Suzuki outboard motors 1988 2003 repair manual., Page 311Get this manual
LOWER UNIT 8-43 [I Push
rod Rear end of gear
' 05008G2E
Step If this tooth bearing position is not correct, the pinion gear tooth may be chippedThis problem must be correctedStep 1
PINION GEAR TO FORWARD GEAR THRUST PLAY Obtain the following special tools to perform the measurement: Gear adjusting set (09951-09510) 1Fit the propeller shaft to the forward gear and press the forward gear forward by pushing with the propeller shaft(In this case, first remove the push rod from the propeller shaft) 2Set the special tool up on the driveshaft3Push the driveshaft downHold this position and place the gauge with its rod pushed in approximately mm4Still keeping this position, zero the dial gaugeThen pull up on the driveshaft and read the maximum play on the gaugeIf the amount of backlash is larger than specified, increase the thickness of each of the pinion gear back-up shim(s) or forward gear back-up shim(s)If smaller, decrease the thickness of each shim5When the pinion and forward gear back-up shim are determined to be the correct size, note the amount of thrust play measuredThe thrust play measuremerit will be necessary for the adjustment of the reverse gearREVERSE GEAR THRUST PLAY ADJUSTMENT 1Perform the same procedure as above with the exception of installing the propeller shaft and propeller shaft bearing housing into the gearcase2If the measurement of the play is equal to the pinion gear to forward gear measurement, the condition is correctIf the amount of play is smaller, decrease the thickness of the reverse gear back-up shimPROPELLER SHAFT THRUST PLAY ADJUSTMENT Install the dial gauge adaptor plate and dial gauge with the long rod on the propeller shaft Push the propeller shaft inward Hold the shaft In this position and preload the dial gauge mm Now zero the gauge Pull the driveshaft slowly out and read the amount of play on the gauge Maximum propeller shaft thrust play is 002-0 012 in (0 05-0 mm) If the amount of thrust play is larger than specified, increase the thickness of the reverse gear thrust washer If smaller decrease the thickness of the thrust washer ADJUSTING THE CLUTCH ON GEARCASE SIDE See accompanying illustrations05008G3E