Suzuki outboard motors 1988 2003 repair manual., Page 313Get this manual
LOWER UNIT 8-45Fig41 Check the magnet for sign of debris in the gear oilAll bearings for wear and damage Propeller shaft and driveshaft for wear at oil seal contact points All gear teeth for damage or wear Dogs on clutch dog shifter for wear and damage Dogs on the forward and reverse gears for damage and wear Shifting cam and pushrod for wear Check the magnet for sign of debris in the gear oil Perform gearcase pressure test to check the sealsUse the oil leakage tester (09950-69511) and air pump assembly (09821-00004) and pressurize 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 wear Propeller for nicks, bent blades or other damage and wear Cooling circuit for clogging or other obstructions Gearcase for rusting, pitting and distortionASSEMBLY + See Figure 42
1Install new propeller shaft housing bearing with an appropriate installer2Install new propeller shaft housing oil seals and new housing O-ringCoat seal lips and O-ring with waterproof marine grease3Remove and discard the driveshaft bearing housing oil sealInstall new seal with an appropriate installerCoat seal lips with waterproof marine grease4Assemble the propeller shaft components according to the illustrations5Lubricate all parts with Suzuki Outboard Motor Gear Oil6Install the clutch rod and shift rod guide into the gearcase7Before inserting the shift rod guide housing assembly, check to be sure that the cam portion is facing toward the propeller shaft8Make sure that the dowel pins are in positionTighten the bolts securely and make sure the unit shifts smoothly9Install the two-driveshaft thrust washers into the gearcase bore10Install the driveshaft spring collar into the gearcase bore11Install the driveshaft, preload spring and thrust bearing as an assembly12Install the shift rod assembly13Install the shim, thrust washer and thrust bearing on the forward gear in that orderInstall the forward gear assembly into the gearcase When installing the forward gear bearing housing, align the groove in the gearcase with the pin on the housingFig42 Install the clutch rod and shift rod guide into the gearcase