Propeller Cotter Pin – Fits Yamaha, Suzuki, Johnson/Evinrude (Replaces 09204-03001, 91401-40025, 5030087)
Propeller Cotter Pin – Fits Yamaha, Suzuki, Johnson/Evinrude (Replaces 09204-03001, 91401-40025, 5030087) is backordered and will ship as soon as it is back in stock.
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Worry-free returns
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Delivery and Shipping
Delivery and Shipping
Free standard shipping on all orders under 1 KG
Propeller Cotter Pin – Fits Yamaha, Suzuki, Johnson/Evinrude (Repla...
Product Details
This high-quality Propeller Cotter Pin is designed to secure the propeller on a wide range of Yamaha, Suzuki, and Johnson/Evinrude outboard motors. Made from marine-grade 304 stainless steel, it offers exceptional resistance to corrosion in saltwater environments. It fits various 2-stroke and 4-stroke engines, with specific compatibility varying by model and year.
This part serves as a direct replacement for Suzuki 09204-03001, 09204-03003, 09204-03004; Yamaha 91401-40025-00, 91401-40028-00, 91401-40030-00; Johnson/Evinrude 5030087; and Mallory 9-73912.
- Easy to install; simply insert through the propeller shaft and secure with pliers.
- Engineered for marine use with high resistance to rust and wear.
- Package includes 12 pins for multiple replacements or to keep as spares.
Part Number Matrix
Use this matrix to confirm equivalent references across OEM and aftermarket.
| Brand | Part Number |
|---|---|
| Suzuki | 09204-03001 |
| Suzuki | 09204-03003 |
| Suzuki | 09204-03004 |
| Yamaha | 91401-40025-00 |
| Yamaha | 91401-40028-00 |
| Yamaha | 91401-40030-00 |
| Johnson/Evinrude | 5030087 |
| Mallory | 9-73912 |
Engine & Model Compatibility
Confirm your engine model/year in the table below.
For Yamaha outboards, this pin fits various 2-stroke and 4-stroke models from 25 HP to 150 HP.
| Brand | Model | Rated HP | Stroke | OEM Part No. |
|---|---|---|---|---|
| Yamaha | Various | 25 | 2-Stroke & 4-Stroke | 91401-40025-00 |
| Yamaha | Various | 40 | 2-Stroke & 4-Stroke | 91401-40025-00 |
| Yamaha | Various | 50 | 2-Stroke & 4-Stroke | 91401-40025-00 |
| Yamaha | Various | 60 | 2-Stroke & 4-Stroke | 91401-40025-00 |
| Yamaha | Various | 90 | 2-Stroke & 4-Stroke | 91401-40025-00 |
| Yamaha | Various | 115 | 2-Stroke & 4-Stroke | 91401-40025-00 |
| Yamaha | Various | 150 | 2-Stroke & 4-Stroke | 91401-40025-00 |
For Suzuki outboards, this pin fits a broad range of 2-stroke and 4-stroke models from 2.5 HP to 300 HP.
| Brand | Model | Rated HP | Stroke | OEM Part No. |
|---|---|---|---|---|
| Suzuki | Various | 2.5 | 4-Stroke | 09204-03001 |
| Suzuki | Various | 4-9.9 | 4-Stroke | 09204-03001 |
| Suzuki | Various | 14-20 | 2-Stroke & 4-Stroke | 09204-03001 |
| Suzuki | Various | 25-30 | 2-Stroke & 4-Stroke | 09204-03001 |
| Suzuki | Various | 40-60 | 2-Stroke & 4-Stroke | 09204-03001 |
| Suzuki | Various | 65-90 | 2-Stroke & 4-Stroke | 09204-03001 |
| Suzuki | Various | 100-150 | 4-Stroke | 09204-03001 |
| Suzuki | Various | 175-300 | 4-Stroke | 09204-03001 |
For Johnson/Evinrude outboards, compatibility is confirmed for some models but not fully documented across all horsepower ranges.
