Suzuki outboard motors 1988 2003 repair manual., Page 247Get this manual
POWERHEAD 7-35 TCCS3041
TCCS3042
Fig19 Drill out the damaged threads with the specified size bitBe sure to drill completely through the hole or to the bottom of blind hole
Fig20 Using the kit, tap the hole to receive the thread insertKeep the tap well oiled and back out frequently to avoid clogging the threadsFig21 Screw the insert onto the installer tool until the tang engages the slotThread the insert into the hole until is -12 turn below the top surface, then remove the tool and break of the tang using punch
To properly rebuild powerhead, you must first remove it from the outboard, then disassemble and inspect itIdeally you should place your powerhead on standThis affords you the best access to the componentsFollow the rnanufacturer's directions for usina the stand with vour oarticular oowerheadNow that you have thepowerhead on astand, it's time'to strip it of all but the necessary components Before you start disassembling the powerhead, you may want to take moment to draw some pictures, fabricate some labels or aet some containers to mark and hold the various components and the bolts andor studs which fasten themModern day powerheads use lot of little brackets and clips which hold wiring harnesses and such and these holders are often mounted on studs andor bolts that can be easily mixed upThe manufacturer spent lot of time and money designing your outboard and they wouldn't have wasted any of it by haphazardly placing brackets, clips or fastenersIf it's present when you disassemble it, put it back when you assemble it, you will regret not remember-