Suzuki outboard motors 1988 2003 repair manual., Page 218Get this manual
7-6 OIL INJECTION DT4 and DTSY 1Remove the engine cover2Remove the fuel tank3Remove the hand rewind starter4Using flywheel holder loosen and remove the flywheel nut5Remove the flywheel using the flywheel puller6Label and disconnect the stator and CDI unit electrical leads7Remove the ignition coil and CDI unit8Disconnect the throttle cable from the carburetor9Loosen the hose clamp, disconnect and plug the fuel hose10Remove the silencer11Remove the carburetor12Remove the fuel pump13Remove the powerhead mounting bolts14Remove the powerhead If the powerhead will not come off, rotate the propeller to free the powerhead from the driveshaftStep 12
891011121314Disconnect the spark plug leadLabel and disconnect the stator lead wiresRemove the choke knob Remove the throttle link knob and the control panelRemove the carburetor and fuel shut-off valveRemove the bolts holding the powerhead to the driveshaft housing, Remove the powerhead15Remove and discard the powerhead mounting gasketTo install: 16Clean the powerhead mounting and driveshaft housing gasket surfaces thoroughly17Lightly coat the driveshaft splines with marine grease18Install new powerhead new mounting gasket19Install the powerhead, rotating the propeller as required to align driveshaft and crankshaft splines20Coat powerhead mounting bolt threads with silicone sealer21Install the powerhead mounting bolts and tighten to specification22Install the fuel pump23Install the carburetor24Install the silencer25Connect the throttle cable top the carburetor and adjust it to specification26Install the ignition coil and CDI unit27Connect the stator and CDI unit electrical leads28Install the flywheelTighten the flywheel nut to specification29Install the hand rewind starter30Install the fuel tank31Unplug and connect the fuel hoseUsing new hose clamp, fasten the hose properly32Start the engine and make adjustments as necessary33Check engine for proper operation34Install the engine coverDT6 and DT8