10262080 OPERATION MANUAL, 40/50 2-Stroke Mercury
1040203FL
OPERATION
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1040203FL
Mercury
Mercury entire parts catalog list:
Information:
(1) Diameter of the drive shaft (new) ... .7407 .0003 in.(18.814 0.008 mm)Bore in the bearings for the drive shaft ... .7425 .0005 in.(18.860 0.013 mm)Clearance between drive shaft and bearing (new) ... .0018 .0008 in.(0.046 0.020 mm)Maximum permissible clearance between shaft and bearing (worn) ... .005 in.(0.13 mm)(2) Length of gear ... 2.9955 .0005 in.(76.086 0.013 mm)Depth of counterbore for gear ... 3.0008 .0008 in.(76.220 0.020 mm)Clearance between end of gear and cover (new) ... .0053 .0013 in.(0.135 0.033 mm)(3) Length of gear ... 1.9975 .0005 in.(50.737 0.013 mm)Depth of counterbore for gear ... 2.0008 .0008 in.(50.820 0.020 mm)Clearance between end of gear and cover (new) ... .0033 .0013 in.(0.084 0.033 mm)(4) Diameter of the shaft for the drive idler gear (new) ... 1.1225 .0005 in.(28.512 0.013 mm)Bore in bearing of gear (new) ... 1.1260 .0019 in.(28.600 0.048 mm)Clearance between shaft and bearing (new) ... .0035 .0024 in.(0.089 0.061 mm)Maximum permissible clearance between shaft and bearing (worn) ... .008 in.(0.20 mm)(5) 1S3921 Spring for pressure relief valve (engine oil):Length under test force ... 3.25 in.(82.6 mm)Test force ... 39.8 3.2 lb.(177.5 14.0 N)Free length after test ... 3.57 in.(90.7 mm)Outside diameter ... .77 in.(19.6 mm)(6) Diameter of the shaft for the idler gear (clutch pump) (new) ... .7407 .0003 in.(18.814 0.008 mm)Bore in the bearing ... .7425 .0005 in.(18.860 0.013 mm)Clearance between shaft and bearing (new) ... 0.0018 .0008 in.(0.046 0.020 mm)Maximum permissible clearance between shaft and bearing (worn) ... .008 in.(0.20 mm)(7) Diameter of the shaft for the idler gear (scavenge pump) (new) ... .7407 .0003 in.(18.814 0.008 mm)Bore in the bearing of the idler gear ... .7425 .0005 in.(18.860 0.013 mm)Clearance between shaft and bearing (new) ... .0018 .0008 in.(0.046 0.020 mm)Maximum permissible clearance between shaft and bearing (worn) ... .008 in.(0.20 mm)Length of gear ... .9975 .0005 in.(25.337 0.013 mm)Depth of counterbore for gear ... 1.0008 .0008 in.(25.420 0.020 mm)(8) 4J4790 Spring for pressure relief valve (clutch oil):Length under test force ... 1.548 in.(39.32 mm)Test force ... 12.27 lb.(54.6 N)Free length after test ... 2.163 in.(54.94 mm)Outside diameter ... .72 in.(18.3 mm)(9) Torque for nut holding drive gear ... 60 lb. ft.(80 N m)Tighten farther to get alignment for cotter pin.(7S1849 & 7S9461)
(1) Diameter of the drive shaft (new) ... .8747 .0002 in.(22.217 0.005 mm)Bore in the bearings for the drive shaft ... .8763 .0003 in.(22.258 0.008 mm)Clearance between drive shaft and bearings (new) ... .0016 .0005 in.(0.041 0.013 mm)Maximum permissible clearance between shaft and bearing (worn) ... .005 in.(0.13 mm)(2) Diameter of the shaft for the drive idler gear (new) ... 1.1225 .0005 in.(28.512 0.013 mm)Bore in the bearing ... 1.1260 .0019 in.(28.600 0.048 mm)Clearance between shaft and bearing (new) ... .0035 .0024 in.(0.089 0.061 mm)Maximum permissible clearance between shaft and bearing (worn) ... .008 in.(0.20 mm)(3) Diameter of the shaft for the idler gear (new) ... .8747 .0002 in.(22.217 0.005 mm)Bore in the bearing ... .8763 .0003 in.(22.258 0.008 mm)Clearance between shaft and bearing (new) ... .0016 .0005 in.(0.041 0.013 mm)Maximum permissible clearance between shaft and bearing (worn) ... .008 in.(0.20 mm)(4) 1S3921 Spring for pressure relief valve:Length under test force ... 3.25 in.(82.6 mm)Test force ... 39.8 3.2 lb.(177.5 14.0 N)Free length after test ... 3.57 in.(90.7 mm)Outside diameter ... .77 in.(19.6 mm)(5) Length of gear ... 1.4988 .0010 in.(38.070 0.025 mm)Depth of counterbore for gear ... 1.5038 .0008 in.(38.197 0.020 mm)Clearance between end of gear and cover (new) ... .0050 .0018 in.(0.127 0.046 mm)(6) Length of gear ... 2.0003 .0010 in.(50.808 0.025 mm)Depth of counterbore for gear ... 2.0053 .0008 in.(50.935 0.020 mm)Clearance between end of gear and cover (new) ... .0050 .0018 in.(0.127 0.046 mm)(7) Torque for nut holding drive gear ... 60 lb. ft.(80 N m)Tighten farther to get alignment for cotter pin.(2P1785 and 6N2642)
