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We have the same 2.5 Suzuki on our CS20.3, some days it will start with 1/2 pull, some days 156 pulls are required..... I try to do absolutely the same procedure, but with varying results. I currently have a chicken bone tied to the tiller. After it starts it runs beautifully, just those first few revolutions.

I would add a step between 2 and 3 above. 2b. flush out with alcohol - this will absorb any moisture and clean out any oils and contaminants. 5. Screws and cured epoxy do not add strength to each other. That does not mean don't use them. Some times you need a clamping force in a place you cannot get a clamp. If I use a screw as part of installation I have no issue leaving them in provided I can bung them or fill in over them and then seal. Or just pull them after and fill the divet.

I would 1. Clean the joint with a vibrating saw, thinnest blade, to get what ever “nonboat “ stuff in the open joint out 2. Blow out the stuff with high pressure air hose (dry air) 3. Inject it with thin epoxy, let it soak a few minutes then inject some slightly thickened epoxy 4. Clamp it with lots of clamps, without a lot of pressure, don’t want to squeeze the epoxy out. Just eliminate any voids. 5. I think I wouldn’t use screws, just my preference. it’s fixed....