Suzuki outboard motors 1988 2003 repair manual., Page 282Get this manual
8-14 LOWER UNIT 13Insert propeller shaft into housing bore and engage the forward gear14Coat bearing housing outer edges (front and rear) with waterproof marine grease15Carefully install bearing housing on propeller shaft16Check propeller shaft thrust clearance17When proper propeller shaft thrust clearance has been established, coat the bearing housing bolt threads with Silicone sealerInstall housing and tighten bolts securely18Install the gearcaseFill with recommended type and quantity of lubricant19Check gearcase lubricant level after engine has been runChange the lubricant after 10 hours of operation (break-in period)@ (P)@
Forward gear Clutch dog shifter Propeller shaft Reverse gear
SHIMMING PROCEDURE
Adjust the forward gear in such way that the tooth contact pattern produced by rolling this gear against the pinion gear will extend from the center of the tooth toward the toeThis is accomplished by increasing or decreasing the shim thicknessBe sure to produce the specified amount of backlash between the pinion gear and forward gearTo measure the backlash, hold the pinion steady with your hand and move the forward gear back and forthCheck the backlash at the heelBacklash should measure 0.0039-0.0079 in(0.1-0.2 mm)Be sure that there is no backlash between the reverse gear and the pinion gear, although small amount of backlash is permittedTo eliminate the backlash, if any, increase the thickness of the shim behind the reverse gearBy means of the shim on the inner side of the forward gear and reverse gear, adjust the thrust play of the propeller shaft to this specification: 0.002-0.020 in(0.05-0.50 mm)Fig7 DT6 and DT8 transmission assembly
DISSASSEMBLY