Thanks for your videos. Just bought a 1978 Johnson 115hp to replace a Force 125hp. The Johnson will be my winter project. My wife asked how I know what to do - the answer is your video's and automotive my knowledge. Thanks again.
Hi Stu, I started to tear down my Evinrude fuel pump with a view to replacing all the gaskets and valves, but my local dealer told me the reco kits were weeks away from arriving in Australia. They also quoted a whole new fuel pump assembly which they were able to order in a couple of days for not that much more money. It also includes the cover, the tiny springs, and caps that aren't included in the kit. So, I took the easy option and got the whole pump which helped me get back onto the water asap. Keep the videos coming!
Great video again, something that might help that was shown to me years ago was during fuel pump reassembly use the two long fuel pump mounting bolts as guides through there normal holes to assist in lining everything up. Once the other machine screws are installed take the mounting screws out. Good that you explained what the hole in the back of the fuel pump is there for.
very good video!!!! it's got to where if I see you on dangar I automatically stop and watch the video. I have a 50 hp. evinrude, I drained the gas tank, 10 gals. , all the lines, everything, didn't think about fuel pump, so took it apart cleaned the screen, and wallaa, running better, after 4 yrs. sitting there. thank buddy, ur the best!!!!
Excellent repair by a man who obviously knows what he is doing. VeryRare, since many DIY videos are made by fools, especially marine/car-truck/firearms videos! I have also built (in the triple & quadtriple digits) various engines & components, however, I just bought a new fuel pump for 1977 Evinrude/Johnson on Amazon for $17.29. probably Chinese, but Chinese parts quality have improved over the last few years. Again, this video rebuild explanation is of excellent quality.
Mate - I can't thank you enough for making these videos. I'm a first time boat renovator and I've just picked up an old 82 35hp enivrude. This series has already given me the confidence to get in and give it a good cleanout. Slow and steady - and it looks like I've got a few service kits to order! Thanks again!
Your video is the most clear and concise of any to do w outboard motors of any kind by anyone. BRAVO! Perfect camera image and sound. You are both knowledgeable and easy to follow along with. Great job. I look forward to your next one. Thanx for the professionalism. It's rare these days.
Thank you, thank you ! I’ve been having problems with my first boat for a year now. A few people looked at it but nothing resolved. I changed 3 fuel pumps. Now I’m sure the pump is good after finding some faults (pinhole in diaphragm, sticky spring) Next is complete cleaning of the carb. Thanks to your video I was able to start and idle no problem. My biggest problem is on the water I can’t go full throttle, only half way. If I push the throttle it stalls. Hopefully the carb cleaning solves this issue. Thanks again. :)
torbjörn petersson I brought it to another mechanic and he cleaned the carb. I changed fuel tank and put in new fuel. New spark plugs. It still has the same issue. Dropped it off today again, he’ll double check the electrical
Jim Banks, I put in new plugs, meassured compression, checked sparks, ignition timing att idle and low speed is ok (can not test att high rpm since apx 2000 rpm is the limit. The pump does pump fuel at idle and low speed, disconnected sensor for overheating - no change. Did fiddle with linkage and tuning the carborettor. Nothing works...Im into changing the pump to eliminate malfunction in that one, replace tha coil, the pump and the CDI-package.
Dude!!! Your videos have helped me so much, I am in the process of bringing a non VRO 1995 Evinrude 88 SPL back to life. It has been setting for nearly 10 years, your channel has been so much help in the journey. Thanks so much and keep it up.
The Nylon Ties that hold the fuel lines onto the fuel pump are made specifically for fuel lines, if you look at them they are made differently than regular Cable Ties, when you tighten them onto the hose, they contact the hose all the way around, I buy mine at a Anchor Marine in East Missoula, Montana, USA, it is used on Johnson and Evinrude Outboards, of which I own one of each. I am an Avid Fan of your channel, keep up the great job.
Another VERY helpful video. So far I have used your videos to help me rebuild my water pump, carburetor and today, the fuel pump. Great Job! Thanks Again.
Another great video Stu! I just got a late 90's Tohatsu 25hp that is hard to find a ton of detail on. I've learned so much valuable information from your wonderfully delivered tutorials. Keep em coming. Thanks buddy!
Thanks Matt. I'll try to grab an old Tohatsu one day to do the same series of video on, particularly as all the smaller Mercury motors are made by Tohatsu too.
Stu, you came through for me again! I have a similar John/Rude (J25TESOM) and this is a breakdown I've been looking to do. Thanks in advance! Best marine engine channel on the interwebs!!!
