Suzuki 2.5 HP Outboard Carburetor Repair - No Start, Hard Starting, Poor Idle, Rough Running Fix.

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If your Suzuki 2.5 HP Outboard doesn't start, is hard starting, idles rough, loses power, or most other ailments, it is probably due to issues with your carburetor. I will show you how to easily remove your carb, disassemble, clean out the ports and jets, and reassemble. It will get your outboard running like new.
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KEY WEST KAYAK FISHING: Equipment Used
The RODS AND REELS:
1) Esky Rods - Spinning 7' (Med 12-15lb Saltwater) - Slow Parabolic Action - Solid Carbon - Fuji Guides(8) and Reel Seat.
- Quantum Cabo 4000
-20lb Power Pro
2) Esky Rods - Spinning 7' (Med/Hvy 15-20lb Saltwater) - Fast Action - Solid Carbon - Fuji Guides(8) and Reel Seat.
- Quantum Cabo 5000
-30lb Power Pro
3) Esky Rods - Spinning 7' (Med 12-15lb Saltwater) - Med Fast Action - Solid Carbon - Fuji Guides(8) and Reel Seat.
- Quantum Cabo 6000
-50lb Power Pro
4) Esky Rods - Spinning 6'4" (25-30lb Saltwater) - Mod-Fast Action - Solid Carbon - Fuji Guides(9) and Reel Seat.
- Shimano Torium 16
-65lb Power Pro
Esky Rods
920 B Kennedy Drive
Key West, Fl 30040
305-896-4637
[e-mail]
www.eskyrods.com/
The Kayaks
1) 2010 Wilderness Systems Tarpon 140.
2) 2012 Hobie Adventure Island w/ Outboard Motor Mount
- 2010 Suzuki 2.5 HP 4-Stroke Outboard
- Lowrance Hook-5
The Rods/Reels (RETIRED)
1) 7' MH Shimano Teramar, TMS-X70MH, Line Wt. 10-20lb, Lure Wt 1/2-1 1/2oz, Power: Medium Heavy, Action: Extra Fast
- Penn Conflict 4000
- Power Pro 20lb
- Power Pro 10lb
- Andes 15lb pink mono
2) 7' H Shimano Teramar, TMS-F70H, Line Wt. 15-20lb, Lure Wt 1/2-2oz, Power: Heavy, Action: Med Fast
- Penn Conflict 6000
- Power Pro 65lb
3) 5'8" XH Shimano Treval Jigging Trigger Rod, TVC-58XH, Line Wt. 80-200, Lure Wt, 160 - 270grams, PowerExtra Heavy
- Shimano Torium 16
- Power Pro 65lb
4) 7'6" M Hurricane Calico Jack IM7, CAJ-457, Line Wt. 8-17lb, Lure Wt 3/8-3/4oz, Power: Medium
- Shimano Solstace 4000 FI
- Power Pro 20lb
5) 6' Ande Tournament Stand Up Rod, ASU-601A SDRMH, Line Wt. 20-50, Power: Medium Heavy
- Shimano TLD-30A 2-Speed
- Power Pro 65lb
6) 6'6" Shimano Trevala, TVC-66MH, Line Wt. 50-100lb, Jig Wt 50-100g, Power: Medium Heavy, Action: Medium Fast
- Abu Garcia 6500C3
- Power Pro 30lb
7) 7' Shimano Trevala, TVC-70ML, Line Wt. 20-50lb, Jig Wt 55-135g, Power: Medium Light, Action: Medium Fast
- Abu Garcia 6500C3
- Power Pro 30lb
Plus a few other misc saltwater rigs that are used sparingly and some Bass rigs which I won't use in salt water.
Cast Nets
-5' 3/8" Plastic enclosed weights
-6' 3/16" Super Spreader SS-1000 1 lb per foot
-7' 3/8" Mako 1lb per foot
Filming
GoPro Hero 8 Black
GoPro Hero 4 Black with Sennheiser MKE2 Elements waterproof microphone.
GoPro Hero 4 Silver
GoPro Hero 3 Black
Panasonic G7
-14-42mm F3.5-5.8
-20mm F1.7
Software: Adobe Premeire Elements and Photoshop Elements
The Car - 1997 Honda Civic Hatchback DX
The Motorcycle - 1997 BMW F650
Header Graphic Created By: Jeff Kaphingst (www.jeffthedesigner.com) (www.rack30.com)

