Suzuki outboard motors 1988 2003 repair manual., Page 295Get this manual
LOWER UNIT 8-27 If the amount of backlash is larger than 0.0039-0.0079 in(0.1-0.2 mm), increase the thickness of each of the pinion gear back-up shim(s)If the backlash is smaller, decrease the thickness of each shimTop side toe cotact
In setting the dial gauge, set the gauge rod end to contact the convex side of the forward gear tooth heel endUse care to not have the rod contact on the neighboring toothCHECKING AND ADJUSTING TOOTH CONTACT (FORWARDPINION GEARS)
See accompanying illustrations
Check tooth contact pattern using the following procedure1Too correctly assess tooth contact, smear light coating of Prussian Blue compound on the convex surface of the forward gear2Install the propeller shaft and bearing housing assembly (minus the reverse gear and internal components)3Push the propeller shaft inward and hold it in that positionRotate the driveshaft clockwise 5-6 times by hand4Then pull out the propeller shaft and bearing housing and then check the gear tooth contact patternHEEL
5This is the ootimum tooth contactDoina shim adjustment mav be necessary to obtain this contact pattern6An example of incorrect top side toe contactTo correct this condition, decrease the forward gear shim thickness and slightly increase the pinion gear shim thickness Do not set the tooth contact in this position (top side toe contact)Damage and chipping of the pinion and forward gear may result7An example of incorrect bottom side toe contactTo correct this condition, increase the forward gear shim thickness and slightly decrease the pinion gear shim thickness05008G75