(1) Bore in bearing of idler gear ... 1.1260 .0024 in.(28.600 0.061 mm)Diameter of shaft for the idler gear ... 1.1255 .0005 in.(28.588 0.013 mm)Clearance between bearing and shaft ... .0035 .0029 in.(0.089 0.074 mm)(2) Clearance between gears and body of pump ... .002 to .026 in.(0.05 to 0.66 mm)(3) Diameter of shafts for pump ... .8747 .0002 in.(22.217 0.005 mm)Bore in bearings for shafts ... .8763 .0003 in.(22.258 0.008 mm)Clearance between shafts and bearings ... .0016 .0005 in.(0.041 0.013 mm)(4) Length of gears ... 2.0003 .0010 in.(50.808 0.025 mm)Depth of bore in pump body for gears ... 2.0053 .0008 in.(50.935 0.020 mm)Clearance between end of gears and pump body ... .0050 .0018 in.(0.127 0.046 mm)(5) Length of gears ... 1.4988 .0010 in.(38.070 0.025 mm)Depth of bore in pump body for gears ... 1.5038 .0008 in.(38.197 0.020 mm)Clearance between end of gears and pump body ... .0050 .0018 in.(0.127 0.046 mm)(6) Torque for bolt holding drive gear to drive shaft ... 32 5 lb. ft.(43 7 N m)
(1) Diameter of the drive shaft (new) ... .8747 .0002 in.(22.217 0.005 mm)Bore in the bearings for the drive shaft ... .8763 .0003 in.(22.258 0.008 mm)Clearance between drive shaft and bearings (new) ... .0016 .0005 in.(0.041 0.013 mm)Maximum permissible clearance between shaft and bearing (worn) ... .005 in.(0.13 mm)(2) Diameter of the shaft for the drive idler gear (new) ... 1.1225 .0005 in.(28.512 0.013 mm)Bore in the bearing ... 1.1260 .0019 in.(28.600 0.048 mm)Clearance between shaft and bearing (new) ... .0035 .0024 in.(0.089 0.061 mm)Maximum permissible clearance between shaft and bearing (worn) ... .008 in.(0.20 mm)(3) Diameter of the shaft for the idler gear (new) ... .8747 .0002 in.(22.217 0.005 mm)Bore in the bearing ... .8763 .0003 in.(22.258 0.008 mm)Clearance between shaft and bearing (new) ... .0016 .0005 in.(0.041 0.013 mm)Maximum permissible clearance between shaft and bearing (worn) ... .008 in.(0.20 mm)(4) 1S3921 Spring for pressure relief valve:Length under test force ... 3.25 in.(82.6 mm)Test force ... 39.8 3.2 lb.(177.5 14.0 N)Free length after test ... 3.57 in.(90.7 mm)Outside diameter ... .77 in.(19.6 mm)(5) Length of gear ... 1.4988 .0010 in.(38.070 0.025 mm)Depth of counterbore for gear ... 1.5038 .0008 in.(38.197 0.020 mm)Clearance between end of gear and cover (new) ... .0050 .0018 in.(0.127 0.046 mm)(6) Length of gear ... 2.0003 .0010 in.(50.808 0.025 mm)Depth of counterbore for gear ... 2.0053 .0008 in.(50.935 0.020 mm)Clearance between end of gear and cover (new) ... .0050 .0018 in.(0.127 0.046 mm)(7) Torque for nut holding drive gear ... 60 lb. ft.(80 N m)Tighten farther to get alignment for cotter pin.(2P1785 and 6N2642)
(1) Bore in bearing of idler gear ... 1.1260 .0024 in.(28.600 0.061 mm)Diameter of shaft for the idler gear ... 1.1255 .0005 in.(28.588 0.013 mm)Clearance between bearing and shaft ... .0035 .0029 in.(0.089 0.074 mm)(2) Clearance between gears and body of pump ... .002 to .026 in.(0.05 to 0.66 mm)(3) Diameter of shafts for pump ... .8747 .0002 in.(22.217 0.005 mm)Bore in bearings for shafts ... .8763 .0003 in.(22.258 0.008 mm)Clearance between shafts and bearings ... .0016 .0005 in.(0.041 0.013 mm)(4) Length of gears ... 2.0003 .0010 in.(50.808 0.025 mm)Depth of bore in pump body for gears ... 2.0053 .0008 in.(50.935 0.020 mm)Clearance between end of gears and pump body ... .0050 .0018 in.(0.127 0.046 mm)(5) Length of gears ... 1.4988 .0010 in.(38.070 0.025 mm)Depth of bore in pump body for gears ... 1.5038 .0008 in.(38.197 0.020 mm)Clearance between end of gears and pump body ... .0050 .0018 in.(0.127 0.046 mm)(6) Torque for bolt holding drive gear to drive shaft ... 32 5 lb. ft.(43 7 N m)