[@KevinDecker-p3c]

Thanks for putting this together. It's much clearer and step-by-step than a couple other videos I watched. I followed the steps on my Suzuki 2.5 and after about 40 minutes' work it is running great now. Well done! The only other thing I would mention is to be sure to clean out those 3 or 4 very tiny openings in the wall on the throttle side of the carb where the butterfly is. They're so tiny they are easy to miss. Spray a bunch of carb cleaner in there and then blow them out with compressed air. Maybe use a piece of thin floral wire to clean them.

[@robertlaforge6864]

Steve, This is a detailed step by step helpful video. I removed and cleaned my carb following these steps and it works like new now. However, it did not start immediately after reinstallation of the carburetor, I suspect because the spark plug was not getting gas. It seemed that the fuel pump needed to be primed, and since the 2014 DF2.5S does not have a primer bulb, I put half a syringe of gas into the sparkplug hole, reinserted the sparkplug, and then it started and purrs like a kitten now. It has worked fine ever since. I will use no ethanol fuel in the future to hopefully prevent the carburetor from gumming up in the future. Thank you for putting this video together.

[@franckmihalic1671]

Hello Key, thank you for your videos. I'm French (sorry for my bad english speaking but I will try to comment in your own language). I had some major issues with one 18 years old age (2006) DF 2.5 Suzuki that has been running in salted mediterranean sea witout any care for a looong time. Everything I can say bellow don't overtake the big thank I have to say to you because you've managed to resolve my engine failure(s). My engine didn't have the good care that you provide to your little Suzuki children :) , I don't even think the oil has been changed once in almost 2 decades in mine. I found out your videos on youtube and followed your procedures. You've made me found and resolve almost 2 main issues. First of all carburator issue : I've put apart everything like you did in this video and my engine was running again after that. I filled it with a 4 stokes pure engine to avoid any other issue. I've notice in your video at 20min that you have reassembled the "choke" yellow plate (in french we call it the starter). I think that you've did'nt assembled it correctly. The little hole on this yellow plate was on the other side when you've dissabled it previously. May be it's not a big deal but anyway at 6min30 it was on the other side. Check it, we can see on the video the brown mark that has to be upside down. After that, I had a big problems with my "race horse pee" like you say in another video ^^ . In french we can say "it pees like a cow :)" I've unparted everything bellow the engine and find out that the water pump had some big troubles. I've manage to change the water pump screw and after that everything was going fine ! I thought I have to change the whole main engine but thanks to your videos, you've made me save some money. Thanks to you and thank you to your really good videos that even a french guy can understand because it's so well explained. Franck

[@thetelescopeworkshop]

Back after a couple of years with hard start problem. Steve, this is absolutely the clearist, best instructional! Thanks again!

[@SailingCISO-ty1lm]

Drained float bowl using that valve and started right up. Thanks for such a thorough video!

[@revosail]

You're a blessing, a very good teacher! Learned a lot and thanks for the inputs of other readers as well.

[@kylewenzel3584]

Steve, thanks so much for doing this! I have a 2.5 on my paddleboard and was having starting, idle, and power issues. I just went through the carb and it’s running great again! It was really helpful to have this video, thanks again!

[@charliezhang841]

You are my hero, Steve. Fix my suzuki 2.5 and my friend's after watching your video. Thank you!

[@switchbacklife6484]

Brother, you have saved me from 8 years of frustration!!! Never could get it to idle right and it was the jet under the screw on the top! Top work my friend! Cheers and may the seas be flat and your lines taunt!!!

[@dwightmarshallphoto]

Did you remove the jet in there to clean? Or just remove the screw and shoot cleaner in there? Thank you

[@rbiel100]

I don't even own an outboard - but this video was fascinating and I learned a lot........great job!

