 22 |
32-9912688 |
TUBING, (36.00 Inches Bulk) (Cut to 4-1/2 Inches)- To Top Carb |
| 23 |
32-9912688 |
TUBING, (36.00 Inches Bulk) (Cut to 3-3/4 Inches)-To Middle Carb |
| 24 |
32-85682257 |
TUBING, (26.00 Inches Bulk) (Cut to 18 Inches) |
| 25 |
22-822769 |
CONNECTOR |
| 26 |
NSS |
NOT SOLD SEPARATE, Cap |
▶Fuel Pump (21 parts)
| Ref |
OEM Part # |
Part Name |
| - |
813043T00 |
POWERHEAD ASSEMBLY Comment: (200) |
| 1 |
NSS |
NOT SOLD SEPARATE, Fuel Pump |
| 2 |
NSS |
NOT SOLD SEPARATE, Disc Check Valve |
| 3 |
NSS |
NOT SOLD SEPARATE, Diaphragm |
| 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 |
27-8M0204705 |
GASKET, Base |
| 11 |
NSS |
NOT SOLD SEPARATE, Gasket-Boost |
| 12 |
NSS |
NOT SOLD SEPARATE, Gasket-Pulse |
| 13 |
987752 |
PLATE |
| 14 |
22-996642 |
FITTING, Elbow 90 Degree (.125-27 x .250) Nylon |
| 15 |
10-82130050 |
SCREW, (M6 x 50), Pump to Crankcase |
| 16 |
10-82104540 |
SCREW, (M5 x 40), Fuel Pump |
| 17 |
144303 |
BASE |
| 18 |
32-8M0108349 |
TUBING, (.312) (70.00 Inches Bulk) (Cut to 6 Inches) |
| 19 |
54-816311T |
TIE STRAP, (8.00 Inches) |
| 20 |
NSS |
NOT SOLD SEPARATE, Decal-Assembled in Mexico |
▶Gear Housing(Driveshaft)(Standard/Counter Rotation) (49 parts)
| Ref |
OEM Part # |
Part Name |
| - |
27-815791A00 |
GASKET SET, Engine, Cylinder head o-rings and seal not included |
| 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 |
32-85944975 |
TUBING, (72.00 Inches Bulk), Cut to 12 Inches Comment: X-Long |
| 13 |
22-881866 |
FITTING |
| 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 |
| 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 |
| 48 |
23-29804T |
SLEEVE |
▶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 |
| - |
27-815791A00 |
GASKET SET, Engine, Cylinder head o-rings and seal not included |
| 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 |
▶Instrumentation (12 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
87-19674A1 |
SWITCH ASSEMBLY, Lanyard |
| 2 |
10-18303 |
SCREW, (.190-16 x 1.750) Stainless Steel |
| 3 |
813679 |
ADAPTER |
| 4 |
15920Q54 |
LANYARD ASSEMBLY |
| 5 |
10-32866 |
SCREW, (#10-32 x 2.00) Stainless Steel |
| 6 |
18321 |
CLAMP, Mounting |
| 7 |
12-24676 |
WASHER, (.200 x .440 x .032) |
| 8 |
10-32,11-68219 |
NUT, Stainless Steel |
| 9 |
79146 |
RETAINER |
| 10 |
54-816311T |
TIE STRAP, (8.00 Inches) |
| 11 |
812497A2 |
DIODE ASSEMBLY |
| 12 |
84-11149A2 |
CABLE ASSEMBLY, (6.00 Inches) |
▶Jet Components (25 parts)
| Ref |
OEM Part # |
Part Name |
| - |
26-89238A2 |
SEAL KIT |
| 1 |
10-88447 |
SCREW, (.190-32 x 1.62) |
| 2 |
12-38833 |
WASHER |
| 3 |
23-94304 |
SPACER |
| 4 |
13381 |
PLATE |
| 5 |
821889A30 |
REV LIMITER |
| 6 |
84-823147A5 |
