Suzuki outboard motors 1988 2003 repair manual., Page 224Get this manual
7-12 POWERHEAD 15Remove both under covers 16Remove the bolts holding the powerhead to the driveshaft housing17Remove the powerhead
If the powerhead will not come off, rotate the propeller to free the powerhead from the driveshaft05007P51
18Remove and discard the powerhead mounting gasketTo install: 19Clean the powerhead mounting and driveshaft housing gasket surfaces thoroughly20Lightly coat the driveshaft splines with marine grease21Install new powerhead new mounting gasket22Install the powerhead, rotating the propeller as required to align driveshaft and crankshaft splines23Coat powerhead mounting bolt threads with silicone sealer24Install the powerhead mounting bolts and tighten to specification25Install both under covers and tighten the bolts securely26Connect the water outlet hose to the engine lower cover27Install the clutch link on the throttle control arm and the clutch shaft side arm28Connect the fuel hose29Install the flywheel30Connect the electrical leads to the starter motor and relay31Install the CDI unit32Install the electrical parts holder cover33Connect all electrical connectors in the electrical parts holder34Install the power trim and tilt relays35Install the power trim and tilt motor relay cover36Install the oil tank37Connect the oil hose38Connect the electrical leads to the oil level switch39Connect the negative battery cable, then the positive battery cable40Start the engine and make adjustments as necessary41Check engine for proper operation42Install the engine cover DT75 and DT85