Marine Propeller Cotter Pin – Fits Yamaha, Suzuki, Johnson/Evinrude (Replaces 91401-40025-00, 09204-03003, 5030087)

$6.99

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Marine Propeller Cotter Pin – Fits Yamaha, Suzuki, Johnson/Evinrude (Replaces 91401-40025-00, 09204-03003, 5030087) is backordered and will ship as soon as it is back in stock.

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Product Details

This Marine Propeller Cotter Pin is a crucial piece of hardware for securing your propeller, designed for a wide range of outboards. It is compatible with Yamaha models from 25–150 HP (1984–2019), Suzuki models from 2.5–300 HP (1977–2017), and Johnson/Evinrude models from 4–225 HP (1998–2007).

This part serves as a direct replacement for Yamaha 91401-40025-00, 91401-40028-00, 91401-40030-00, 91490-40025-00, 91490-40030-00; Suzuki 09204-03001, 09204-03003, 09204-03004; Johnson/Evinrude 5030087; Mallory 9-73912; and Sierra 18-3735-9.

Installs by manual insertion through the propeller shaft nut.
Made from corrosion-resistant 304 Stainless Steel, ideal for marine environments.
Each pack includes multiple pins, providing spares for maintenance.

Part Number Matrix

Use this matrix to confirm equivalent references across OEM and aftermarket.

Brand	Part Number
Yamaha	91401-40025-00 / 91401-40028-00 / 91401-40030-00 / 91490-40025-00 / 91490-40030-00
Suzuki	09204-03001 / 09204-03003 / 09204-03004
Johnson/Evinrude	5030087
Mallory	9-73912
Sierra	18-3735-9

Engine & Model Compatibility

Confirm your engine model/year in the table below.

Fits a wide array of Yamaha outboards from 25 HP to 150 HP manufactured between 1984 and 2019.

Brand	Model	Rated HP	Stroke	Years	OEM Part No.
Yamaha	Various	25–150	2 & 4-Stroke	1984–2019	91401-40025-00

Compatible with an extensive list of Suzuki outboards from 2.5 HP to 300 HP manufactured between 1977 and 2017.

Brand	Model	Rated HP	Stroke	Years	OEM Part No.
Suzuki	DF2.5	2.5	4-Stroke	2012–2017	09204-03001
Suzuki	DF4	4	4-Stroke	2003–2017	09204-03001
Suzuki	DF5	5	4-Stroke	2003–2017	09204-03001
Suzuki	DF6	6	4-Stroke	2003–2017	09204-03001
Suzuki	DF8/DT8	8	2 & 4-Stroke	1980–2017	09204-03001
Suzuki	DF9.9/DT9.9	9.9	2 & 4-Stroke	1977–2017	09204-03001
Suzuki	DF25/DT25	25	2 & 4-Stroke	1977–2015	09204-03001
Suzuki	DF30/DT30	30	2 & 4-Stroke	1983–2015	09204-03001
Suzuki	DF40/DT40	40	2 & 4-Stroke	1986–2016	09204-03001
Suzuki	DF50/DT50	50	2 & 4-Stroke	1977–2016	09204-03001
Suzuki	DF60/DT60	60	2 & 4-Stroke	1984–2016	09204-03001
Suzuki	DF70/DT70	70	2 & 4-Stroke	1983–2016	09204-03001
Suzuki	DF90/DT90	90	2 & 4-Stroke	1989–2016	09204-03001
Suzuki	DF115/DT115	115	2 & 4-Stroke	1983–2016	09204-03001
Suzuki	DF140/DT140	140	2 & 4-Stroke	1981–2016	09204-03001
Suzuki	DF150/DT150	150	2 & 4-Stroke	1986–2016	09204-03001
Suzuki	DF175/DT175	175	2 & 4-Stroke	1987–2016	09204-03001
Suzuki	DF200/DT200	200	2 & 4-Stroke	1986–2015	09204-03001
Suzuki	DF225/DT225	225	2 & 4-Stroke	1990–2015	09204-03001
Suzuki	DF250	250	4-Stroke	2004–2015	09204-03001
Suzuki	DF300	300	4-Stroke	2007–2015	09204--03001

Fits a selection of Johnson/Evinrude outboards from 4 HP to 225 HP produced between 1998 and 2007.