HARNESS ASSEMBLY, Adaptor - Rev Limiter |
| 7 |
46-8M0077147 |
BASE ASSEMBLY, Water Pump |
| 8 |
27-8M0204678 |
GASKET |
| 9 |
26-89238 |
SEAL, Oil |
| 10 |
26-16977 |
SEAL, Oil |
| 11 |
27-8M0090319 |
GASKET |
| 12 |
27-858524 |
GASKET |
| 13 |
8M0204677 |
FACE PLATE |
| 14 |
46-96148T1 |
BODY ASSEMBLY, Water Pump |
| 15 |
48752T |
INSERT |
| 16 |
26-38970 |
SEAL |
| 17 |
47-89984T3 |
IMPELLER |
| 18 |
28-8M0214992 |
KEY |
| 19 |
10-8M0215009 |
SCREW, (#14-8 x 2.25) |
| 20 |
12-8M0204649 |
WASHER, (.281 x .500 x .060) Stainless Steel |
| 21 |
11-8267119 |
NUT, (.250-28) |
| 22 |
10-19924275 |
SCREW, (.312-18 x 2.75) |
| 23 |
12-36001 |
WASHER |
| 24 |
23-29804T |
SLEEVE |
▶Jet Pump Assembly (34 parts)
| Ref |
OEM Part # |
Part Name |
| - |
856143A3 |
JET PUMP ASSEMBLY |
| 1 |
803145T |
HOUSING, Pump |
| 2 |
878377 |
SHIFT LINKAGE KIT |
| 3 |
878382 |
CAM |
| 4 |
878380 |
GATE, Reverse - With Bumper |
| 5 |
32-827490 |
HOSE, Lube |
| 6 |
10-848497 |
SCREW, (.312-18 x 1.00) |
| 7 |
16-855840 |
STUD, (.312-18 x 1.81) |
| 8 |
11-82670910 |
NUT, (.312-18) Stainless Steel |
| 9 |
85576890 |
HOUSING, Intake |
| 10 |
855771 |
LINER |
| 11 |
45-8M0084524 |
SHAFT, Drive |
| 12 |
12-8796522 |
THRUST WASHER |
| 13 |
30-8796531 |
BEARING, Ball |
| 14 |
23-8271891 |
SLEEVE |
| 15 |
11-8271901 |
NUT |
| 16 |
47-803985T |
IMPELLER |
| 17 |
12-36001 |
WASHER |
| 18 |
28-801405875 |
KEY |
| 19 |
15-801404875 |
SHIM, Impeller |
| 20 |
14-801403875 |
TAB WASHER |
| 21 |
10-19923062 |
SCREW, (.250-20 x .625) |
| 22 |
10-60411 |
SCREW, (.312-18 x 1.250) |
| 23 |
801410 |
BRACKET, Cable Support |
| 24 |
11-82670910 |
NUT, (.312-18) Stainless Steel |
| 25 |
17-801407 |
PIN, Dowel |
| 26 |
16-786382 |
STUD, (.437-14/.437-20 x 3.120) |
| 27 |
16-8M0133358 |
STUD, (.437-14/.437-20 x 2.060) |
| 28 |
11-8M0204653 |
NUT, (.437-20) Stainless Steel |
| 29 |
12-48926 |
WASHER |
| 30 |
12-45176 |
WASHER, (.453 x .812 x .105) Stainless Steel |
| 31 |
16-306671 |
STUD, (.250-20/.250-28 x 3.125) |
| 32 |
10-68299 |
SCREW, (.375-16 x 3.00) Stainless Steel |
| 33 |
12-8M0214963 |
WASHER, (.406 x .750 x .105) Stainless Steel |
▶Oil Injection Components (39 parts)
| Ref |
OEM Part # |
Part Name |
| - |
1257-8742A22 |
TANK ASSEMBLY, Remote Oil Comment: (USE WITH DESIGN II BRACKET) |
| 1 |
1257-87421 |
TANK |
| 2 |
NSS |
NOT SOLD SEPARATE, Cord |
| 3 |
816190A4 |
SENDER ASSEMBLY, Oil Level, Adaptor |
| 4 |
25-11332 |
O-RING, (2.225 x .210) |
| 5 |
36-43298A2 |
CAP ASSEMBLY |
| 6 |
25-11332 |
O-RING, (2.225 x .210) |
| 7 |
32-99802 |
TUBE |
| 8 |
32-99439 |
HOSE, (114.00 Inches) |
| 9 |
12335A1 |
BRACKET KIT Comment: (DESIGN I) |
| 10 |
884481A1 |
BRACKET KIT Comment: (DESIGN II) |
| 11 |
12320 |
BRACKET |
