Suzuki 30-40HP outboard motors Service Manual, Page 25Get this manual
SERVICE MANUAL modelsDuring disassemblynote the location of all shims and thrust washers to aid in reassemblyTo remove gear case, first unscrew plug (30) and drain gear lubricantDisconnect shift linkage at connector (2) located externally on the drive shaft housingRemove the cap screws securing gearcase to drive shaft housing and separate gearcase assembly from drive shaft housingRemove water pump assembly (FigSZI212)Remove propeller with related components from propeller shaftUnscrew two bol ts retaining gearcase end cap (50FigSZI2-22), then attach suitable puller to propeller shaft (44) and withdraw propeller shaft assembly with gearcase end capUnscrew pinion nut (33) and remove pinion gear (32), then extract forward gear (36)Drive shaft (20) and related components may be withdrawn from gearcase after removal of bearing housing (13)Unscrew shift cam retaining screw (12) from gearcase to remove lower shift rod assemblyInspect gears for wear on teeth and on engagement dogs Inspect clutch (40) for wear on engagement surfacesInspect shafts for wear on splines and on friction surfaces of gears and oil sealsCheck shift cam (11) and shift pin (38) for excessive wearCheck condition of shift spring (43)Spring free length should be 69 mm with minimum length of 67 mmAll seals and "0" rings should be renewed when unit is reassembledBacklash between pinion gear (32) and drive gears (36 and 46) should be 0.05-0.30 mm and is adjusted by varying thickness of shims (35) and thrust washer (47)Propeller shaft end play should be 0.05-0.30 mm and is adjusted by increasing or decreasing the thickness of thrust washers (37 and 45)Reassemble gearcase by reversing disassembly procedure while noting the following: Install clutch (40) on propeller shaft (44) so "F" marked side (see FigSZI2-23) is towards forward gear (36-FigSZI2-22)Tighten pinion nut (33) to 35 mApply water-resistant grease to mating surfaces of gearcase end cap (50) and gearcaseApply silicone