[@iang1429]

Thank you so much for sharing this the little jet in the top was my problem and I didn’t realise it was there until I followed this ..

[@jedibusiness789]

Its great when one finishes a fix then giggle admiring ones work.

[@user-wx8uj4xr2q]

Mine runs fine after water logging it in the ocean by accident. Suzuki is the man.

[@antonioortiz4544]

Thanks. Very clear and specific. I have the confidence now to clean my carb, which has been stalling.

[@andyhemens4386]

Thanks for a very clear video. My Suzuki was spluttering and wouldn't idle. I followed your advice and now it purs. Fyi I didn't need to remove the choke shaft to get the top plate off

[@Subariblet]

Thanks for this video. I'm going to get busy cleaning my carb now.

[@MinhTran-ut8xk]

awesome video steve, will definitely try to clean mine today

[@AhnkoCheeOutdoors]

I love these 2.5 Suzukis, I've had mine for about 13 years. Good reliable engines. Very light weight too.

[@SleepyBoBos]

They are pretty cool. Have you replaced the gaskets in the carbie at all? Any other issues you've had?

[@jeremyvelkoff1487]

Thanks Steve, again you have great step by step information. I really appreciate that you take the time to make this information available.

[@jremodel9294]

Wish I saw this vid earlier today. motor is new, but sat for a year. was messing with it all day and couldnt get it to turn over. taking off work tomorrow so I can do the things you did in the vid. fingers crossed.

[@mickcollings9705]

Well done found our last mechanic had put the choke plate in upside down Very informative now runs lovely👍👍👍 😂

[@velocity800]

the best complete detailed explanation! thanks!

[@holidaycontractor]

thanks dude! saved me so much time and was able to follow perfectly

[@seewind]

Great video....this will be project in the coming weeks.

[@davidforce1012]

Thank you so much! Best video for this motor and allowed me to replace my own jets for high altitude operation.

[@chuckdilmore2040]

Thanks for the great video - and details! A fellow DF2.5 brother.

[@shawnbarnes1949]

Awsome heading down my boat clean carb 2.5.Thankd

[@neilfigueredo7041]

Thank you so much for the great video. Very helpful

[@lucky13ncka]

This video earned my sub. Great info.

[@youngchillman]

This video helped me out so much thank you for taking the time to make it! I know you licked those o-rings off camera and for that, I will be a lifetime subscriber👍🏼

[@davidgreenhalgh3946]

Great video - many thanks

[@1moerawn]

Thanks. Made it very simple

[@pierrevanderdeure8164]

Brilliant ! Thank you so much !

[@megatron2956]

Your saving my day right now

[@Mrfluefiske]

Thank you so much! This helped me out allot! All the best, Eivind Berulfsen

[@skswig1]

My 2.5 sat for several months with gas in it, after it would start but not run, putters a little then dies, If you try to restart it you get less putter unless you wait. Carb has been off and cleaned but does the same thing. The bowl has plenty of gas in it. I don't know what to try next. Love your vids.

[@ssmith1627]

Very much appreciate the videos ! My issue doesn't quite fit the scenarios you listed above. I'm going to take the carb off and clean it. But mine revs great in neutral. It will idle fine in gear. But if I give it any throttle at all it dies immediately. I'm hoping it's the carb and not something more serious.

[@Kyleinasailing]

Nice and clear……Very good.

[@faza1586]

Thanks for your sharing 👍👍👍

[@11ccom]

Good job...you are ready for a Quadrajet.

[@pepevidal3586]

Thanks a lot!!

[@rweinc1424]

The hoses you refer to as emission hoses are actually fuel lines going to and from the fuel pump . The third line is the vacuum pump from the engine side of the carburetor that works the fuel pump.

[@Island_Jigging]

Hi cool vid. Is that short or long shaft - thanks and more power !!! :)

[@dwightmarshallphoto]

Have you ever had to drill out the plug that is over the fuel mixture adjustment screw? Thank you for your videos. We like all of them ❤

[@user-vl5ku6ld6y]

I just bought an 2010 2.5s. Cleaned the carb as discribed. Works well idle up until half throttle. After half throttle the engine dies. What could be the reason and what can I do. Thanks for the great video.