I have a fresh rebuild on a 1995 Johnson 225 Venom I'm in the last part of brake in period. Engine runs good at lower RPM, But when I get over 5,000 rpms the engine starves for fuel . I can pump the primer ball back up and engine runs good again until I reach 5,000 rpms. Carbs have been rebuilt, I installed a new fuel/ oil pump. New primer ball, hoses and fuel filters. All connections are tight. And advice is appreciated. Thanks, Basserron.
After replacing the VRO twice on my 1988 140hp johnson I installed the pulse type pump about 10 years ago and have not had a problem since. Just have to make sure I bring 2 stroke oil, a measuring cup and my 50-1 mix cheat sheet when I fill it up.
@@fanciscovargas2559 Sorry but I can't remember for sure where I got it. Got it online. Check I-boats, Boats.net, Marine engine.com, Crowley marine or some of the other ones online.
THANK YOU SO MUCH for an excellent info-packed instruction on the fuel pump rebuild. Did it yesterday and just came back from a test ride... never ran better!!!! Thanks again!
Excellent and informative video. I have this engine and am fixing it as I go. It’s awesome that you have this resource available. Saves 100’s of dollars
Great video- the dealer told me that it was difficult to get fuel pump kits since there were too many small parts and springs- which tend to go flying- never to be seen again by human eyes. I get the new pump already assembled.
Great video Stu. I had a problem getting a tight connection with the small fuel line to the fuel pump. It kept leaking fuel after I rebuilt pump and put a new ziptie on. I used a common ziptie. Mercury makes a rounded head ziptie (the bottom side of square). It helps make an even seal and it solved my leak, just from being an older stretched line. Couldn't find them cheap online so I went to a local shop and he sells big and small sizes 8 cents a piece. I think his were an aftermarket brand. I know you could also use the metal auto ones too. But being close to other lines and being smaller makes them a better option to me. If you can find some give them a try
Hey Jim. I know the ones you are talking about, I really should grab some. I've never really had any trouble in the past with regular ties if the hose is in good shape, but buying a pack of the correct style wouldn't be a bad thing. We have a rack of different size stainless steel hose clamps, but they do need a bit of space around them and I don't find they work on small hoses like the outlet that well.
Stu, that's probably why the OEMs use those little wire hose clamps. I have a few I got from Picknpay one day- I went through and grabbed a heap from radiator over flow hoses, PCV and other low pressure hose clamps. I paid an extra $5 for about 100 of them, a bargain in dollar terms, damn expensive in terms of my labour and driving time.
Hi Stu, Been busy still working and remodeling our master bathroom which is coming along good. My last day on my temp job assignment working on aircraft is April 24th so will start up more videos then. I did at least hook up the new steering cable on the Starcraft this week and it works great. I just need to clean out the tilt tube and put all back together and make a video to ad to my collection. Oh I'll send a picture to you this week as well with my new Danger shirt. Good ad on the end of the fuel pump video to test for leaks on rebuilds. also a good idea to pull the cover before going to the water as well.
Thanks for this video! I need to rebuild one kf mine for an 87 johnson 150. I couldnt find one w the red gasket anymore but i found one w a black that says jts for my model, so it is about to ship and your video is going to make it alot more manageable. I attempted to use a cheapo Amazon one until my rebuild kit came, but it cant handle top end. At wot it starts to bogg until i let up
TY Sir, after a few brisk ( above 4500 rpm ) runs, my 115 would limp back to the ramp on what I assumed 2 cyl, push the key and it would regain but only momentarily, leading me to believe fuel issue, took the screen out of fuel pump and it was 1/3 clogged
I HAVE A 70 HP EVINRUDE JOHNSON 1975 JUST GOT A NEW FUEL PUMP FROM AMAZON I THINK A UNIVERSAL ONE BUT MINE HAS 3 HOSES AND THE RUBER CIRLE PIECE YOU DIDNT USE MY QUESTION IS THE BOLT THAT YOU CAN TIGHTING BY HAND WHERE THE MAIN GAS GOES THROUGH CAN YOU TIGHTING TO MUCH AND DO YOU HAVE TO USE THE LAST GASKET YOU PUT ON I HAVE IT CAUSE IT CAME WITH NEW ONE BUT MY OLD ONE DID NOT HAVE IT ON THERE IM HAVING ISSUES KEEPING MY ENGINE RUNNING NOW
The flat sheet partnof my diaphragm had a good 1/4inch hole that caused lots of kaboom and engine flooding! Just replace the fuel pump, fuel hoses, and decarb! These engines runs forever
Hi, that little dome @ 7:58, should it push up and down? My plastic "pin" is a tight fit in the hole, so it doesn't push down. Is that right? If not, what does that pin valve do and what would the symptoms be? My motor kept running then almost cutting out, then running, almost like a misfire but it just caught again. I suspected the fuel pump.. Could this be the issue? Thanks
Hi Stu,I have a 1999 25hp Johnson,I fitted a new fuel pump,which I am not sure is the correct one. The new one is from China,the part no's seem the same,but the fuel pipe on the outlet on the pump is a bigger dia than the original.The pipe from the engine to the diaphragm is the same.The engine ticks over sweet,but when I accelerate,the engine phut,phuts,and then picks up.I can't get the boat into the water at the moment,so I can't check it under load.I fitted a new inline (clear) fuel filter,which doesn't seem to get much fuel through it. I changed the nipple on the pump for the old one,so that the dia was the same .The reduced size of pipe goes to the primer which is manual with no solenoid.It also goes to the bottom of the bowl. The model number id. is-J25RLEEB. Hope you don't mind me picking your brains, Stan,from Manchester Uk.
