Suzuki outboard motors 1988 2003 repair manual., Page 312Get this manual
8-44 LOWER UNIT DISASSEMBLY
1Remove the gearcase2Secure the gearcase in suitable holding fixture or vise with protective jawsIf protective jaws are not available, position the gearcase upright with the gearcase skeg held between wooden blocks in vise3Remove the water pump4Remove the bolts holding the bearing housing5Install the bearing housing remover (09930-39411) and special bolts (09930-39430)6Remove the propeller shaftlbearing housing assembly7Remove the driveshaft bearing housing fasteners8Pry the driveshaft bearing housing free and slide it up and off of the driveshaft9Carefully remove the driveshaft thrust bearing and shim from the bearing housing10Attach driveshaft holder tool (09921-29410) to the top of the driveshaft11Fit an appropriate size box-end wrench over the pinion nut and pad the sides of the gearcase prop shaft bore to prevent the wrench from damaging or distorting the gearcase prop shaft bore12Holding pinion nut with the wrench, turn the driveshaft counterclockwise to loosen the pinion nut13Remove the toolsRemove the pinion nut and oinion dear14Remove the forward gear, thrust washer and shim@)15Remove the driveshaft, preload spring and thrust bearing as an assembly16Remove the driveshaft spring collar from the gearcase bore17Remove the driveshaft thrust washers from the aearcase bore18Remove the clutch rod and shift rod guide housing from the gearcase 19Slide all components except the clutch dog from the propeller shaft20Disassemble the prooeller shaft clutch assembly21Clean and inspect all parts22If the inspection of the forward gear bearing indicates replacement is necessary, perform the following procedure: Install bearing housing remover (09930-39411) using the long bolts from tool (09930-39430)Remove forward gear bearing housing with slide hammer (09930-301 02)Use an appropriate installer to install new bearing 23Remove and discard the propeller shaft bearing housing oil seals and bearing24Install new propeller shaft housing bearing with an appropriate installer25Install new propeller shaft housing oil seals and new housing O-ringCoat the seal lips and O-ring with an appropriate waterproof marine grease26Remove and discard the driveshaft bearing housing oil sealInstall new seal with an appropriate installerCoat seal lips with waterproof marine greaseCLEANINGINSPECTION