Suzuki 2.5hp Carburetor strip and idle fix

[@jeffbarnes5979]

I just finished rebuilding the carb and servicing mine. This video really helped. I did find a couple of tricks. 1) Make sure to clean the 4 small air jets in the venturi. They cause most of the problems Also make sure to clean the main jet. The easiest way is to buy an assortment of copper jewelry wire. I used 18-28 gauge. THe 28 gauge will fit way down in the small idle jets where a pick only gets to the surface of the holes. You can also use the coarser wire for the main jets. 2) If your tearing the carb down, make sure to soak it in carb cleaner. 3) Use a new bowl gasket and intake gasket. They are cheap from Suzuki. Just finished mine up, and it runs like new. THanks for the video.

[@dp47280]

Thanks for the comments. They are always useful to hear and help.

[@pierrevanderdeure8164]

Your vids are precious. I was given a 2008 2.5 engine by a friend which requires care, and maintenance does not give me any worries anymore.

[@dp47280]

Thank you- good luck with it all!

[@nonnonnoo1898]

Helllo and thanks for the video❤ I had same problem as you. My problem was located to clogged pilot jet(idle jet). Jet is located inside carb and its covered with flathead screw. I had to remove jet and clean it with thin metal wire. Hope this comment helps someone with same issue.

[@dwightmarshallphoto]

It’s always the idle jet. It’s under a screw under the top plate. The hole is smaller than a pin, so you have to soak it in carb cleaner and try and clear out that hole. You can barely see light through it when it’s clean. Once you get that clean it runs

[@briangilliland3620]

Your video in repsect to the water pump etc was one of the best "how to" I've ever benefited from - it worked well for me. This one with that horribly repetitive "music" crowding out your dialogue is pretty well useless. I can barely discern what you are saying. I know it's supposed to smoothly provide continuity but clarity is one hell of a lot more important in a video such as this. SO far these are the only two that I have (tried?) to watch so I sincerely hope that this is the only one with that noise. Incidentally, I love my Suzie 2.5 --

[@dp47280]

Thanks for the feedback- I’ll take it on board.

[@briangilliland3620]

Again I thank you for the tech content and presentation. It helped me a lot. Just some input here. My motor worked like a gem after winter on test, I topped up the fuel with petrol from a mate's jerry can, then took it in the back of the car down to the boat and away we went - uh oh. Stalled after several minutes running. Many tries and the best it would do is run occasionally with choke out. Next morning gave it another try. 10 minutes down the harbour she stopped and would only go intermittently and short periods. On draining the carb - lots of fuel but when bowl emptied I turned on the tap turned and the fuel barely ran out. I removed and inspected the tank - a load of very fine black sand in the bottom. On removing the tap assembly from the tank I found a very fine filter - blinded. Cleaned filter and tank and she runs like a dream. Lesson here, don't borrow fuel from a mate Maybe that's why his 140hp outboard is running at low power, he thinks that it's down one cylinder and is looking at a replacement I reckon he should check his carbs first. Anyway - thanks again for your wisdom

[@dp47280]

I’ll drain my tank and have a look at that then. Thanks for the advice. Could be the same problem.

[@JohnRosendaal]

I got the same issues with my 6hp , greet info.

[@jamesanyname4077]

That screw you took out to get to the main jet? That actually is the main jet. Comes in 3 sizes (62, 64, 66, dependent on year of engine), what's above that is called the main nozzle. Both need cleaning. If the main jet is blocked, not enough fuel is getting past to the nozzle. Clean/replace the main and you will be running without choke 😊

[@terrypenton-ford630]

Excellent video, and well presented information. One request. Please no music!!

[@dp47280]

Your not the first to have said that and if it could be removed I would.

