Lower Unit Gears-Shimming And Adjustment - Suzuki DF 90 Service Manual

LOWER UNIT GEARS-SHIMMING AND ADJUSTMENT

If lower unit has been rebuilt or has had components replaced, shimming for correct gear contact and back-
lash will have to be adjusted to ensure smooth, reliable operation of gears.
Shim/Washer & Mounting position
Numerical
index/item
Pinion gear
1
back up shim
Forward gear
2
back up shim
Forward gear
3
thrust washer
Reverse gear
4
thrust washer
Reverse gear
5
back up shim
PINION GEAR BACK-UP SHIM ADJUSTMENT
(1) Position the shimming gauge A horizontally in a vise and
tighten vise securely.
09951-09010: Shimming gauge
(2) Assemble the bearing outer race 1, back-up shim 2 and
driveshaft oil seal housing 3 to the driveshaft.
NOTE:
Use a thinner pinion back-up shim 2 than the standard shim
so that a clearance B exists.
(3) Insert the driveshaft through the shimming gauge A open-
ing and then install pinion gear 4 and nut 5 to the driveshaft,
tighten pinion nut.
Pinion nut: 120 N . m (12.0 kg-m, 87.0 lb-ft)
(4) Install oil seal housing to shimming gauge with bolts 6.
(5) Depress and hold driveshaft so that driveshaft bearing is
firmly seated in bearing outer race.
Available
thickness
(mm)
0.60, 0.65, 0.70, 0.75, 0.80,
0.85, 0.90, 0.95, 1.00, 1.05,
1.10, 1.15
0.60, 0.65, 0.70, 0.75, 0.80,
0.85, 0.90, 0.95, 1.00
9.0
1.5, 1.7, 1.9, 2.1, 2.3, 2.4,
2.6, 2.7, 2.8
1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6
DF140 "K2" ('02) MODEL
Design
specification
Thickness
(mm)
1.0
1.1
9.0
1.5
1.5
(Normal rotation model)
11-61