Suzuki 2.5 HP Outboard - Head Gasket Repair - Thanks Supporters

With a no go fishing day, I decided to fix my damaged outboard. I diagnosed a blown head gasket by spraying carb cleaner along the seams. Since I have rebuilt this outboard a few times, this repair was actually fairly easy and straight forward. Thanks to my Patreon Supporters who help to keep the old outboard running.
"Firebrand" Kevin MacLeod (incompetech.com)
Licensed under Creative Commons: By Attribution 3.0 License
creativecommons...
KEY WEST KAYAK FISHING: Equipment Used
The Car - 1997 Honda Civic Hatchback DX
The Motorcycle - 1997 BMW F650
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
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 4 Silver
GoPro Hero 3 Black
GoPro Studio Editing Software
Panasonic G7
-14-42mm F3.5-5.8
-20mm F1.7
Header Graphic Created By: Jeff Kaphingst (www.jeffthedesigner.com) (www.rack30.com)

[@nauticalstar8363]

Steve, you are truly a handy dude. At the 1:00 minute mark, that is when I say, “F*ck this! I am buying a new motor.”

[@DingDangg]

Don’t you need to use a torque wrench on those head bolts?

[@littlebighead15]

No patreon link in the description Steve?!?!?

[@hawaiiandan2758]

Aloha Steve, luv your channel. Can you please tell me what the top speed is with your outboard setup and the average amount of time it takes to setup? I'm considering the same setup if it extends my fishing reach. I'm sure other viewers, myself included would like to see how and how long it takes for you to setup for your trips. Mahalo in advance my bruddah!

[@timothylines3867]

how diid you build your engine stand??thanks.

[@willmacaluso5293]

Good informative vid, I always get a kick out of, watching the Master at work. But, for the second time, you didn't fire it up! Bummer, Man! I guess I'll just have to wait for the next vid.☹️

[@DanSanChannel]

He FINALLY getting a better mic lol.

[@davemojarra2666]

It's the putting it all back together part, that I usually get wrong.

[@12clscls]

Hi Steve-Live in Vermont but spent my Honeymoon in Key West. Loved it down there. Hey, I bought a new Suzuki 2.5 HP last year. I live on Lake Champlain and had a lot of fun duck hunting last fall and early winter using the Suzuki. However, the last few outings (before the lake froze over) I noticed the engine oil becoming milky. Changed it and within 10 minutes, it's milky again. No doubt water is getting in the crank case, but what's the most likely place of entry? I'm gonna tear her down soon and thought you might point me in the right direction and hey, if you're every in VT, don't forget to bring some bug spray, a parka, a snow shovel and a return ticket to paradise (Key West). Thanks, Craig

[@drvnucrzy]

I would of adjusted the valves while I was in there. That seems to be an overlooked maintenance.

[@abefrohman1759]

Fisherman, chef, foot model and now mechanic gets added to the resume.

[@lojofishing]

those loose chickens tho...

[@regressmenot]

They're all over Key West lol.

[@dcgo44r]

That makes you feel alive.... When you are awake tho' ! But when you've been fishing all night long and come for a sleep... I would be having chicken soup! 😂

[@carl3233]

i have a susuki 2.5 four stroke can you put a video on replacing a water pump thank you

[@benhe6994]

My family and I came down here yesterday, I was wondering if u can do a " fishing with fans" video. Haha

[@bigchad8929]

I knew you were having a problem starting it. Now that you fixed your head gasket you won't have that problem. Great!

[@1FishinAddict]

Do you flush with freshwater after each outting? I have a 2.5 Honda, very similar built. Love those rod holders on the scooter lol, i got it on my electric fat bike.

[@dozamm]

I can not take out prop from Suzuki 2.5 df outboard. Is something jammed there? What shall I do?

[@dougs4477]

Hi Ken. Question: When you change the crankcase oil on your 2.5 suzuki, do you re-use the gasket (o-ring) on the oil plug screw? If/When you replace the gasket, do you use an OEM Suzuki gasket, or an aftermarket gasket? Thanks.

