Suzuki outboard motors 1988 2003 repair manual., Page 217Get this manual
POWERHEAD 7-5 12Connect the battery negative battery cable13Install the engine cover DT115, OT140 and V4
IRemove the engine cover2, Remove the electrical junction box cover and disconnect the stator leads3Remove the flywheel cover4Using flywheel holder (09930-487201, remove the flywheel nut5Using flywheel holder, flywheel remover (09930-39411) and flywheel bolts (09930-39420), remove the flywheel6Remove the flywheel from the crankshaft To install: 7Throughly clean the mating surface of the flywheel and crankshaft taper with cleaning solventlnstall the key onto the crankshaft securely8lnstall the flywheel onto the crankshaft9Using flywheel holder, tighten the flywheel nut to 181-188 ftlbs(250-260 Nm)10Connect the stator wire leads to their proper connections11, Connect the battery negative battery cable12lnstall the engine coverremoved with the outboard still mounted on the boat and the powerhead is equipped with an electric starter, disconnect first the negative, then the positive battery cables to prevent accidental startingOn some powerheads it will be necessary to remove attached components if the powerhead is to be overhauledRefer to the specific sections covering these components for removal and installation information DT2 and DT2.2
See accompanying illustrations
I23456Remove the engine coversTurn the fuel shutoff to the OFF DositionDisconnect and the fuel line a Remove the fuel tankRemove the rewind starter assemblyRemove the starter cup and flywheel insulatorUsing flywheel holder loosen and remove the flywheel nut7Remove the flywheel using flywheel pullerRemove the engine cover2Remove the electrical junction box cover and disconnect the stator leads3Remove the flywheel cover, 4Using flywheel holder (09930-48720), remove the flywheel nut5Using aflywheel holder, flywheel remover (09930-39411) and flywheel bolts (09930-39420) remove the flywheel To install: 6Throughly clean the mating surface of the flywheel and crankshaft taper with cleaning solventlnstall the key onto the crankshaft securely7Install the flywheel onto the crankshaft8Using flywheel holder, tighten the flywheel nut to 181-188 filbs(250-260 Nm)9Connect the stator wire leads to their proper connections10Connect the battery negative battery cable11Install the engine coverINSPECTION