Suzuki outboard motors 1988 2003 repair manual., Page 299Get this manual
LOWER UNIT 8-31 the gearcase to 14.22 psi (1.0 kglcm)With the gearcase pressurized, spray soapy water onto the seals and check for escaping air bubblesO-rings and oil seals for cracks, tears and wearPropeller for nicks, bent blades or other damage and wear Cooling circuit for clogging or other obstructions Gearcase for rusting, pitting and distortion, on the preload springFit the washer into the collar, making the tab on the washer show out of the slip provided in the top end of the collar, and then put on the collarAfter this, insert the thrust washer at the near side10After putting on the preload spring collar, push down the collar all the way to compress the preload spring inside, and then install the circlip to retain the collar11When installing the driveshaft bearing housing, apply silicone sealant to the gearcase mating surface 12Apply water proof marine grease to the gearcase O-ring, shift rod guide O-ring and inside the shift rod bootASSEMBLY
See accompanying illustrations
1Replace the bearings and seals in the propeller bearing housing2When replacing the oil seal, make sure to position the lip and spring to the outside and apply waterproof marine grease to the seal lip and install the retaining ring into the groove3The clutch dog shifter is marked for easy assemblyThe end with the letters "REV is meant to face the Reverse gearBe sure to mount the shifter correctly on the propeller shaft4Install the clutch return springpush pin and push rod into the propeller shaft5Bring the push pin to the slot, making the hole of the push pin visible in the slot, 6Slide the clutch dog shifter over the slot, aligning the pin hole to the hole in the push pin and drive the spring pin into the dog shifter7Install the clutch dog spring into the groove on the dog shifter so that the spring pin does not come out After connecting the dog shifter to the push pin, check to be sure that the spring pin is all the way in, with its driven end flush with the surface of the shifter8After sliding the spring onto the shaft, make sure the end of the spring fits into the notch provided in the inner race of the drive shaft bearing9Be careful not to miss the driveshaft lock washer when putting the collar