Suzuki outboard motors 1988 2003 repair manual., Page 279Get this manual
LOWERUNIT 8-11 14Check propeller shaft thrust clearance15When proper propeller shaft thrust clearance has been established, coat the bearing housing bolt threads with silicone sealerInstall housing (use installer 09914-79610) and tighten bolts to specifications16Install the gearcaseFill with recommended type and quantity of lubricant17Check gearcase lubricant level after engine has been runChange the lubricant after 10 hours of operation (break-in period)3This shows top side toe contactIn this case, decrease the forward gear shim thickness and increase the pinion gear shim thickness The top side toe contact will result in chipped forward gear tooth or damage to tooth bottom of the pinion gearAvoid this gear tooth bearing positionSHIMMING PROCEDURE
Measurement Of Thrust Play
Top side toe contact
1Using dial indicator and stand, push the propeller shaft inward towards the gearcaseKeep the shaft in this position and set the dial indicator on the shaft with the indicator rod depressed 0.78 in(2 mm)2Keeping the shaft pushed in, zero the dial indicator gauge, then pull the propeller shaft outwards until the dial indicator reads its maximum: 0.0039-0.0079 in(0.1-0.2 mm)3To measure the thrust play on the drive shaft, set up the dial indicator on the drive shaftAgain, press in the shaft and zero the dial indicator and then pull out and read the dial indicator for the maximum thrust play: 0.008-0.016 in(0.2-0.4 mm) Pinon And Forward Gear Tooth Contact Pattern Adjustment
See accompanying illustrations05008G50
4If the tooth contact pattern is as shown, the bottom side toe contact is producedIn this case, increase the forward gear shim thickness and decrease the pinion gear thickness and check the tooth contact pattern If this gear tooth bearing position is not correct, the pinion gear tooth may be chipped, this condition must be correctedCoat the entire surface of the forward gear lightly with Prussian Blue or equivalent, and install the propeller shaft and all related parts into the gearcaseIt is unnecessary to install the propeller shaft housingWhile pushing the propeller shaft in, hold it firmly by hand so it does not turnSlowly rotate the drive shaft about turns, and remove the forward gear from the gearcaseCheck the Prussian Blue for proper the gear tooth contact pattern1The forward gear runs with localized tooth contact, and from this it can be determined whether the tooth bearing position is correct or not2This is the correct gear tooth bearing positionIt is advisable to obtain this tooth contact pattern by means of shim adjustments'