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Mercury 40 Service Manual

Mercury 40
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MANUAL TILT ASSIST
90-828631R3 MARCH 1999 Page 5D-29
O-Ring Description and Sizes
O-Ring Description O-Ring I.D. O-Ring O.D. O-Ring Width
1 Wiper Ring
2 Cyl. Cap, Inner 0.671 in. (17.04 mm) 0.949 in. (24.10 mm) 0.139 in. (3.53 mm)
3 Cyl. Cap 1.864 in. (47.34 mm) 2.004 in. (50.90 mm) 0.07 in. (1.78 mm)
4 Shock Piston 1.6 in. (40.64 mm) 2.02 in. (53.086 mm) 0.21 in. (5.334 mm)
5 Piston Bolt 0.676 in. (17.17 mm) .816 in. (20.726 mm) 0.07 in. (1.78 mm)
6 (2) Manifold Split Line 0.208 in. (5.283 mm) 0.348 in. (8.839 mm) 0.07 in. (1.78 mm)
7 Slow Valve 0.114 in. (2.90 mm) 0.254 in. (6.451 mm) 0.07 in. (1.78 mm)
8 (2) Plug 0.489 in. (12.42 mm) 0.629 in. (15.97 mm) 0.07 in. (1.78 mm)
9 Accumulator 2.114 in. (53.69 mm) 2.254 in. (57.25 mm) 0.07 in. (1.78 mm)
10 Lip Seal
11 Cam Shaft 0.301 in. (7.645 mm) 0.441 in. (11.20 mm) 0.07 in. (1.78 mm)
12 Back Up Ring
13 Surge Valve02664) 0.301 in. (7.645 mm) 0.441 in. (11.20 mm) 0.07 in. (1.78 mm)
14 Memory Piston 1.6 in. (40.64 mm) 2.02 in. (53.086 mm) 0.21 in. (5.334 mm)
Manual Tilt System Cleaning and Inspection
1. It is recommended that all O-rings exposed during disassembly be replaced.
2. Clean components, filter, and check valve seats using engine cleaner and compressed
air. Do not use cloth rags.
3. Inspect all machined surfaces for burrs or scoring to assure O-ring longevity.
4. Inspect shock rod. If scraper (located in cap) has failed to keep rod clean, replace
scraper.
Manual Tilt System Reassembly
IMPORTANT: Components must be dirt and lint free. Slightest amount of debris in tilt
system could cause system to malfunction.
Apply Quicksilver Power Trim and Steering Fluid to all O-rings during reassembly. If not
available, use automotive (ATF) automatic transmission fluid.

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Mercury 40 Specifications

General IconGeneral
BrandMercury
Model40
CategoryOutboard Motor
LanguageEnglish

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