[@normansaulmercado668]

Good vídeos...

[@gotherefindout]

Hi Key West KF ... I was hoping you might have a technique to attach the tiniest spring I have ever seen on the carburetor float. While following your very thorough carb clean this spring came off and vanished as it is nearly invisible... thanks

[@SleepyBoBos]

Great vid. Thankyou. I would suggest to everyone wearing gloves with carb cleaner and not putting your mouth where the carb cleaner has been and working in ventilated area. If you look at the safety data sheets for these products they are pretty nasty (including nervous system damage and fertility!)

[@tleofresh]

when I last used the motor, it wouldnt start and also I noticed either oil or gas coming out of the lower unit on the surface of the water. I rebuilt the carb, and it still wont start. My question is do the lower unit seals need to be replaced and do you have a video on how to do that ? Or would the carb flooding cause some gas to go into the water?

[@petrovuch]

nice video thanks!!what if motor won't start after cleaning,? any other solutions thanks

[@outandaboutwithrobnyc]

Carbs are not that expensive these days. Just replace the old carb with the new one,done! Clean the old one and keep it as a back up. Back on the water! Great video. Did you readjust the idle?

[@LU8HRW]

What is covered in these carburetors are the ducts between the jet ralenti and the carburetor venturi. They are very thin and difficult to uncover.

[@DaBinChe]

use SeaFoam or similar every month in your gas to keep things clean saves lots of work, also run the carb dry after each use helps too

[@eduffy4937]

I run 1.5 ounces of seafoam per gallon of fuel continuously. When I scoped my motor it is VERY clean. One thing with non oxy fuel is it builds carbon FAST since it has less, or no detergents on it

[@DaBinChe]

@@eduffy4937 That is too much for continuous use. 1oz. per gallon should be more than enough

[@eduffy4937]

@@DaBinChe I meant to type 1oz or .5ounce for normal running. My mistake.

[@dough3208]

Im looking at my uncles 2.5 and I cleaned the carb good and added a fuel filter (rust from the fuel cap keeps getting in the fuel tank) i also changed the oil / inline and new spark plug and it ran good for about 30 mins then stopped running, The oil is milky after the short run would it be the head gasket leaking causing the issues or is there another place water can leak into the oil?

[@rweinc1424]

Have you found a fuel filter? If not, they are critical to prevent the jets from plugging.

[@onjofilms]

If you can blow starter ether on it and it runs, does that mean the carburetor is all well?

[@danthomasma7524]

I have high altitude replacement main and pilot jets. How do I do that?

[@applesetoranges]

Hello! Where is your repair shop, please? The brand-new Suzuki df6a I bought in January 2021 has not been used. The test run is very normal. It hasn't been used in the garage for five months. I tried it today and it can't be started. Using Sterling can help start it, but when starting stops spraying, it turns off. It can't operate normally. Can I send it to you to help me repair it?

[@delstep2255]

Hi my brother. Where can I get a air snorkle to buy?

[@dozamm]

I have Suzuki 2.5hp outboard portable. It was not started on its 4th trip on a 10.5 ft inflatable boat. Every time it started max 2-3 pull. It was traveled the wrong side up and the fuel switch was on. Not sounded once after maybe 100 pulls. What may be the problem and how can I fix it by myself? I am a first-time user and I am, skeptical to open carb whether I will return all parts of carb in the right way. May I get help from you?

[@roberttaylor4157]

Try taking off the plugs,place a towel over the opening. now, pull the cord. If its flooded, fuel will exist the cylinders. Repeat !ALSO, Spray little starts fluid, replace the plug and pull the draw cord.

[@mymonster156]

All these 2.5 Suzuki engines need an inline fuel filter just before the carburetor. Otherwise, be prepared for endless problems.

