Marine Propeller Cotter Pin for Yamaha, Suzuki & Johnson/Evinrude Outboards – Replaces 91401-40025-00, 09204-03003 & 5030087
Marine Propeller Cotter Pin for Yamaha, Suzuki & Johnson/Evinrude Outboards – Replaces 91401-40025-00, 09204-03003 & 5030087 is backordered and will ship as soon as it is back in stock.
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Marine Propeller Cotter Pin for Yamaha, Suzuki & Johnson/Evinru...
Marine Propeller Cotter Pin for Yamaha, Suzuki & Johnson/Evinrude Outboards – Replaces 91401-40025-00, 09204-03003 & 5030087 is backordered and will ship as soon as it is back in stock.
Product Details
This marine propeller cotter pin is used to secure a propeller castle nut on compatible outboard engines. It is listed as a replacement for selected Yamaha, Suzuki, and Johnson/Evinrude applications. Always compare the original pin, dimensions, and manufacturer part number before ordering.
Listed replacement references include Yamaha 91401-40025-00, 91401-40028-00, 91401-40030-00, 91490-40025-00, and 91490-40030-00; Suzuki 09204-03001, 09204-03003, and 09204-03004; Johnson/Evinrude 5030087; Mallory 9-73912; and Sierra 18-3735-9.
- Installs through the aligned hole in the propeller shaft and castle nut.
- Designed for use as a replacement propeller-retaining cotter pin.
- Stainless-steel construction is suitable for normal marine service when the part is correctly matched to the application.
- Replace the pin whenever the propeller is removed or when the existing pin shows corrosion, cracking, or deformation.
Part Number Matrix
The references below are listed replacement and aftermarket numbers. They are provided for identification and cross-reference purposes; they do not replace verification against the exact engine model and serial-number range.
| 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 and Model Compatibility
The product record associates this replacement pin with a range of Yamaha, Suzuki, and Johnson/Evinrude outboards. The ranges below are application guidance rather than a substitute for an exact parts-catalog lookup. Model, year, stroke, shaft configuration, and serial-number conditions must be checked together.
| Brand | Listed application coverage | Listed replacement reference | Fitment verification |
|---|---|---|---|
| Yamaha | Various outboards, approximately 25–150 HP, model years 1984–2019 | 91401-40025-00 and related Yamaha references | Confirm exact model, year, and serial number |
| Suzuki | Various outboards, approximately 2.5–300 HP, model years 1977–2017 | 09204-03001, 09204-03003, and related Suzuki references | Confirm exact model, year, stroke, and serial number |
| Johnson/Evinrude | Various outboards, approximately 4–225 HP, model years 1998–2007 | 5030087 | Confirm exact model, year, and serial number |
Technical Specifications
- Product Type
- Marine propeller cotter pin
- Material
- 304 stainless steel
- Dimensions
- Approximately 4 × 35 mm (5/32 × 1-3/8 in.)
- Color
- Silver/metallic
- Installation
- Manual insertion through the aligned propeller shaft and castle-nut hole
- Application
- Propeller retention on compatible marine outboards
- Pack Quantity
- The available product record does not establish a definitive package count. Confirm the current package labeling before ordering.
What's in the Box
- Marine propeller cotter pin package
Package quantity is not confirmed in the available product record. Please verify the package label or product variant before purchase.
Installation Notes
- Turn the engine off, remove the emergency-stop lanyard, and place the engine in neutral.
- Remove the old cotter pin with pliers. Do not reuse a bent or previously installed pin.
- Remove the propeller castle nut, washer, and propeller as required by the engine manufacturer's procedure.
- Inspect and clean the propeller shaft and related hardware.
- Reinstall the propeller, washer, and castle nut.
- Tighten the castle nut to the manufacturer's specified torque.
- Align a castle-nut slot with the hole in the propeller shaft.
- Insert the new cotter pin through the aligned hole.
- Bend the pin legs around the nut to secure the assembly, following the engine manufacturer's instructions.
Maintenance and FAQ
How do I confirm that this cotter pin fits my engine?
Compare the original pin's dimensions and shape, then confirm the applicable manufacturer reference in the engine parts catalog. Check the exact model, year, stroke, shaft configuration, and serial-number range together. The replacement references listed on this page are identification aids and do not confirm every engine application.
Should I reuse a propeller cotter pin?
No. A cotter pin is normally a single-use retaining part. Removing and rebending it can weaken the metal, so install a new pin whenever the propeller is removed.
What are signs that the pin needs replacement?
Replace the pin if it is corroded, cracked, excessively bent, loose, or damaged. A loose propeller or unusual movement at the propeller assembly also requires immediate inspection before operating the boat.
Is this an OEM part?
This listing is for an aftermarket replacement cotter pin. The manufacturer references shown above are provided for cross-reference and identification only.
How many pins are included?
The available product record does not confirm a definitive package quantity. Check the package labeling or current product variant details before ordering.
Safety and Important Information
- Verify the part number, dimensions, and original hardware before installation.
- Do not rely on horsepower or brand alone to confirm fitment; exact model and serial-number conditions may apply.
- Use a new cotter pin after propeller removal or whenever the existing pin is damaged.
- Follow the outboard manufacturer's torque and installation procedures.
- Professional installation is recommended when the correct procedure or fitment is uncertain.
About Sea Sierra
- Marine Replacement Parts — Practical replacement components for maintenance and repair applications.
- Fitment-Focused Listings — Product references are provided to help customers compare their original part before ordering.
- Customer Support — Contact support with the engine brand, model, year, and serial number when fitment assistance is needed.
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