I'm having a hard time with a 90 hp etec. It was operating last season and I went to start it this year and discovered a disentegrated fuel hose I have a picture of it but cannot tell where it connected to could I send you a picture and see if you could advise me where the other end connects ? I'm so desperate for help
Thank you for this and the carb rebuild video. Your presentation and step by step is very professional you are one of a rare breeds that can teach as well as do the job properly!
Great stuff Stu. Cant believe I gave away a classic mint condition old yammy 15 when all that was wrong was the pump (or so I learnt from your excellent channel). It won't happen again!
does this mix 2-stroke oil with gasoline? if not, could someone point me to a device that could? i'm looking for a way to automatically mix the oil and gasoline at the proper ratio from two separate containers.
Nicely explained. Would you suggest giving those short fuel lines a quick flush through to get rid of any possible flakes of rubber after being disturbed? I hope you have had a good Easter break .
Hey Ron, for sure, you can never do too much cleaning while something is apart. I always get a bit torn between giving a video a single searchable topic and running through all the things I would do while I was there. I was pleased to see there was no sign of varnish or fuel lining in the pump's mesh. That always gives me a fair bit of confidence they are still fine.
Hi Stu, swedish fan here! Im working on A similar motor (evinrude 30hp -92) and I recently rebuilt the carburator. Im wondering about what dimension the different fuel lines have (carb, primer etc) and How to flush and/Or replace them. Would Love get a tutorial on that. It would also be great if you would make a tutorial on How to set the idling speed using the mixture screw and idling screw on the left side of the motor. Having some issues with my sneezing motor! Your videos has helped me alot, keep them coming! Cheers!
Hi Cristoffer, these fuel lines tend to be 6mm inner diameter for smaller outboards and the 8 and 10mm for larger ones. I would be inclined to just replace fuel hoses. This video will give you a few tips on setting the idle (just ignore the vacuum gauge part for a two stroke, the rest is the same) ua-cam.com/video/bsHCMJnRY9A/v-deo.html. Generally if a motor is sneezing it is because either the carbs are out of sync (if there is more than one) or it is running lean (blocked carburettor jets or a vacuum leak).
great stuff, and thanks for sharing. Love the way you explain everything in detail. I have a 2000 Evinrude 9.9 4-stroke outboard, that I have to keep pumping the fuel bladder to keep the motor running when in high throttle, but sitting still in neutral it can run forever. I had a local shop work on it, and they replaced the original fuel pump that was designed to work with the crankshaft, which has a deeper diaphragm with one that is much shallower, but the problem still exist. Any idea on how to repair the fuel pump? I don't seem to be able to get any replacement parts for it. I appreciate it if you could help.
Love all your video's I have a 1987 110 evinrude and after did a carburetor rebuilt the motor keeps dying change all the fuel line..new fuel pump...new fuel primer...but every time your press fuel from primer to the motor it runs until burn all the fuel then motor shuts off...prime fuel back into the motor it starts again until fuel burn out....i did everything everyone say on youtube.....any clue would help. Thanks
I have been having full throttle issues. The motor runs fine low speed. Give it full throttle and it acts like its starving for fuel. I noticed that the inline filter is not filling up and that there is only a trickle coming from the tank. I looked at the pump diaphragm and it looks ok but has lost its pliability so I suspect it may be bad. I pump up the primer and it fills the filter but then depletes as the motor runs. I cant see fuel in the filter so I have no idea how it is even running.
1st, I’m a new subscriber & want to thank you for your tutoring. I’ve learned more from watching your video’s than I learned cumulatively through my trials over the years, so thank you again! I do have a question on the fuel pump though. If there is fuel in the carbs & you spray starter fluid in them or in cylinders, should the engine at least fire or show signs of firing, provided there is spark and everything else is in order? I ask because my 150 will not fire and I suspect fuel pump is part of problem if not the problem.