| Brand | Model | Rated HP | Years | OEM Part No. | Notes |
|---|---|---|---|---|---|
| Johnson | 90 | 90 | 2006 | 5030087 | Verified application |
| Johnson/Evinrude | Various | 5030087 | Complete model compatibility not documented |
Technical Specs
- Product Type
- Outboard Lower Drive Cotter Pin
- Material
- 304 Stainless Steel
- Dimensions
- Approximately 4mm x 25mm
- Corrosion Resistance
- High (marine-grade stainless steel)
- Application
- Secures propeller on outboard motors
- Color
- Silver/Metallic
- Quantity Per Package
- 12 pieces
- Other Technical Attributes
- High hardness, wear-resistant, rust-resistant
What’s in the Box
- 12 x Propeller Cotter Pins (Replaces Suzuki 09204-03001, Johnson Evinrude 5030087, Yamaha 91401-40025-00)
Installation Notes
- Ensure the engine is off and the shifter is in the neutral position. For safety, disconnect the battery.
- Remove the old cotter pin from the propeller nut castle using pliers.
- Unscrew the propeller castle nut and remove any washers.
- Slide the propeller off the propeller shaft.
- Clean the propeller shaft and apply fresh marine grease.
- Slide the new propeller on, followed by the washers and castle nut.
- Tighten the castle nut to the manufacturer's specified torque.
- Align the grooves in the castle nut with the hole in the propeller shaft.
- Insert the new cotter pin through the hole.
- Bend the ends of the cotter pin around the castle nut to secure it in place.
Troubleshooting & FAQ
Will this fit my specific outboard model?
This cotter pin is designed for a wide range of Yamaha, Suzuki, and Johnson/Evinrude motors. Please review the compatibility tables and part number cross-references on this page. The most reliable method is to match the OEM part number from your service manual to the numbers listed.
What are the signs of a failing cotter pin?
A worn, corroded, or broken cotter pin can lead to a loose propeller, excessive vibration, or rattling sounds from the lower unit. In a worst-case scenario, the propeller nut could back off, causing the propeller to detach. Regular inspection during propeller maintenance is recommended.
How often should I replace my propeller cotter pin?
It is best practice to use a new cotter pin every time you remove and reinstall your propeller. The metal can fatigue when bent, and reusing an old pin increases the risk of it breaking. Since this package includes 12 pins, you will have plenty of spares for routine maintenance.
Is this pin made of the same material as the OEM part?
This aftermarket pin is made of high-quality 304 stainless steel, a material known for its excellent corrosion resistance in marine environments. This is comparable to, and in some cases may exceed, the material specifications of the original OEM part, ensuring long-lasting performance.
What tools are needed for installation?
You will typically need a set of pliers to remove the old pin and bend the new one into place. You will also need a wrench or socket of the appropriate size to remove and tighten the propeller nut.
Can I use this for applications other than propellers?
While this cotter pin's dimensions (approx. 4mm x 25mm) may suit other hardware applications, it is specifically designed and verified for securing outboard motor propellers. Using it for other critical applications is not recommended unless the specifications match exactly.
OEM vs. Aftermarket?
This listing is an aftermarket replacement (not OEM). Built to OEM-level specifications with comparable materials. Manufactured in an ISO 9002 facility, batch-inspected for consistency.
Shipping speed & cost
We ship worldwide quickly—typical transit 5–15 days. Standard shipping is free; expedited options appear at checkout where available.
Warranty & returns
Covered by a 1-year warranty against manufacturing defects under normal use. If issues arise, contact support with your order details. Returns are accepted within our standard window (unused & in original condition). See our policy page or reach out for instructions.
Safety & Important Info
- Verify images/specifications vs your original part. If anything differs—even if your model appears compatible—do not purchase.
- This is an aftermarket replacement, not an OEM component.
- Professional installation is recommended for safety and performance.
About Sea Sierra
- Pro-Grade Standards — We supply marine parts engineered to OEM-level tolerances and tested for real-world conditions.
- Fast Global Fulfillment — Free standard delivery to most regions in 5–15 days.
- Manufacturer-Direct Value — Fair pricing without compromising on materials or QC.
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