Suzuki 3.5 HP outboard question.

[Binman]

I acquired same today, what position should the gear lever be in before undoing the gear shift shaft?
Also the engine requires a new petrol cap, as the bleed valve has snapped off, I have found loads for the 2.5 HP but not one for a 3.5 HP. Looked on Ebay, I will be getting a manual shortly, as I have for all my engines, unable to find a free download though, which is surprising considering the age of the engine 1982. I'm a avid searcher on the net. Got the number for my local dealer. Saw the engine running no problems water spitting out the leg, most of the cooling water is discharged below the water line where the exhaust is, Got this engine for two fold problem, my Pandora is on a mooring and my main engine is to heavy to get out and on my boat by dingy, I'm going to use this new engine to get my boat back to the yard for haul out, got about 500 yards to travel, then use this engine on my 9ft Grp dingy tender.i will have an existing 2hp Yamaha to sell, found this not up to it, depending on tides and wind.

 

[VicS]

I acquired same today, what position should the gear lever be in before undoing the gear shift shaft?
Also the engine requires a new petrol cap, as the bleed valve has snapped off, I have found loads for the 2.5 HP but not one for a 3.5 HP. Looked on Ebay, I will be getting a manual shortly, as I have for all my engines, unable to find a free download though, which is surprising considering the age of the engine 1982. I'm a avid searcher on the net. Got the number for my local dealer. Saw the engine running no problems water spitting out the leg, most of the cooling water is discharged below the water line where the exhaust is, Got this engine for two fold problem, my Pandora is on a mooring and my main engine is to heavy to get out and on my boat by dingy, I'm going to use this new engine to get my boat back to the yard for haul out, got about 500 yards to travel, then use this engine on my 9ft Grp dingy tender.i will have an existing 2hp Yamaha to sell, found this not up to it, depending on tides and wind.

The cap is the same part number as for DT2 models but there is some variation in the part numbers over the years. I cannot say if the caps from other years will fit or not.

The 2.5 is a much later 4 stroke ( DF2.5 ) and the caps are different.

Looking at the diagrams I think I would put the clutch into the engaged position , but you may simply have to put it in the position that gives you access to the clamp bolt.

I think I would undo and completely remove the top clamp bolt as that engages with a groove in the end of the upper clutch rod. If you disturb the lower one you should mark the position of the clamp or you will have to adjust the operation of the clutch on reassembly.
However if you have a manual on the way the correct procedure should be explained in that.

 

[Binman]

Thank you for that, as for the fuel cap, might have to buy fuel tank with cap, so still looking.