Brand	Model	Rated HP	Stroke	Years	OEM Part No.
Johnson/Evinrude	Various	4	2 & 4-Stroke	2003–2007	5030087
Johnson/Evinrude	Various	5	2 & 4-Stroke	1998–2007	5030087
Johnson/Evinrude	Various	6	2 & 4-Stroke	2005–2007	5030087
Johnson/Evinrude	Various	25	2 & 4-Stroke	2000–2007	5030087
Johnson/Evinrude	Various	30	4-Stroke	2000–2007	5030087
Johnson/Evinrude	Various	40	2 & 4-Stroke	1999–2006	5030087
Johnson/Evinrude	Various	50	2 & 4-Stroke	1999–2006	5030087
Johnson/Evinrude	Various	60	4-Stroke	2002–2006	5030087
Johnson/Evinrude	Various	70	2 & 4-Stroke	1998–2006	5030087
Johnson/Evinrude	Various	90	2 & 4-Stroke	2003–2006	5030087
Johnson/Evinrude	Various	115	2 & 4-Stroke	2003–2006	5030087
Johnson/Evinrude	Various	140	2 & 4-Stroke	2003–2006	5030087
Johnson/Evinrude	Various	200	4-Stroke	2004–2006	5030087
Johnson/Evinrude	Various	225	4-Stroke	2004–2006	5030087

Technical Specs

Product Type: Marine Propeller Cotter Pin
Installation: Manual insertion through propeller shaft nut
Material: 304 Stainless Steel
Dimensions: 4 × 35 mm (5/32" × 1-3/8")
Color: Silver/Metallic
Technical Attributes: Corrosion resistant for marine environments
Quantity per Pack: 10-12 (varies by seller)

What’s in the Box

10 or 12 x Marine Propeller Cotter Pins (quantity varies by manufacturer)

Installation Notes

Ensure the engine is off, the kill switch lanyard is disconnected, and the motor is in neutral.
Remove the old, damaged cotter pin using pliers.
Loosen and remove the propeller castle nut, washer, and propeller.
Clean and grease the propeller shaft.
Reinstall the propeller, washer, and castle nut.
Tighten the castle nut to the manufacturer's recommended torque specification.
Align the slots in the castle nut with the hole in the propeller shaft.
Insert a new cotter pin through the hole.
Bend the two legs of the cotter pin in opposite directions around the nut to secure it firmly in place.

Troubleshooting & FAQ

How do I know if this cotter pin will fit my engine?

The best way is to check the part number. This pin replaces multiple OEM and aftermarket numbers, including Yamaha 91401-40025-00, Suzuki 09204-03003, and Johnson/Evinrude 5030087. You can also consult the compatibility tables on this page to find your engine's HP, stroke, and year range.

How often should a propeller cotter pin be replaced?

It is best practice to use a new cotter pin every time you remove and reinstall your propeller. They are single-use components designed to deform upon installation, and reusing them significantly increases the risk of failure.

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What are the signs of a failing cotter pin?

Visible corrosion, cracking, or any signs of deformation are clear indicators that the pin needs immediate replacement. A loose propeller or rattling sounds from the lower unit can also signal a failing pin. Never operate your boat if you suspect the cotter pin is compromised.

Can I reuse a cotter pin?

No. Cotter pins are designed for one-time use. Bending the legs during installation and then straightening them for removal weakens the metal, making it brittle and prone to breaking. Always install a new pin to ensure your propeller remains securely fastened.

Why is the quantity listed as 10-12 pins?

We source high-quality aftermarket parts from different manufacturers. Depending on the brand, packages contain either 10 or 12 pins. Rest assured, all pins meet the same specifications for material and dimensions.

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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