Thank you so much! helped a great deal. I have a question: When do you open the Core Plugs, those little aluminium caps? how do you open them? how do you seal in the new one? What is the purpose of those Core Plugs?
I have a 86 85 hp force and it runs for awhile then stalls if you give the bulb a squeeze it will start back sometimes some times it wont .if it cools some it starts back up. I have a glass filter and theirs always got fuel.should I start with rebuilding the fuel pump?? replaced water pump impeller 2 yrs ago.it acts like it runs hard then falls off like you turn the key off. some times you can save it by squeezing the bulb sometimes you cant
Just bought a '91 Johnson fast strike 150 that the previous owner attempted to remove the VRO; no parts left for me so I needed up buying a manual pump that looks like this one. I am assuming the 2 middle ports are for the full rails for each carb/carb bank? The larger top inlet is for the bulb side (main fuel line)?
hello Dangar Marine thanks for all the videos, i have an issue with my 150 evinrude 1983, i think its running too rich and wasting too much gas, but the motr runs good and acelerates perfect, but wasting too much gas, what is the possible issue there?
Hi mate, great video. I’ve got a Johnson 35q that’s in reasonable condition for its age but it has been sitting idle on my brother’s boat for 3-4yrs. Was going when put in storage. I’d like to give it a birthday and put it on my boat. What steps would you recommend? I’m thinking Fuel pump service, water pump service and new fluids. Am I missing anything? TIA
Another really good, simple video. You might check the cost of a pump versus a kit & rebuild, sometimes it's less to buy a pump. What kind of brew was that Wild Turkey? Here on the East Coast of the US, that's a name of a bourbon.
Yes, it is amazing how cheap entire units can be sometimes. Once for a Tohatsu I was looking into a carburettor kit and it turned out that an entire carburettor was $100 so I just replaced it. This is the same Wild Turkey you know of, it is from the US.
Hi, Great video and really welly explained! I have just subscribed. Does the existing fuel pump have a part number on? How do I know what I need to purchase for my 1991 50HP? (The link for the kit says no longer available by the way, but probbaly can't get to my country anyway). I have located it locally in New Zelaand where I am which says it's for "432962". Also - Any advice for an engine which mostly starts fine at home but sometimes doesn't like to start on the ocean - Turns over fine but not firing. Spark plugs replaced and no change. Removed fuel line off engine when strandard (after an hour) and basically just plugged it back on, then engine fired up. (Also seems to not like idle/low revs and cut out when idling for no more tha 20 seconds).
Howdy from Sugarland Texas. I have a 90SPL Pre mix. I noticed that I am getting 2-Stroke oil residue all over the inside of engine cover and engine. However the engine runs great and never fouls plugs. What could be the problem ? Is this a sign that its time for a rebuild ? Even though it runs great.
You didn't explain how the engine will act if this fuel pump is having issues, and thus needs a rebuild. How do you test the pump before disassembly? OOPS, you have a diagnostic video called "outboard fuel pumps."
If those zip ties are not designed for a round surface and are not designated to be used and installed with the proper tool you are asking for trouble. Air will enter your system and create all kinds of issues. I had all kinds of these problems until I replaced them with proper screw type hose clamps. Common zip ties are not to be used for hose clamps according to Mercury certified mechanics. Just saying.
There are special tools for tightening tie-wraps. They pull to a certain force and then cut the remaining part. You can buy then at a good E store. For cutting a tie-wrap flat and save you can use a small, flat bottom pliers. They are sold in E stores but also in Modelmaking stores.
Christina- cable ties are not great hose clamps I agree- I have earned some great money chasing down air leaks in pitot static systems because people used them inappropriately. When you have to pull a wing off to get to some tubes it chews up a lot of hours very quickly. However, on thick wall rubber like those fuel lines, using cable ties above a barbed pipe end, and only tight enough to act as hose retainer, cable ties are ok. It would be preferable to use hose clamps , but Stu isn't even sure that the motor will run yet. A good source for hose camps is car wrecking yards, those ones that let you remove your own bits from the wrecks. Most yards let you have 10-20 fuel hose clamps if you take them when getting some car part or other. I have a small stash of those 'wire ' ones the car people love putting on radiator over flow hoses, windscreen washer lines etc.
I agree the curved back type are better, but when the hose is in good condition I've just never had any trouble to worry about them. Having said that, I mostly use stainless steel hose clamps for the bulk of the work we do but I just avoid using them to unless they are really needed to keep the cost down. I should find a back of proper fuel ties to keep in the workshop one day though.