| 12 |
10-79968 |
SCREW, (#12-11 x .750) |
| 13 |
12323A1 |
CORD/HOOK KIT |
| 14 |
815699T |
PUMP ASSEMBLY, Oil Comment: (140/150/XR6/MAGNUM III/200) |
| 15 |
8141032 |
BUSHING, Worm |
| 16 |
25-11379 |
O-RING |
| 17 |
25-48462 |
O-RING, (.614 x .070) |
| 18 |
23-859112 |
BEARING, Drive Gear |
| 19 |
43-8591111 |
GEAR, Driven |
| 20 |
10-41507 |
SCREW, (#10-32 x 1.120) |
| 21 |
193855 |
LINK ASSEMBLY, Throttle Lever to Oil PUmp |
| 22 |
22-8M0207780 |
FITTING |
| 23 |
NSS |
NOT SOLD SEPARATE, Plug |
| 24 |
32-8M0108355 |
HOSE, (57.00 Inches Bulk) (Cut to 6 Inches) |
| 25 |
994436 |
RESERVOIR |
| 26 |
10-690201 |
SCREW, (#10-32 x .875) |
| 27 |
12-42118 |
WASHER |
| 28 |
25-42117 |
GROMMET |
| 29 |
23-42116 |
BUSHING |
| 30 |
32-82381455 |
TUBING, (25.00 Inches Bulk) (Cut to 4-3/4 Inches) Oil Reservoir to Oil Pump |
| 31 |
54-816311T |
TIE STRAP, (8.00 Inches) |
| 32 |
36-43300A5 |
CAP ASSEMBLY |
| 33 |
8M0187298 |
FLOAT ASSEMBLY |
| 34 |
11-99265 |
PUSH NUT |
| 35 |
27-43307T |
GASKET |
| 36 |
NSS |
NOT SOLD SEPARATE, Decal-reservoir Warning |
| 37 |
32-8588531 |
HOSE, To Check Valve on Block |
| 38 |
22-858955 |
CONNECTOR |
▶Power Trim Components (Cast Pump Housing (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) |
▶Power Trim Components (Removeable Pump Housing) (41 parts)
| Ref |
OEM Part # |
Part Name |
| - |
855998A11 |
POWER TRIM ASSEMBLY, Complete |
| 1 |
811604F |
MANIFOLD ASSEMBLY |
| 2 |
22-878089 |
PLUG, Pipe (.0625-27) |
| 3 |
880952A03 |
CYLINDER ASSEMBLY, Tilt |
| 4 |
823553T |
ROD, Trim Piston |
| 5 |
878239A02 |
GUIDE KIT |
| 6 |
811607A1 |
REPAIR KIT |
| 7 |
811610A1 |
CHECK VALVE KIT |
| 8 |
1100-8M0021648 |
GUIDE ASSEMBLY |
| 9 |
878414T01 |
PISTON ASSEMBLY Comment: (STBD.) |
| 10 |
35-12184A1 |
TRIM FILTER ASSEMBLY |
| 11 |
893929A01 |
MANUAL RELEASE ASSEMBLY |
| 12 |
53-815949001 |
E RING |
| 13 |
811612A3 |
O-RING KIT |
| 14 |
811617T1 |
PUMP |
| 15 |
19-811613 |
PLUG ASSEMBLY |
| 16 |
10-4000327 |
SCREW, (M6 x 14) |
| 17 |
12-4002315 |
WASHER |
| 18 |
811611 |
COVER |
| 19 |
828710 |
DRIVE JOINT |
| 20 |
878265A4 |
TRIM MOTOR Comment: (BREAKDOWN ON POWER TRIM MOTOR) |
| 21 |
10-811616 |
SCREW Comment: (SHORT) |
| 22 |
8M0142997 |
SHAFT ASSEMBLY |
| 23 |
22-878089 |
PLUG, Pipe (.0625-27) |
| 24 |
17-878267 |
PIN, Groove |
| 25 |
17-821539 |
PIN, Trilobe |
| 26 |
99625002 |
SHAFT |
| 27 |
97-818298Q1 |
ANODE KIT |
| 28 |
10-8M0204707 |
SCREW, (M6 x 25) |
| 29 |
12-8M0204649 |
WASHER, (.281 x .500 x .060) Stainless Steel |
| 30 |
10-4000377 |
SCREW, (M10 x 30) |
| 31 |
12-4002319 |
WASHER |
| 32 |
54-26550 |
CLAMP |
| 33 |
10-878608 |
SCREW, (#10-16 x .500) |
| 34 |
8M0084613 |
C WASHER |
| 35 |
8M0045383 |
STRIKER PLATE |
