Suzuki outboard motors 1988 2003 repair manual., Page 239Get this manual
POWERHEAD 7-27 5Remove the reed valve assembly6Remove the exhaust cover attaching bolts7Insert pry bar between the exhaust cover and cylinder block and pry the cover to remove itDiscard the exhaust cover gasket8Remove the lower oil seal housing attaching bolts9lnserl pry bar between the oil seal housing and cylinder block and pry the cover to remove itDiscard the oil seal housing gasket10Loosen the cylinder head bolts in several stages using criss-cross pattern11Insert pry bar between the cylinder head and cylinder block and pry the head to remove itDiscard the cylinder head gasket12Loosen the cylinder head cover bolts13Insert pry bar between the cylinder head cover and the cylinder headPry the head cover to remove it14Loosen the crankcase bolts15Insert pry bar between crankcase and the cylinder blockPry the crankcase to remove it16Remove the rotating assembly by carefully lifting the crankshaft from the cylinder block17Carefully 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 free1
05007GlW
Fiu7 Crankcase bolt tiahtenina seuuence-1988-92
DT55 and DT65
18 Piston pin retaners only good for one usage, dscardthe retaners are after removing them 19 Push the piston pin from tbore In the plston using brass drft necf essary
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 necessary20, Remove the piston from the connecting rod,