Thank you for the comments, but, when I pay a pro I expect a proper job. I should not have to have taken the boat back two times to have me told nothing was wrong. I found the problem on my own. Dealer never received any business from me again even after I informed him of what was going on he denied it and I told him in a very nice way. So if it cost me another 20 dollars so what I paid him 350 dollars for the job, what is another 20 dollars to have it right'
Have a question if you don't mind... I broke off the stem that goes in the bottom of the carburetor bowl. I'm pretty sure it's the return from the fuel pump is this necessary or can I delete it and plug the hole in the bowl? Or is it necessary for keeping a constant pressure in the carburetor?
All your videos are very informative. I removed the carbs. from a J50PLSTD 2003 outboard and can't figure out where some of the fuel hoses connect to. Any help would be greatly appreciated.
I have a question. I'm trying to replace the water pump and impe.lor on a 89 48hp johnson. Now I have ordered three water pump kits and each one of them have come with an impeller that's inside diameter was larger then the shift. Now shouldn't that inside diameter of the impeller fit snug onto the drive shaft? The Impellers I am getting are about one inch in diameter and the drive shift is about 5/8 in diameter. I keep giving the part number giving by evenrudd but they keep sending the same one
I've been having issues recently and no one seems to know how to help. When I'm underway with my 20hp johnny anything after 16knts the outboard violently jerks and the revs drop right down. If you give it throttle, the outboard then misses profusely. It's running clean, new fuel, a serviced carb, new fuel lines. I checked the pump and found a crack when the inlet housing screws into the main body. Could this be causing the issues I'm having? Apologise for asking on here, running out of ideas.
Stu , I’ve seen that there are 2 diff sizes of replacement fuel pump for removing vro unit , would my Johnson gt 150 v6 take the larger or smaller one ? And I’m getting a lot of unburnt oil on the inside of the cowl and running down the front of the motor . And ideas on that as well sir?
Hello Stu. I love you videos, and I have a 60hp Evinrude E60TLETD. It will not get up to speed. Only to about 15 mph. The VRO was removed by the previous owner and I am wondering where I mount the new fuel pump I purchased. My mechanic removed the pulse limiter and replaced it with a hose barb and connected it to the pulse line off the pump. I do not see anywhere to connect the pump housing to the motor to get the middle hole on pump the oscillating pressure. I have a solenoid where all of the videos I have watched show to mount the pump. Please help!! Thank you very much in advance!! 🚤
I had alot of trouble getting the holes in the gasket and diaphragm to line up because of the presure from the springs on each side. I had to use a feeler gauge on each side to keep the springs from deforming it. Or was I just being to picky ?
This is a great video. I have the exact same Johnson outboard. Recently the outboard start up fine, but when I push the gear to forward or reverse, it doesn’t trigger the throttle and the boat travelling at idle speed (about 2.4knot). Any idea what could be the issue? The last thing I did before this happen was changing the lower unit lube oil, which I don’t think causing the throttle issue.
Thanks for your videos. Just bought a 1978 Johnson 115hp to replace a Force 125hp. The Johnson will be my winter project. My wife asked how I know what to do - the answer is your video's and automotive my knowledge. Thanks again.
One of the best repair videos I have ever seen. Complete and accurate information without any extra stuff.
Hi Stu, I started to tear down my Evinrude fuel pump with a view to replacing all the gaskets and valves, but my local dealer told me the reco kits were weeks away from arriving in Australia. They also quoted a whole new fuel pump assembly which they were able to order in a couple of days for not that much more money. It also includes the cover, the tiny springs, and caps that aren't included in the kit. So, I took the easy option and got the whole pump which helped me get back onto the water asap. Keep the videos coming!
Hey Andrew, replacing the whole pump is often a great way to go. Unfortunately in my case though it doesn't make for a very long video. ;)
Good point!
Great video again, something that might help that was shown to me years ago was during fuel pump reassembly use the two long fuel pump mounting bolts as guides through there normal holes to assist in lining everything up. Once the other machine screws are installed take the mounting screws out. Good that you explained what the hole in the back of the fuel pump is there for.
Hey James, that's a great suggestion, makes a lot of sense. Thanks for mentioning it. :)
very good video!!!! it's got to where if I see you on dangar I automatically stop and watch the video. I have a 50 hp. evinrude, I drained the gas tank, 10 gals. , all the lines, everything, didn't think about fuel pump, so took it apart cleaned the screen, and wallaa, running better, after 4 yrs. sitting there. thank buddy, ur the best!!!!
Glad to hear it is running well again. :)
Excellent repair by a man who obviously knows what he is doing. VeryRare, since many DIY videos are made by fools, especially marine/car-truck/firearms videos!
