Suzuki outboard motors 1988 2003 repair manual., Page 285Get this manual
LOWERUNIT 8-17 13Coat bearing housing outer edges (front and rear) with waterproof marine grease14Carefully install bearing housing on propeller shaft15Check propeller shaft thrust clearance16When proper propeller shaft end playlthrust clearance has been established, coat the bearing housing bolt threads with silicone sealer17Use the special tool (09922-59510) to install housing and tighten bolts to 4.5-7.0 ftIbs(6-10 Nm)18Install the water pump19Install the gearcaseIn assembling the gearcase assembly and extension case to the driveshaft housing, apply silicone sealant to both joining faces and assemble after aligning the dowel pinsTighten the bolts to 11.0-14.5 ftIbs(15-20 Nm)20Fill with recommended type and quantity of lubricant21Check gearcase lubricant level after engine has been runChange the lubricant after 10 hours of operation (break-in period)SHIMMING PROCEDURE
Transmission Gear Adjustment
THRUST WASHERSHIM MOUNTING POSITION
ISee Figures 14 and 15
If the lower unit has been rebuilt or any of the components have been replaced, then shimming for correct gear contact and backlash will need to be performedInitial selection-shim adjustment may be requiredStep 2
3Fit the forward aear shim(s) over the shaft at the rear of the near and install gearlshim assembly into the prop shaft bore4Insert the shift rod assembly into the gearcase bore and install the collar nut5Insert the pinion gear into the prop shaft boreFit the gear into the driveshaft bore and mesh it with the forward gear6Reassemble the bearina, shims and thrust washer to the driveshaft in the same order as noted during removal Insert the driveshaft into the gearcase housing with rotating motion and engage the pinion gear Install new driveshaft bearing snap ring Make sure the snap ring fits properly into its groove Install rubber exhaust seal 10 Check pinion gear depth and forward gear backlash 11 Install new bearing housing 0-rlng Lubricate housing O-ring with wateroroof marine arease 12Insert propeller shaft into housing bore and engage the forward gearFig14 Thrust washer and shim mounting positions