Suzuki 30-40HP outboard motors Service Manual, Page 34Get this manual
Suzuki DT35 (After 1986)DT40 (After 1983) assemblyDuring disassemblynote location of all shims and thntst washers for refere nce during reassemblyTo remove lower unit, first drain oilRemove engine cover, loosen nut (7) and turn shift rod coupler (6) to separate upper and lower shift rodsHemove six screws securing gearcase to drive shaft housing, remove gearcase and place in suitable holding fixtureRemove the trim tabStraighten tabs on lock washer (62), remove propeller nut (63), propeller, thrust hub (61) and bushing (60)Remove two screws securing bearing carrier (55)Using Suzuki special tools (or equivalent) as shown in FigSZI3-31pull propeller shaft assembly from gearcaseSlide water tube seal collar (2-FigSZI3-I8) off drive shaft (31-FigSZI3-:30) and remove water pump assembly (FigSZI3-18)To remove pinion gear (44-FigSZI3-30), fit Suzuki drive shaft holder (part 0992129510) or equivalent splined tool, on top of drive shaftHeach into gearcase and hold pinion nut (43) with the proper size wrench and rotate drive shaft to unscrew nut (4:3)After removing pinion gear (44), reach into gearcase and withdraw forward gear (39) along with shim