I have also built (in the triple & quadtriple digits) various engines & components, however, I just bought a new fuel pump for 1977 Evinrude/Johnson on Amazon for $17.29. probably Chinese, but Chinese parts quality have improved over the last few years. Again, this video rebuild explanation is of excellent quality.
Mate - I can't thank you enough for making these videos. I'm a first time boat renovator and I've just picked up an old 82 35hp enivrude. This series has already given me the confidence to get in and give it a good cleanout. Slow and steady - and it looks like I've got a few service kits to order! Thanks again!
You're welcome mate, good luck with the renovation. :)
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Your video is the most clear and concise of any to do w outboard motors of any kind by anyone. BRAVO! Perfect camera image and sound. You are both knowledgeable and easy to follow along with. Great job. I look forward to your next one. Thanx for the professionalism. It's rare these days.
Great video, mate! I especially liked the beer bottle repositioning and going down!
Thank you, thank you ! I’ve been having problems with my first boat for a year now. A few people looked at it but nothing resolved. I changed 3 fuel pumps. Now I’m sure the pump is good after finding some faults (pinhole in diaphragm, sticky spring) Next is complete cleaning of the carb. Thanks to your video I was able to start and idle no problem. My biggest problem is on the water I can’t go full throttle, only half way. If I push the throttle it stalls. Hopefully the carb cleaning solves this issue. Thanks again. :)
Jim Banks think I have the same issue, not reving more than half in water and forward gear. Did you manage to solve it at your motor?
torbjörn petersson I brought it to another mechanic and he cleaned the carb. I changed fuel tank and put in new fuel. New spark plugs. It still has the same issue. Dropped it off today again, he’ll double check the electrical
Jim Banks, I put in new plugs, meassured compression, checked sparks, ignition timing att idle and low speed is ok (can not test att high rpm since apx 2000 rpm is the limit. The pump does pump fuel at idle and low speed, disconnected sensor for overheating - no change. Did fiddle with linkage and tuning the carborettor. Nothing works...Im into changing the pump to eliminate malfunction in that one, replace tha coil, the pump and the CDI-package.
torbjörn petersson I’ll keep you posted for the mechanics assessment tomorrow 👍
from Argentina. your videos have served me a lot. here the mechanics are a disaster. Thank you very much
Dude!!! Your videos have helped me so much, I am in the process of bringing a non VRO 1995 Evinrude 88 SPL back to life. It has been setting for nearly 10 years, your channel has been so much help in the journey. Thanks so much and keep it up.
Glad I could help!
The Nylon Ties that hold the fuel lines onto the fuel pump are made specifically for fuel lines, if you look at them they are made differently than regular Cable Ties, when you tighten them onto the hose, they contact the hose all the way around, I buy mine at a Anchor Marine in East Missoula, Montana, USA, it is used on Johnson and Evinrude Outboards, of which I own one of each. I am an Avid Fan of your channel, keep up the great job.
Yes, I really should order another bag of the proper ones. Having said that, I've never found regular ones leak so long as they aren't too thick.
Another VERY helpful video. So far I have used your videos to help me rebuild my water pump, carburetor and today, the fuel pump. Great Job! Thanks Again.
You're welcome mate. :)
Another great video Stu! I just got a late 90's Tohatsu 25hp that is hard to find a ton of detail on. I've learned so much valuable information from your wonderfully delivered tutorials. Keep em coming. Thanks buddy!
Thanks Matt. I'll try to grab an old Tohatsu one day to do the same series of video on, particularly as all the smaller Mercury motors are made by Tohatsu too.
Dangar Marine Thanks again. That would be wonderful. Looks beautiful in Dangar i hope someday to visit. Much love from Chesapeake Maryland U.S.
Stu, you came through for me again! I have a similar John/Rude (J25TESOM) and this is a breakdown I've been looking to do. Thanks in advance! Best marine engine channel on the interwebs!!!
Super good vid. Just a note you can purchase the whole fuel pump new on e-bay for around $14
The best, educational outboard videos anywhere.. thanks again dangar stu!!
My pleasure!
thanks Stu. I enjoy watching you work and explaining things. I think I pick up good mechanic habits by watching you.
Thanks Donald, glad you enjoyed.
I have a fresh rebuild on a 1995 Johnson 225 Venom
I'm in the last part of brake in period. Engine runs good at lower RPM, But when I get over 5,000 rpms the engine starves for fuel .
I can pump the primer ball back up and engine runs good again until I reach 5,000 rpms. Carbs have been rebuilt, I installed a new fuel/ oil pump. New primer ball, hoses and fuel filters. All connections are tight. And advice is appreciated.
