Update:
The marine shop called Friday and said I could pick up the motor. I had been hounding them all week about what was taking so long, and I told them I had planned to go fishing this weekend in my new boat. So when I got there Friday afternoon they said I could take it with me but they needed me to bring it back as soon as I could. Huh? They said they installed the new carb and tuned it, but that Suzuki still wanted them to make one last adjustment they hadn't had time to do. They said it would run fine for my fishing trip and that they had worked double time to get it back to me before the weekend so I could go fishing, but I still needed to bring it back.
I wish they had told me before I drove up there. I used the fishing outing as a way to put some pressure on them, but I'd have cancelled it to save myself a trip. Oh, well. I appreciate the effort, but I really didn't want to have to drive all the way back up there to drop it off, and then again to pick it up. Nice guys, though.
When I got there Friday they had the motor on a stand with the prop in a tank. It started right up. The first thing I noticed was that it was idling a good bit higher than when I had brought it in. The shop manager said he thought the company I bought it from never tested or adjusted it before shipping. I figured that to be the case because it came in a box that looked like it had not been opened since leaving Japan. He said the idle was way too low when I brought it in, and the idle is actually supposed to be set pretty high.
When I asked the manager why I had to bring it back, he said Suzuki wants them to make an adjustment to the pilot jet. When I asked him to be more specific he said they want him to replace the pilot jet with a slightly larger one. So I asked if that would be a 66, but he said, no, they want him to replace the size 32 with a 33. So, Symore, I don't know if this is the same jet you were talking about, but the factory setting appears to be different from what you mentioned. He definitely called it the "pilot" jet. He said Suzuki knows that the factory jet may be a bit lean, but they set it the way they do for emissions reasons. Suzuki told him there's no recall but they are tweaking the jets on a case-by-case, as-needed basis.
Anyway, the throttle seemed to work fine now with the new carb, both in neutral and in gear. No problem accelerating. So, I paid for the oil they had replaced (the new carb was warranty) and took it with me. Today, I put it on my brand new Zodiac Zoom SIB and took it out on the 350-acre lake where I like to fish. It was my first time using the new boat, so it wasn't until I got the boat in the water that I realized the transom is really low. When I put the motor on, the anti-cavitation plate was a good three or four inches under water. The motor pushed the boat pretty well, much better than it pushed my old Sea Eagle. But the transom definitely needs a shim, and I think the 2.5 will run even better if I can get the prop a little higher in the water. It never seemed to max out on rpm, even at full throttle. Full throttle sounded to me like three-quarters throttle. I think it was because the prop was so low it was putting more load on it. I'll work on that. Great day on the water, anyway, and in the end I'm glad I got my fishing trip in after all.
I'll try to take the motor back to the shop sometime this week, and I'll update when I get it back with the new jet.
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