[@stevecowham1017]

I've just taken my cyl head gasket off. All I did was take off the lower bolts on the cowl. I then had enough space to take off the head, complete with carburettor on. Took about half an hour. Strangely there was only one pushrod, which had fallen into the crankcase. A couple of shakes got it out. Even stranger is the rod that the Vietnamese bloke gave me as he handed me the outboard to repair. I hadn't a clue what it was and assumed it was a gauge. He'd told me he had run out of fuel, refilled it and it wouldn't start. Si I cleaned out the carb and checked for a spark but noticed it was low on compression, way down actually. He's given me the engine as payment. But why the pushrod issue? His English was terrible but had he had a go at repairing it and forgotten to put the pushrod in? Erm probably no. So, I'm awaiting parts and currently have a no stroke outboard. Btw. the cylinder had a lot of petrol and oil in it plus there was some in the breather pipe.

[@robertbrander2074]

Now I have to watch tomorrow to see if it starts ! Great movie MacGyver ! You are wearing that little motor out ! Time to upgrade to a Big Boy motor ! Twin 70 Yamis should do the Trick !

[@fredfable5655]

You own it!! Now your last name is Susuki. Steven Susuki!!!!!! LOL. Regards. Fred.

[@NMG3]

Do you know information about valve clearance? Engine hot or cold? How much is valve clearance ? Thank you. Nik from Greece.

[@matias_calypso]

Hello my friend! I have a 2007 2,5 suzuki, and I am trying to remove a stuck powerhead! I took of all four bolts, I see the powerhead is loose but provably the shaft is stuck. Do you have any advice on how to get out?? I already romeved engine oil, gasoline and put it upsidedown with wd40 sprayed in... Thanks!

[@jayvanhouwe2132]

Great vid! Are you a out board mechanic ? How did you do it the first time?Did you have friends help you or utube help? you the man.

[@ncairguner]

Steve , my 2008 Suzuki 2.5 it doesn’t go to gear some times . Plus my engine doesn’t !pee in the back

[@nastyfox86]

Hi bro i have a problem with my df 2.5carb..can i replace to any tipe of carb like grass cutter carb...?

[@maxevans2571]

Got the same engine as yours went to clean the carburettor out and the main jet and the floor at all stuck together with all fuel and ended up damaging the carburettor so put a Honda gxv120 carburettor off the mower works perfect Half the price and change

[@juliosdiy3206]

I can see that boat motors r not easy to fix thats y they r so expensive.

[@hashtagjustadad5110]

Makes it look like it was a simple fix.

[@williamcaldwell748]

Maintenance is a must 👍

[@MackinNC1]

Nice!,....I got a 2.5 Mercury and thanks goodness I have only had to do 1 Carburetor rebuild.

[@blakethesnake1555]

I wish you would explain why you only put permatex gasket sealant in one small spot. I like the video but some explanation would make it alot better

[@notyetjp]

It's a hack to deal w/casting/machining imperfection that the designed gasket can't always seal, causing an oil leak. They have seen the leak often enough to include that silicone gasket sealant spot in the later Zuke service manuals for the DF2.5. That Permatex Black is good stuff. Sometimes you can do w/o the actual gasket, at least in low pressure applications. It is a good motor, but Steve thrashs his shallow water one. At least he knows how to repair it. He has actually become the internet's specialist on repairing this engine, if you don't speak Russian. Good luck.

[@JupiterGeorgeFishing]

Liking your choice in toys Steve. Checking that microphone out now. Santa might have to hook me up too!!

[@cheapescapefishing57]

I just got a new Suzuki df2.5. I cannot figure out how to raise the engine to the upward position so I can dolly my boat from the car to the water. The manual says to just raise it but it is locked into position. I tried holding the little slide piece on the mounting bracket to the forward position but motor is still locked. Any advice would be great....thanks.

[@KennyInVegas]

Very nice of you to take the time to make that video......... I REALLY appreciate it. I just bought today a Suzuki 2.5 for $770.00 shipped. People like you really help so many others....... God bless you........Kenny in Vegas.

[@sinisahercog6563]

Pleas...send video how clean carburator suzuki 2.5 hp 4t...thanx

[@sinisahercog6563]

Hay ...how i clean carburator suzuki 2.5 hp 4t pleas video...thanx

[@YoutubeTravelerSoloVagabond]

hi question for you, my suzuki 2.5 i bought used off craigs list, theres no water coming out of the water discharge hole, what should i do to fix it?

[@TheRealJoeyB]

Impressive, did you go to Suzuki for the gasket

[@velocity800]

Hi, i plan on getting a 2.5hp suzuki 4stroke,, whats your review on this? Do you recomend this outboard?, im going to hook it up on my kayak--Bob

[@cheapescapefishing57]

You seem very handy with this motor. I just bought one brand new and used it once. I put it in my garage and went to bed. I got up the next morning and went to the garage and it had fallen over and laid with the tiller up. Now it won't idle. Any suggestions?

