Suzuki outboard motors 1988 2003 repair manual., Page 233Get this manual
POWERHEAD 7-21 DT9.9 and DT15
See accompanying illustrations
1Loosen the inlet case bolts in several stages using criss-cross pattern2Remove the inlet case (I), inner piece (2)and reed valve assembly (3)3Remove the exhaust plate and gasket from the cylinder4Remove the exhaust cover attaching bolts5Insert pry bar between the exhaust cover and cylinder block and pry the cover to remove itDiscard the exhaust cover gasket6Remove the exhaust plate and discard the gasket7Loosen the cylinder head bolts in several stages using criss-cross pattern
8Remove the cylinder headIf the cylinder head is hard to remove, use plastic hammer to drive the dead at the placed indicated in the illustration9Loosen the crankcase bolts in several stages using criss-cross pattern, Then remove the crankcase10Remove the rotating assembly by carefully lifting the crankshaft from the cylinder block11Carefully pry the piston pin retainer from its groove on the pistonThen repeat the procedure for the other side The circlip will tend to fly when removedBe ready to catching it as it comes free12Piston pin retainers are only good for one usage, discard the retainers after removing them13Push the piston pin from it bore in the piston using brass drift if necessary The piston pin should slide smoothly from its boreIf opposition is felt, either the bore is out of round or the pin is bentInspect the components and replace as necessary14Remove the piston from the connecting rodTo assemble: 15Install the piston on the connecting rodMake sure the arrow on the pistons point to the exhaust port side16Push the piston pin into the piston bore using brass drift if necesary17Install new piston pin retainers18Lubricate the seals with marine grease prior to installation19Install the top and bottom crankshaft oil seals with the numbers facing the ends of the crankshaft20Lubricate the rotating assembly with 2-stroke oil prior to installation21Install the rotating assembly into the cylinder block, making sure the crankshaft faces the correct wayThe splined end of the crankshaft should face driveshaft housing sideStep 2