Suzuki outboard motors 1988 2003 repair manual., Page 274Get this manual
8-6 LOWER UNIT 13Remove the gearcase from the driveshaft housing and mount it in suitable holding fixtureDo not rotate the flywheel counterclockwiseThis can damage the water pump impeller and cause the engine to overheat 16Seat the gearcase in place, rotating the flywheel clockwise as required until the driveshaft and crankshaft engage, 17Apply silicone sealer to the mounting bolt threads and tighten to specifications18Connect the clutch shaft onto the clutch rod and install the nutTighten the nut securely19lnstall the propeller, 20Reconnect the spark plug leads and refill the gearcase with proper type and quantity of lubricantlnstall the engine coverDo not grease the top of the driveshaftThis may excessively preload the driveshaft and crankshaft when the mounting bolts are tightened and cause premature failure of the power head or gearcaseTo install: 14Lightly lubricate the driveshaft splines with waterproof marine grease or equivalent15Apply thin but uniform coat of silicone sealer to the gearcase and driveshaft housing mating surfaces16Make sure the locating dowels are in place17Position the gearcase under the driveshaft housing18Align the driveshaft splines with the crankshaft, insert the water tube into the water pump case and the water pump seal tube19Guide the clutch rod into the clutch rod connectorDT75, DT85, DT115, DT140, V4 and V6 models
1Remove the engine cover2Disconnect the spark plug leads to prevent accidental starting of the engine during lower unit removal3Place container under the gearcaseRemove the vent and drain plugs4Drain the lubricant from the unitIf the lubricant is creamy in color or metallic particles are found, the gearcase must be completely disassembled to determine and correct the cause of the problem 5Wipe small amount of lubricant on finger and rub the finger and thumb togetherCheck for the presence of metallic particles in the lubricantNote the color of the lubricantA white or creamy color indicates water in the lubricantCheck the drain container for signs of water separation from the lubricant6Remove the propeller7Place the outboard in NEUTRAL and remove the cover at the front of the clutch rod8Use needlenose pliers and remove the clutch rod connector cotter pinDiscard the cotter pin9Remove the connector pin10On V6 models, remove the trim tab bolt access cap on the top surface of the driveshaft housingRemove the bolt and lockwasher securing the trim tab and remove the trim tab1I On all other models, remove the bolt and lockwasher securing the trim tab and remove the trim tab12Remove the bolts and lockwashers securing the gearcase to the driveshaft housingDo not rotate the flywheel counterclockwiseThis can damage the water pump impeller 20Seat the gearcase in place, rotating the flywheel clockwise as required until the driveshaft and crankshaft engage21On DT115 and DT140 models, apply thread locking compound to the mounting bolt threads and tighten securely22On all other models, apply silicone sealer to the mounting bolt threads and tighten to specifications23lnstall the trim tab and the bolt and lockwasherTighten the bolt securelyOn V6 models, install the trim cap over the bolt hole in the driveshaft housing24Connect the clutch rod into the clutch rod connector and insert the connector pin through both parts25lnstall new cotter pinBend the ends over completely26lnstall the clutch rod cover27lnstall the propeller28Reconnect the spark plug leads and refill the gearcase case with proper type and quantity of lubricant29lnstall the engine coverDISASSEMBLY