Sealegs Innovision 8.5m – Yamaha F250 Replacement with Suzuki DF250AP
A challenging repower completed on Waiheke Island
In the summer of 2026, a long-term customer came to us after purchasing a used Sealegs Innovision 8.5m. Unfortunately, the boat’s first outings were cut short when the Yamaha F250 suffered a catastrophic engine failure on its second trip.
The failure had caused a connecting rod to break through the side of the engine block, leaving the Yamaha beyond economical repair. Rather than replace the failed engine with another powerhead, we recommended the Suzuki DF250AP as a modern, reliable replacement that would suit the Sealegs well.
Taking the Repower to the Boat
Our repowers are normally carried out at our workshop at the Kōpū Marine Precinct, where we have the equipment and facilities to carry out this type of work efficiently. In this case, however, getting the Sealegs to Kōpū presented a significant logistical challenge.
The boat was located at the owner's home on Waiheke Island. Transporting an 8.5m Sealegs by road and ferry would have added considerable cost to the project, while bringing it across the water wasn't an option with the Yamaha completely out of action.
The solution was to take the workshop to the boat.
Our technician loaded the new Suzuki DF250AP, specialist tooling and equipment onto our small crane truck and travelled to Waiheke Island. Over the next three and a half days, the old Yamaha was removed and the new Suzuki installed and commissioned on site.
One of the more challenging repowers
The Sealegs Innovision is not a straightforward boat to repower. The hydraulic motor and associated equipment mounted at the transom significantly reduce the available working space, while the boat's sealed gunnels and cable routes make accessing and routing new cables particularly challenging.
Rather than dismantling large sections of the boat unnecessarily, our technician used a videoscope to investigate the existing cable routes and locate suitable access channels. This allowed the new control and electrical cables to be routed through the boat while minimising disruption to the existing structure.
This is where experience matters. A repower isn't simply a matter of removing one engine and bolting another in its place. Every boat presents its own challenges, and finding practical solutions is an important part of achieving a clean, reliable installation.
Sea trial and performance
Once the installation was complete, the Sealegs was sea-trialled to check the installation and establish the performance of the new Suzuki DF250AP.
The results were:
- 4,000 rpm – 24 knots
- 4,500 rpm – 28 knots
- 6,000 rpm – 37.8 knots
The successful sea trial confirmed the new Suzuki was performing strongly on the 8.5m Innovision.
This project was a good example of why choosing an experienced repower specialist can make a significant difference. When transporting the boat to our workshop wasn't practical, we were able to take the equipment and expertise to the customer instead — completing a technically challenging Suzuki repower on site and getting the Sealegs back on the water.
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