[@notyetjp]

This is pure truth. It eliminates these engines worse weakness. If you also drain carb bowl (w/drain screw) and fuel tank before storage, use fresh rec fuel, you will never have ANY fuel problems. It's a simple, well proven Walbro LMJ carb. As long as its kept clean it will work forever as it did new. WE ruin them. After 1yr. storage, enough pulls to get fuel to carb, it starts immediately. I can't believe small engine manufacturers don't make this required maintenance. If you don't do these things, they can become unreliable nightmares that can get you into real trouble on long dinghy rides. The tiny jets can be clogged by a piece of lint, pollen or hair, much less actual dirt/ varnish from evaporated fuel being left in bowl. Keep the fuel spotless. And fresh as possible. It should smell as strong as the gas you pump into your car. Good luck.

[@mymonster156]

@@notyetjp .. and change the filters every year or two! It must be the only outboard made without a fuel filter, crazy! The float bowl chamber is do easy to empty at the end of the season through the access hole! You can also prime the fuel pump easily with intermittent suction using the manifold "third tube" of the vacuum pump. Then the engine starts first pull.

[@yaboi8616]

Thanks. Do you know what size the line is?

[@windowclean100]

👍🏻👍🏻👍🏻👍🏻

[@fishonkayakadventure]

gotta use that ethanol free gas from WaWa

[@axscdvfb]

Very good instructions! I have a new 2020 DF6A but the cab seems to be the same type. My motor started rough from the very beginning, and today it finally refused to start (only 4th trip, less than 2 total hours). I can't believe it got gummed up by the fuel. Probably there was some dirt that got in during manufacturing. Does anyone else have the same problem?

[@nastyfox86]

Me too...same issue in df 2.5....

[@rudihenry5298]

Exactly the same happened to me, hate this 2,5 Hp engine from the beginning, starting problems since I bought it new, now it doesn’t run at all anymore,10 hours on the clock! 😡 The typical carb issue!

[@axscdvfb]

@@rudihenry5298 I cleaned the carb and the motor runs smoothly now. You need to drain fuel from the carb every time before you store the motor for more than a few days. Otherwise the fuel will gum up and clog the carb.

[@axscdvfb]

@@rudihenry5298 You can also try to spray carb cleaner into the carburetor. There's a hole that you can spray into. That may clean up the gum as well, without requiring the disassembly of the carburetor itself.

[@eduffy4937]

Run non oxygenated gasoline ONLY, and use a fuel treatment such as seafoam at 1.5ounces per gallilon of fuel. 2oztgal to clean after storage. Add an inline fuel shutoff between the rank and fuel pump. When done using, shut the fuel valve off and run it until it dies takes a couple minutes but consumes the fuel in the carb/bowl and fuel lines. Do those things and it's highly unlikely you'll ever have an issue I run 6 of these motors on rental boats and have yet to have the carb issue in over 10years.

[@zzs7253]

Hi Steve, Can I ask how to clean the handle? because I can feel mine has sand in the handle when I twist to adjust throttle.

[@airplanegeorge]

that cover comes off if you just remove the idel adj screw.

[@onjofilms]

That is what he did in the video.

[@mahendrahodivala]

ब्लॉक भेटेल का सुझुकी 2.5

[@francisctison7583]

Suzuki df 9,9 a årsmodel 2009 utbytta termostat

[@psmitty8149]

First

[@judyperez7142]

We tried cleaning the carburetor and no bueno.

[@user-dn7pm3ws4n]

Hey, great video! Thank you, i learned a lot. I have one question. I have a 2016 df2,5. I need a new main jet due to corrosion. I can order 3 sizes #60,#62 and #64. Which is the one that is usually installed? I can not see any marks on mine because its all eaten up.

[@DaBinChe]

JIS screw driver would be the correct tool for japanese brands, I like Hozan or Vessel both japanese brands

[@javitondsouza1841]

hi I have brought a second hand suzuki outboard 2.5 the problem is when u start it gets start quick n good accelerate but when u put in gear n accelerat it gets off.the pee is good.how can it help.thnku regards javiton india

[@chadwce]

You missed the boat by not removing the pivot pin for the float, dropping the needle valve out and cleaning the seat for the needle valve. That was you most likely reason for the flooding.