Thanks, Basserron.
Have all the fuel and vacuum l lines been checked for leaks. Either could be sucking air.
Excellent video on a widely overlooked subject !! Thank You Master !!
After replacing the VRO twice on my 1988 140hp johnson I installed the pulse type pump about 10 years ago and have not had a problem since. Just have to make sure I bring 2 stroke oil, a measuring cup and my 50-1 mix cheat sheet when I fill it up.
I have a 140hp 1988 Johnson too and was having the same issue what’s the part number for the new pump?
@@fanciscovargas2559 Sorry but I can't remember for sure where I got it. Got it online. Check I-boats, Boats.net, Marine engine.com, Crowley marine or some of the other ones online.
Thanks bud. Might use this for some preventative maintence on my old Evinrude 👌 love your work!
THANK YOU SO MUCH for an excellent info-packed instruction on the fuel pump rebuild. Did it yesterday and just came back from a test ride... never ran better!!!! Thanks again!
You're welcome Jim, glad to hear you boat is running well now. :)
Excellent and informative video. I have this engine and am fixing it as I go. It’s awesome that you have this resource available. Saves 100’s of dollars
Subscribed because your videos are so informative even though I may not need that particular repair.
Thanks mate, welcome aboard!
Great video- the dealer told me that it was difficult to get fuel pump kits since there were too many small parts and springs- which tend to go flying- never to be seen again by human eyes. I get the new pump already assembled.
I love your videos they have been a great help with me getting my old 1972 shetland 535 and my 1994 evenrude 50 up and running keep up the great work
Thanks David, glad the vids have been helping you with your boat.
Thanks for the video, helped me, my 1975 70 HP johnson fuel pump was playing up, the air dome was stuck
You're welcome. :)
How was it running with that problem
Great video Stu. I had a problem getting a tight connection with the small fuel line to the fuel pump. It kept leaking fuel after I rebuilt pump and put a new ziptie on. I used a common ziptie. Mercury makes a rounded head ziptie (the bottom side of square). It helps make an even seal and it solved my leak, just from being an older stretched line. Couldn't find them cheap online so I went to a local shop and he sells big and small sizes 8 cents a piece. I think his were an aftermarket brand. I know you could also use the metal auto ones too. But being close to other lines and being smaller makes them a better option to me. If you can find some give them a try
Hey Jim. I know the ones you are talking about, I really should grab some. I've never really had any trouble in the past with regular ties if the hose is in good shape, but buying a pack of the correct style wouldn't be a bad thing. We have a rack of different size stainless steel hose clamps, but they do need a bit of space around them and I don't find they work on small hoses like the outlet that well.
Stu, that's probably why the OEMs use those little wire hose clamps. I have a few I got from Picknpay one day- I went through and grabbed a heap from radiator over flow hoses, PCV and other low pressure hose clamps. I paid an extra $5 for about 100 of them, a bargain in dollar terms, damn expensive in terms of my labour and driving time.
Hi Stu, Been busy still working and remodeling our master bathroom which is coming along good. My last day on my temp job assignment working on aircraft is April 24th so will start up more videos then. I did at least hook up the new steering cable on the Starcraft this week and it works great. I just need to clean out the tilt tube and put all back together and make a video to ad to my collection. Oh I'll send a picture to you this week as well with my new Danger shirt. Good ad on the end of the fuel pump video to test for leaks on rebuilds. also a good idea to pull the cover before going to the water as well.
Thanks Tim. Sounds like you've been very busy!
Thanks for this video! I need to rebuild one kf mine for an 87 johnson 150. I couldnt find one w the red gasket anymore but i found one w a black that says jts for my model, so it is about to ship and your video is going to make it alot more manageable. I attempted to use a cheapo Amazon one until my rebuild kit came, but it cant handle top end. At wot it starts to bogg until i let up
Thanks. Just what I needed. Clear and good close ups
TY Sir, after a few brisk ( above 4500 rpm ) runs, my 115 would limp back to the ramp on what I assumed 2 cyl, push the key and it would regain but only momentarily, leading me to believe fuel issue, took the screen out of fuel pump and it was 1/3 clogged
Thanks!
Welcome! Thank you!
I love this series, because as Fate would have it, I bought a pontoon boat that has this very motor on it.
Really great info and a very good video.Thank you Stu!