[@hummer4u2nv11]

Another "Behind the scenes" footage of what it takes to be a successful foot model...I meant fisherman :-) Glad to see you have been pretty avid to keep on top of your maintenance this past year. We don't want you to be out of commission or else you won't be able to get out there and share videos with us. I reeeaally like the Tahitian style music, it makes me feel like I'm back at the Polynesian Hotel at DisneyWorld.

[@fireantsarestrange]

It's not even dirty in there... cool. Was wondering were the squirels lived.

[@tollesbury1]

Nice job!! Speed to your next fishing session and keep us watching.

[@boomboombam7]

Love the vids man. No only are you a stellar fisherman you're a decent mechanic as well. I'm kinda the other way around haha. Great vid as always

[@grahamh1967]

Great work Steve, saved some money there Pal ;-) Whats the New Toy going to be then? Thanks for sharing, Graham.

[@JavierTeran81]

Hey Steve, do you recomend this motor? Looking to put an outboard on my kayak .the Suzuki seams to be the lightest any info is helpful. Thanks

[@SD1Griffin]

Didn't see you using any torque wrench, you will blow the gasket again sooner rather than later unless you use the right torque on those nuts. Perhaps I just missed it?

[@saintarctangent]

What’s the torque on the head bolts? Hope you got it at spec or you’ll be doing it agn 😔

[@magana559]

saintarctangent it'll be fine. Small engines don't care. As long as it's snug enough so they won't back out it'll be fine.

[@saintarctangent]

magana559 clamp force on the gasket interface is critical for the seal. Head bolt torque sets the proper clamp force. That’s why it’s important that head bolts have the proper spec torque.

[@magana559]

On such a low hp/small bore single piston engine, it's not that critical.

[@flysubcompact]

Noticed the little game chicken helpers. They yours?

[@KennyInVegas]

how many hrs. you have before troubles on that 2.5 Suzuki?

[@bigshirley3141]

Box O’ Goodies !!! Love these outboard fix it videos mr Steve!!👍🏾👍🏾

[@patmcdermott8547]

That has to be one of the toughest, easiest to service, most reliable outboards on the planet - how many hours/miles does it have on it? Thanks for another informative video.

[@chuckdilmore2040]

Nice job! (I came to see how you get the carb out - I need to service mine.) Thanks!

[@michaelpicardal4885]

come on, you didn't show us the initial start up...

[@lhw6965024]

on broken or stuck bolts amazing and no torch needed ! and you use it in saltwater you must take care of it! good job

[@kmba-9197]

you realy know what your doing i would be so confused great video

[@lordofthebeans7199]

I am staying in Key West rn, it is so beautiful. Also, great job with the engine

[@robertm4050]

The new toy is a mic adapter for his gopro! That is a good brand to go with too.

[@eriklarson9137]

Specified factory torque level = Steve

[@dcgo44r]

Good job!!! That came out right!

[@heathermhansen98]

notification squad where u at

[@bawanadon1177]

Catch and cook one of those chickens.

[@glynnmiller2038]

Enjoy the new microphone

[@kmba-9197]

how long did that take you to do

[@joethornton7958]

Gasket sealant Steve?

[@chmellen]

That was amazing.

[@ArkyJane]

You are welcome.

[@retiredguyadventures6211]

Wow, I'm 1st...

[@AhnkoCheeOutdoors]

Aloha Steve, as you know I have an identical motor that I have been running on my canoe here in Hawai'i for several years. Very reliable and easy to work on when necessary. Just curious, did you use a torque wrench when tightening up the bolts especially the head bolts? I bought an inch-pound torque wrench especially for working on this motor. Keep up the good work/great vids.

[@dcgo44r]

Ahnko Chee Outdoors man when you are first generation mechanic who needs a torque wrench!! Lol! No seriously, once time I was tightening a tranny's oil pan, so use my cheap autoparts torque wrench and I ended messing the threads on one hole of the pan's seat, the rest all went in by hand! And my spark plugs all 8 of them went in by hand also...in a F-150 like 7 years ago (if you know what that means) Amont a more than a few uncounted bolts! Technology is making us too dependent! But I'm a sinner of it... too!