Suzuki 50-85HP outboard motors Service Manual, Page 19Get this manual
Suzuki DT55DT65 (After 1984) separate gearcase assembly from drive shaft housingRemove water pump assembly (Fig SZI5-13), Remove propeller with related components from propeller shaftUnscrew two screws retaining gearcase end cap (49-Fig, SZ15-20), then attach suitable puller to propeller shaft (43) and withdraw propeller shaft assembly with gearcase end cap (49), Unscrew pinion nut (32) and remove pinion gear (29), then extract forward gear (35)Drive shaft (19) and related components can be withdrawn from gearcase after removal of bearing housing (15), Inspect gears for wear on teeth and on engagement dogsInspect dog clutch (37) for wear on engagement surfaces, Inspect shafts for wear on splines and on friction surfaces of gears and oil sealsCheck shift cam (12) and shift pin (39) for excessive wear, Check condition of shift spring (42)Spring free length should be 73 mm (2.9 in,)All seals and "0" rings should be renewed when unit is reassembled, Backlash between pinion gear (29) and drive gears (35 and 45) should be 0.1-0,2 mm (0,004-0.008 in,) and is adjusted by varying thickness of shims (34 and 46)Propeller shaft end play should be 0.2-0.4 mm (O.OOS{l016 in and is adjusted by increasing or decreasing the thickness of thrust washer (44)Reassemble gearcase by reversing bly procedure while noting the following: Install dog clutch (37) on propeller shaft (43) so "REV" marked side is toward reverse gear (45), Tight.en pinion nut (32) to 30-40 N'm (21-29 ft,-lbs,), Apply water-resistant grease to "0" ring (48), Apply silicone sealer to gearcase and bearing housing (15) mating surfaces and to bearing housing and drive shaft housing mating surfacesCoat retaining cap screws ru:ijacent to cap screw heads with silicone sealerEngage shift shaft (2) in shift rod (3) eyelet and attach shift arm (I), Serure with nutFill gearease with outboard gear oil as outlined in LUBRICATION