[@garyhenneberry72]

no problem, small frost plug at the rear of the carb. has your idle mixer screw under it. remove frost plug screw out the screw, clean with cleaner, and re-adjust

[@dp47280]

That would probably have helped. I used an ultrasonic cleaner in the end and that did the trick. Certainly easier to change the mixture and stop it being so finicky. Thanks

[@nhwine]

I have the same engine that had the same idle problem. After FULLY disassembling and thoroughly cleaning the carb including pushing a small wire through the jets, the engine starts first pull and idles perfectly without using the choke at all. I use 91 octane fuel with NO Ethanol. Not sure why you have to have your choke out to idle. The low idle screw might need adjusting.

[@dp47280]

It seems to be working now after the ultrasonic cleaner. I couldn’t get a wire to fully go though the holes in the carb block. All sorted now though.

[@evan2290]

If I'm trying to keep lightweight (putting it on a inflatable....mariner 4) are there any other small outboards you would recommend? I was thinking maybe the Yamaha 2.5 or the yamaha 3hp 2 stroke. they're both around 35 lbs. Any thoughts on those? Would they run into the same issue? Or should I just go with a 55lb thrust electric troller? Thank you in advance for your wisdom. Great video!

[@budawang77]

Useful video. I have the 5hp model and the components are very similar.

[@dp47280]

Thanks for the comment. It’s good to know.

[@letsgobrandon9592]

Love the video do you happen to know how to take apart the crankshaft took mine apart a little spring came out not sure from where

[@bryanpolden1587]

I had the exact scenario mate and the only thing I did that you didn't is clean the screw that you take out to get to the main jet. I couldn't understand, everthing seemed to be backwards ,it would only idol and rev with the choke put. But when I cleaned that screw it all flipped back to normal and now the choke works as it should. My problem and the reason I found your video seems to be the "air jets" and when I knock it in gear it dies or if I come off the throttle to quick it dies. Do you know about where is the factory setting for the fuel mixture screw?

[@dp47280]

i was a little more trial and error. They don't really seem to be made to alter etc.

[@mates.7506]

Great video! Thank you! Just one question, is it necessery to check/change protection anode on the cylinder block?

[@dp47280]

I never have on mine but only when they wear away to around 1\2 gone.... obviously the one on the leg would need changing much sooner.

[@Frank020]

Great. W try to clean my carb. Engine won't start. Always had trouble starting. Susuki made a poor carb.

[@dp47280]

I agree with you. And seemingly I can’t find spares. Very frustrating!

[@Frank020]

I think there's a man on here that bores, or replaces for bigger jets, but I'm not so mechanically inclined yet..

[@youngypaul]

I have this motor and will never buy a little Suzuki outboard again. I am a fan of the brand, but this outboard is a design failure. The jets are WAY too prone to blocking. I guess they designed them too tiny. Even if you take all the precautions and drain the bowl and run the engine out of fuel before storage they will fail after a while. It seems every time I get to the boat to use it, it goes straight back to the workshop. I'm going to sell this Suzuki and get a 2 stoke Yamaha 3 hp. Won't give me a single problem in 40 years. Some forums say you can swap out the original jets for larger jets, but its a hassle I could do without.

[@dp47280]

I agree and I say I’m going to sell it every time. Trouble is it’s so light and easy to take to places.

[@rudihenry5298]

I agree, mine has 10 hours on it, just horrible, it never starts easy, now it doesn’t start at all, clearly a carburator issue. Hate this little engine!

[@davidthomas9154]

Simple fix.my 2.5 suzuki runs flawless. You have to drill out the plug that is covering the idle mixture screw and turn it out 1/2 to 3/4 turn. The plug is on the outside of the carb.

[@dp47280]

David Thomas which way? Anti clockwise or clockwise?

[@davidthomas9154]

@@dp47280 anti(out)

[@dp47280]

I’ll try that then and see what happens

[@TodSackett]

on the side of the carb? and are you drilling out the plastic motor case "plug"?