| 36 |
13-58643 |
LOCKWASHER, (.375) |
| 37 |
11-46335 |
NUT, (.375-24) |
| 38 |
37-435301 |
DECAL, Caution-Power Trim |
| 39 |
32-828547353 |
CONDUIT, (.350 Inside Diameter x 3.00 Feet Bulk) |
| 40 |
54-816311T |
TIE STRAP, (8.00 Inches) |
▶Power Trim Motor (Removeable Pump Housing) (4 parts)
| Ref |
OEM Part # |
Part Name |
| - |
878265A4 |
TRIM MOTOR |
| 1 |
828714A1 |
BRUSH AND SEAL KIT |
| 2 |
828713T1 |
ARMATURE KIT |
| 3 |
828715A1 |
END FRAME (COMPLETE) |
▶Reed Block and Cylinder Head (35 parts)
| Ref |
OEM Part # |
Part Name |
| - |
813043T00 |
POWERHEAD ASSEMBLY Comment: (200) |
| 1 |
858281A10 |
CYLINDER HEAD ASSEMBLY Comment: (200) SN# 0T801000 & Up |
| 2 |
22-8591001 |
PLUG ASSEMBLY, (M10 x 1.5) Brass Comment: (200) SN# 0T801000 & Up |
| 3 |
25-8M0149612 |
SEAL Comment: (140/150/XR6/ MAGNUM III/200) |
| 4 |
8597721 |
SEAL Comment: (140/150/XR6/ MAGNUM III/200) |
| 5 |
10-8M0125882 |
SCREW, (.375-16 x 2.750) |
| 6 |
17-63779 |
PIN, Dowel (.250 x .625) |
| 7 |
27-8M0204714 |
GASKET Comment: SN# 0T980000 & Up |
| 8 |
90390A1 |
COVER KIT |
| 9 |
75692 |
THERMOSTAT |
| 10 |
10-40011149 |
SCREW, (M8 x 25) Stainless Steel |
| 11 |
974651 |
SENDER (STBD.) |
| 12 |
814612 |
VALVE, Thermal Air |
| 13 |
22-687271 |
FITTING, (.250-18) 90 Degree - Brass |
| 14 |
54-816311T |
TIE STRAP, (8.00 Inches) |
| 15 |
32-77653101 |
HOSE, (48.00 Inches Bulk) (Cut to 12-3/4 Inches) |
| 16 |
22-68728 |
FITTING |
| 17 |
32-77653101 |
HOSE, (48.00 Inches Bulk) (Cut to 13-1/2 Inches) |
| 18 |
22-815914 |
T-FITTING |
| 19 |
32-827602002 |
HOSE Comment: (Molded) |
| 20 |
13536A13 |
SENSOR ASSEMBLY, Temperature (PORT) (2-WIRE) |
| 21 |
137151 |
RETAINER |
| 22 |
10-81893414 |
SCREW, (M8 x 14) |
| 23 |
43517A9 |
PLATE ASSEMBLY |
| 24 |
10-28668 |
SCREW, (.250-20 x .875) Stainless Steel |
| 25 |
54-8M0024808 |
J CLIP |
| 26 |
27-146972 |
GASKET |
| 27 |
855952T3 |
REED BLOCK ASSEMBLY |
| 28 |
54-8M0024808 |
J CLIP |
| 29 |
8M0084613 |
C WASHER |
| 30 |
10-878608 |
SCREW, (#10-16 x .500) |
| 31 |
10-96529 |
SCREW, (.250-20 x 2.00) |
| 32 |
10-55715 |
SCREW, (.250-20 x .880) |
| 33 |
18787A18 |
CYLINDER HEAD ASSEMBLY Comment: (135) |
| 34 |
27-18785T |
GASKET Comment: (135) |
▶Service/Support Material (1 parts)
| Ref |
OEM Part # |
Part Name |
| 0 |
37-804669A05 |
DECAL, EPA Label Information Comment: (2005) |
▶Solenoid Mounting (36 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
8571641 |
PLATE |
| 2 |
54-828991T |
CLIP |
| 3 |
10-60411 |
SCREW, (.312-18 x 1.250) |
| 4 |
12-49436 |
WASHER |
| 5 |
25-833155 |
GROMMET |
| 6 |
23-8502341 |
BUSHING |
| 7 |
828791 |
CLIP |
| 8 |
8261151 |
CLAMP, Connector |
| 9 |
10-82239312 |
SCREW, (M5 x 12) |
| 10 |
883072T2 |
