Suzuki 8-25HP outboard motors Service Manual, Page 42Get this manual
Suzuki DT25C To remove gearcase, first remove drain plug (25) and level plugs (23) and drain gearcase lubricantLoosen shift rod locknut (6-FigSZIO-27) and turn adjustment nut (5) until upper and lower shift rods are separatedRemove six screws and separate gearcase assembly from drive shaft housingRemove propeller and two screws securing bearing carrier (36-FigSZIO-26) to gearcase (27)Using suitable slide hammer type puller, carefully extract bearing carrier and propeller shaft assemblyRemove water pump housing (4), impeller (6), key (5), plate (7) and gasket (8)Install drive shaft holder 09921-29610 or equivalent on upper spline of drive shaft (14), then remove pinion gear nut (30) by turning drive shaftRemove two remaining screws securing bearing housing (9) to gearcaseUse two mm screws positioned as shown in FigSZIQ28 and tighten screws in equal increments to withdraw upper bearing housing and drive shaft componentsReach into gearcase and remove pinion gear (29-FigSZIO-26), shim (28), forward gear (54), shim (55) and bearing (57)Refer to FigSZIO-29 and remove screw securing shift rod guide holder (IO-FigSZIO-27)Lift lower shift rod assembly out top of gearcaseInspect all components for excessive wear or other damageApply suitable water-resistant grease to lip area of all sealsRenew all seals, gaskets and "0" rings upon reassemblyReassemble lower unit in reverse order of disassembly noting the following: Install dog Clutch (51-FigSZIO-30) on propeller shaft (47) so side marked" F" is toward forward gear (54-FigSZlO26)If removed, install pinion bearing (22) into gearcase using suitable driver, Be sure lettered side of bearing (22) faces upApply Suzuki Thread Lock 1342 or suitable equivalent to threads of pinion nut (30) and tighten nut to 2730 N'm (20-22 ft,-lbsForward gear-topinion gear backlash should be 0,1-0.2 mm (0.004-0.008 inAdjust thickness of shims (28 and 55) to obtain specified backlashAfter obtaining the proper backlash, check pinion gear-to-forward