[@davidthomas9154]

@@TodSackett on the left side of carb there is an aluminum plug above the mounting bolt roughly 1.5" to the left of the brass vent tube. I have a picture of it but not sure how to post it

[@garymarilynross3007]

I found your video helpful but difficult to listen to because of the background music. The music adds nothing, it is your comments and explanations that are so important. My suggestion... ditch the background music.

[@motorikiller3150]

air mix screw how many turns??

[@patrickloughridge2420]

background music ruined it

[@dp47280]

Your not the first to say it. Take it on board for the next videos. Thanks for the feedback.

[@pierauspitz]

Hello! Very informative videos, thanks! Have you tried running your engine on alkylate petrol? There are many brands but Aspen 4T is well known. Easy to find in gardening or forestry supply shops. It is pleasant to use (does not smell very strong), clean burning (good for spark plugs) and does not leave any gunk or varnish behind (nice for the carburettors). Also, as it does not contain ethanol, corrosion and water mixing are less of an issue. And it does not degrade like automotive petrol, giving it excellent shelf life. While it is pretty pricey, it is a good solution for rarely used spare motor or as a good engine flush for winter storage.

[@dp47280]

I haven't tried it. I've always stuck to running the carb bowl dry after use. Maybe worth a try though. Thanks for the suggestion

[@pierauspitz]

@@dp47280 Running the carb dry might be the source of your issue: when evaporating automotive petrol leaves a thin coat of "varnish" behind. Not good for tiny perforations ;)

[@dp47280]

pierauspitz you could be right and something that has crossed my mind. I think the next video coming will be the carb in an ultrasonic cleaner!!! See if that works. Thanks for the input. It’s valuable advice.

[@pierauspitz]

@@dp47280 Looking forward to your next videos! Thanks again for your great content!

[@wladsegler4460]

thank you!

[@dp47280]

You're welcome!

[@dronerdronerdroner1193]

perfekt video

[@dp47280]

Thanks for the feedback. Hope it helped!

[@doctorrobin3040]

You do not tell what the problem was at the start. Very confusung.

[@ZampostOk]

Nice video, and music sounds good! Don’t listen to others! Music doesn’t bother at all! lol

[@dp47280]

Thanks 👍

[@erikdigebohansen4645]

Suzuki df6

[@dp47280]

what about the DF6?

[@iang1429]

In my opinion these Suzuki df 2.5 are garbage mine was brand new and it let me down straight away took it to Suzuki to fix under warranty . Suzuki didn’t want to know they said I’d tampered with the carb unbelievable on engine less than 3 hours run . They then charged me to supposedly fix an alignment problem very vague . Didn’t play up after but this corresponded with weather getting warmer . Here we are exactly 12 months after and weather cold again and exactly same problem again . Engine cannot run without choke and cuts out as soon as choke pushed in . Any throttle instantly dies . Just rowed half way back to shore again ....beware do not buy one of these .

[@dp47280]

@Ian G In a way I have to agree with you- this is a motor I really want to like because it’s light weight and when running is great. Getting it running is hard work and keeping it running seems even harder. I’m looking to sell mine because without reliability you may as well not have it at all. Thanks for the input.

[@michaelsimpson9779]

Mixture screw under the blanked off plug at back of carby beside brass tube, drill out centre of plug with fine drill and pull remains of plug using small self tapper into plug blanking off access. This exposes mixture adjustment. Set ridiculously lean at factory for emissions purposes. Hence your need for choke. Some people have documented this fix elsewhere. These engines can be made to run well. Thanks for your video.

[@rudihenry5298]

I have same issue from the beginning, engine has 10 hours now! 😡

[@evan2290]

​@@dp47280 If I'm trying to keep lightweight (putting it on a inflatable....mariner 4) are there any other small outboards you would recommend? I was thinking maybe the Yamaha 2.5 or the yamaha 3hp 2 stroke. they're both around 35 lbs or 16kg. What are your thoughts about those. Would they run into the same issue? Or should I just go with a 55lb thrust electric troller? Thank you in advance for your wisdom. Great video!