REGULATOR, Voltage |
| 11 |
893771 |
BRACKET |
| 12 |
8308971 |
FOAM PAD |
| 13 |
10-82129135 |
SCREW, (M6 x 35) |
| 14 |
13541 |
PLUG, Male (GRAY LEAD) |
| 15 |
8M0207773 |
RELAY ASSEMBLY |
| 16 |
828102 |
BRACKET |
| 17 |
25-818967 |
GROMMET |
| 18 |
23-8M0214955 |
BUSHING |
| 19 |
NSS |
NOT SOLD SEPARATE, Decal-Trim Relay |
| 20 |
10-82129125 |
SCREW, (M6 x 25) |
| 21 |
84-819514A11 |
HARNESS ASSEMBLY, Trim |
| 22 |
89-817109A2 |
SOLENOID ASSEMBLY, (#10-32 / .3125-18 Terminals) |
| 23 |
25-822179 |
GROMMET |
| 24 |
23-8M0214955 |
BUSHING |
| 25 |
12-8M0204649 |
WASHER, (.281 x .500 x .060) Stainless Steel |
| 26 |
84-856583A3 |
CABLE ASSEMBLY |
| 27 |
10-82129114 |
SCREW, (M6 x 14) |
| 28 |
84-88439A34 |
CABLE ASSEMBLY, Positive - Battery |
| 29 |
11-8M0204668 |
NUT, (.312-18) |
| 30 |
13-8M0204647 |
LOCKWASHER, (.312) |
| 31 |
10-32,11-45076 |
NUT, Brass |
| 32 |
84-88807A16 |
CABLE ASSEMBLY, (4.00 Inches) Black |
| 33 |
10-32,11-813938 |
CAP NUT, |
| 34 |
84-93388A14 |
CABLE ASSEMBLY, Yellow/Black |
| 35 |
54-8M0024808 |
J CLIP |
| 36 |
84-88439A24 |
CABLE ASSEMBLY, Negative - Battery |
▶Starter Motor (11 parts)
| Ref |
OEM Part # |
Part Name |
| - |
50-893893 |
STARTER MOTOR ASSEMBLY Comment: SN# 0T408999 & Below |
| 1 |
90645 |
DRIVE KIT |
| 2 |
13310T1 |
PINION ASSEMBLY Comment: SN# 0T469022 & Below |
| 3 |
75660 |
PLATE |
| 4 |
10-749681 |
THRU BOLT |
| 5 |
NSS |
NOT SOLD SEPARATE, Washer (Amercian Bosch #WA3122) |
| 6 |
79216 |
ARMATURE Comment: SN# 0T408999 & Below |
| 7 |
898265016 |
BRUSH/SPRING KIT |
| 8 |
898265014 |
HOLDER |
| 9 |
NSS |
NOT SOLD SEPARATE, Screw (American Bosch #02441-22-SC-30SM) |
| 10 |
15386001 |
END CAP |
▶Swivel Bracket and Steering Arm (38 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 |
| 6 |
22-8M0169589 |
FITTING, Grease |
| 7 |
23-821207 |
BUSHING |
| 8 |
12-816432 |
THRUST WASHER |
| 9 |
878182T01 |
YOKE, Bottom - Stainless Steel (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 |
| 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 |
17-67706A55 |
SWIVEL PIN ASSEMBLY, Steering Arm Comment: (CARBON STEEL) |
| 21 |
10-8M0176309 |
SCREW, (.437-20 x 7.50) |
| 22 |
8M0000516 |
BUMPER |
| 23 |
77326 |
MOUNT Comment: (ALL OTHER MODELS) |
| 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) |
| 32 |
22-8M0214971 |
COUPLER |
| 33 |
22-859732 |
PLUG |
| 34 |
22-8M0214970 |
FITTING, Adapter |
| 35 |
32-85944975 |
TUBING, (72.00 Inches Bulk) (Cut to 52 Inches) |
| 36 |
22-859448T |
FITTING Comment: (Use where Applicable) |
| 37 |
25-8M0153609 |
GROMMET Comment: (Use where Applicable) |
| 38 |
54-850181 |
TIE STRAP, (11.750 Inches) Comment: (Use where Applicable) |
▶Throttle Lever and Shift Shaft (49 parts)
