Suzuki outboard motors 1988 2003 repair manual., Page 277Get this manual
LOWER UNIT 8-9 12Apply waterproof marine grease to the propeller shaft and then fit the propeller onto the greased shaft13After installing the gearcase, fill with the correct amount of SAE 90 hypoid gear oil: 1.35 oz(40cc)14Check gearcase lubricant level after engine has been runChange the lubricant after 10 hours of operation (break-in period)movement exceeds this specification, remove the snap ring and exchange the shim(s) as required to bring the clearance within specificationsShim stock is available in three sizes: 0.004 in(0.lmrn); 0.008 in(0.2mm); 0.020 in(0.5mm)2Once the driveshaft bearing shimming is correct, install new oil seal and driveshaft bushingCoat the seal lips with waterproof marine grease3Install the propeller shaft shims and propeller shaft back into the gearcaseDISASSEMBLY
Secure the gearcase in holding fixture or vise with protective jawsIf protective jaws are not available, Place the skeg between two wooden blocks in vise2Remove the bearing housing boltsRemove the bearing housing and propeller shaft assembly Insert screwdriver into the propeller shaft bearing housing at the section marked with an "0"Gently pry with the screwdriver to separate the housing section3Remove the propeller shaft from the bearing housing4Remove the water pump5, After removing the bolt, detach the shift rod guide stopper6Pull out the shift rod assembly from the gearcase7Use screwdriver to carefully pry loose the driveshaft bearing housing along with the driveshaft8, Reach into the propeller shaft bore and remove the pinion gear and the pinion thrust washers 9Remove the forward gear and its shims and thrust washer10Remove the bolt on the side of the gearcase, then remove the water filter11Remove the reverse gear and bearing housing from the propeller shaft assembly12, Use screwdriver to remove the clutch dog spring from around the clutch dog shifter13Using small drift, drive the pin out of the clutch dog shifter14Slide the clutch dog off the propeller shaft15, Remove the push pin and return spring from the end of the propeller shaft