Suzuki outboard motors 1988 2003 repair manual., Page 227Get this manual
POWERHEAD 7-15 525354555657 Connect the starter relay to the relay holderInstall the starter cable to the starterInstall the relay cover under the starterStart the engine and make adjustments as necessaryCheck engine for proper operationInstall the engine coverRemove the engine cover2Disconnect the negative, then the positive battery cables 3Remove the cover from the electrical parts holder4Disconnect the battery cable and the power trim and tilt motor electrical leads from the powerhead5Disconnect and plug the fuel hose6Remove the cover from the electrical parts holder 7Disconnect all electrical leads inside the electrical parts holder, then remove the electrical parts holder8Remove the bolts holding the powerhead to the driveshaft housing9Remove the lower front under cover10Remove the lower rear under cover11Disconnect the water outlet hose12Remove the bolts holding the powerhead to the driveshaft housing13Remove the upper to lower clutch rod clevis pin14Attach hoist to the engine hooks and lift the powerhead slightly¥Ithe powerhead will not come off, rotate the propeller to free the powerhead from the driveshaftDisconnect the clutch lever rod connector from the clutch shaftDisconnect the upper clutch rod from the clutch shaftRemove the powerhead using hoistRemove and discard the powerhead mounting gasketRemove the aligning dowel pins from the bottom of the powerheadTo install: 20Clean the powerhead mounting and driveshaft housing gasket surfaces thoroughly21Lightly coat the driveshaft splines with marine grease22Install new powerhead new mounting gasket23Install the powerhead, rotating the propeller as required to align driveshaft and crankshaft splines24Install the upper to lower clutch rod clevis pin25Coat powerhead mounting bolt threads with silicone sealer26Install the powerhead mounting bolts and tighten to specification27Connect the water outlet hose28Install the lower rear under cover29Install the lower front under cover30Install the electrical parts holder, then connect all electrical leads inside the electrical parts holder31Install the cover on the electrical parts holder 32Connect the fuel hose33Connect the battery cable and the power trim and tilt motor electrical leads to the powerhead34Connect the positive, then the negative battery cables35Start the engine and make adjustments as necessary36Check engine for proper operation37Install the engine cover