| Ref |
OEM Part # |
Part Name |
| 1 |
41094A3 |
LEVER ASSEMBLY, Spark Advance |
| 2 |
10-64022 |
SCREW, (.250-20 x 2.125) |
| 3 |
11-64015 |
NUT, (.250-20) |
| 4 |
26852 |
CAP, Nylon |
| 5 |
10-13627 |
SCREW, (.190-32 x 1.250) |
| 6 |
10-32,11-68219 |
NUT, Stainless Steel |
| 7 |
48039 |
CAP |
| 8 |
12-46765 |
WASHER, (.390 x 1.50 x .120) |
| 9 |
10-32,11-46438 |
NUT, |
| 10 |
24-823235 |
SPRING |
| 11 |
23-55171 |
BUSHING |
| 12 |
410952 |
LEVER, Throttle Control Comment: SN# 0T801000 & Up |
| 13 |
10-818165 |
SCREW, (.375-16 x 1.75) |
| 14 |
23-55164 |
BUSHING |
| 15 |
10-64022 |
SCREW, (.250-20 x 2.125) |
| 16 |
11-64015 |
NUT, (.250-20) (1/4-20) |
| 17 |
26852 |
CAP, Nylon |
| 18 |
39483 |
LATCH |
| 19 |
10-69026 |
SCREW, (.250-28 x .880) |
| 20 |
24-20099 |
SPRING |
| 21 |
11-826709109 |
NUT, (.250-28) Stainless Steel |
| 22 |
14638 |
BARREL |
| 23 |
8302391 |
ROD, Throttle Control |
| 24 |
23-8M0215006 |
BUSHING, Swivel |
| 25 |
828276 |
CAM, Throttle |
| 26 |
16-20353 |
STUD, (.250-28 x 1.750) |
| 27 |
11-826709109 |
NUT, (.250-28) Stainless Steel |
| 28 |
814283T6 |
BRACKET ASSEMBLY, Anchor, Anchor |
| 29 |
98889 |
LATCH |
| 30 |
10-42975 |
DRIVE SCREW |
| 31 |
39519 |
CUP |
| 32 |
52100 |
WEAR PLATE |
| 33 |
8M0036768 |
LATCH |
| 34 |
12-35462 |
WASHER, (.2656 x .625 x .0625) Stainless Steel |
| 35 |
11-826709109 |
NUT, (.250-28) Stainless Steel |
| 36 |
10-28782 |
SCREW, (.312-18 x .880) Stainless Steel |
| 37 |
814284 |
GUIDE BLOCK |
| 38 |
24-20099 |
SPRING |
| 39 |
67073A1 |
LINK ROD ASSEMBLY |
| 40 |
79932A17 |
SHIFT SHAFT ASSEMBLY Comment: (X-LONG) |
| 41 |
NSS |
NOT SOLD SEPARATE, Roll Pin |
| 42 |
NSS |
NOT SOLD SEPARATE, Shift Shaft Lever-Upper |
| 43 |
23-26856 |
BUSHING |
| 44 |
13-29720 |
WAVE WASHER |
| 45 |
12-35462 |
WASHER, (.2656 x .625 x .0625) Stainless Steel |
| 46 |
11-826709109 |
NUT, (.250-28) Stainless Steel |
| 47 |
87-858863A1 |
SWITCH |
| 48 |
10-77478 |
SCREW, (#6-32 x .875) |
| 49 |
12-27882 |
WASHER |
▶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 |
| 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 |
831207A16 |
HANDLE ASSEMBLY, Black |
| 8 |
23-812707 |
BUSHING |
| 9 |
23-831214 |
SPACER |
| 10 |
13-12134 |
WASHER, Wave |
| 11 |
8M0001081 |
CAM Comment: SN# 0T801000 & 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 |
47341A11 |
ROPE AND HANDLE KIT, Manual Starting (FOR MANUAL STARTING) |
| 24 |
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 |
100-Hour / Annual Service Checklist
Regular maintenance keeps your Mercury XR-6 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.
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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.