Thanks mate, glad you liked it. :)
I HAVE A 70 HP EVINRUDE JOHNSON 1975 JUST GOT A NEW FUEL PUMP FROM AMAZON I THINK A UNIVERSAL ONE BUT MINE HAS 3 HOSES AND THE RUBER CIRLE PIECE YOU DIDNT USE MY QUESTION IS THE BOLT THAT YOU CAN TIGHTING BY HAND WHERE THE MAIN GAS GOES THROUGH CAN YOU TIGHTING TO MUCH AND DO YOU HAVE TO USE THE LAST GASKET YOU PUT ON I HAVE IT CAUSE IT CAME WITH NEW ONE BUT MY OLD ONE DID NOT HAVE IT ON THERE IM HAVING ISSUES KEEPING MY ENGINE RUNNING NOW
You're the man, you're the man. Thanks for what you do.
You’re welcome. :)
The flat sheet partnof my diaphragm had a good 1/4inch hole that caused lots of kaboom and engine flooding! Just replace the fuel pump, fuel hoses, and decarb! These engines runs forever
Hi, that little dome @ 7:58, should it push up and down? My plastic "pin" is a tight fit in the hole, so it doesn't push down. Is that right? If not, what does that pin valve do and what would the symptoms be? My motor kept running then almost cutting out, then running, almost like a misfire but it just caught again. I suspected the fuel pump.. Could this be the issue? Thanks
Hi Stu,I have a 1999 25hp Johnson,I fitted a new fuel pump,which I am not sure is the correct one.
The new one is from China,the part no's seem the same,but the fuel pipe on the outlet on the pump is a bigger dia than the original.The pipe from the engine to the diaphragm is the same.The engine ticks over sweet,but when I accelerate,the engine phut,phuts,and then picks up.I can't get the boat into the water at the moment,so I can't check it under load.I fitted a new inline (clear) fuel filter,which doesn't seem to get much fuel through it.
I changed the nipple on the pump for the old one,so that the dia was the same .The reduced size of pipe goes to the primer which is manual with no solenoid.It also goes to the bottom of the bowl.
The model number id. is-J25RLEEB.
Hope you don't mind me picking your brains,
Stan,from Manchester Uk.
Great videos as always. Great service you provide
I'm having a hard time with a 90 hp etec. It was operating last season and I went to start it this year and discovered a disentegrated fuel hose I have a picture of it but cannot tell where it connected to could I send you a picture and see if you could advise me where the other end connects ? I'm so desperate for help
Another excellent video Stu; Thanks again Friend !!!.
Thanks Angelo!
Thank you for this and the carb rebuild video. Your presentation and step by step is very professional you are one of a rare breeds that can teach as well as do the job properly!
Great explanation thank yuou for that, have you ever work in a outboard johnson evinrude motor 90 hp 4 stroke?
Well I built mine a little different. Like wrong lol. Thats why it was leaking. Back to the drawing board. Thanks for the video duude!
Great stuff Stu. Cant believe I gave away a classic mint condition old yammy 15 when all that was wrong was the pump (or so I learnt from your excellent channel). It won't happen again!
Oh well, live and learn. :)
does this mix 2-stroke oil with gasoline? if not, could someone point me to a device that could?
i'm looking for a way to automatically mix the oil and gasoline at the proper ratio from two separate containers.
I have an evinrude 75 hp year 1977 is going well but runs out of fuel I give it a vla pear and it works well it has to be the pump
One of the best video on UA-cam !!! Thanks man ! respects from USA.
I wish you were my neighbor
For sure😂😂😂😂
Thanks Stu as always spot on.
Thanks John!
Nicely explained. Would you suggest giving those short fuel lines a quick flush through to get rid of any possible flakes of rubber after being disturbed? I hope you have had a good Easter break .
Hey Ron, for sure, you can never do too much cleaning while something is apart. I always get a bit torn between giving a video a single searchable topic and running through all the things I would do while I was there. I was pleased to see there was no sign of varnish or fuel lining in the pump's mesh. That always gives me a fair bit of confidence they are still fine.
Hi Stu, swedish fan here! Im working on A similar motor (evinrude 30hp -92) and I recently rebuilt the carburator. Im wondering about what dimension the different fuel lines have (carb, primer etc) and How to flush and/Or replace them. Would Love get a tutorial on that. It would also be great if you would make a tutorial on How to set the idling speed using the mixture screw and idling screw on the left side of the motor. Having some issues with my sneezing motor!
Your videos has helped me alot, keep them coming!
Cheers!
Hi Cristoffer, these fuel lines tend to be 6mm inner diameter for smaller outboards and the 8 and 10mm for larger ones. I would be inclined to just replace fuel hoses. This video will give you a few tips on setting the idle (just ignore the vacuum gauge part for a two stroke, the rest is the same) ua-cam.com/video/bsHCMJnRY9A/v-deo.html. Generally if a motor is sneezing it is because either the carbs are out of sync (if there is more than one) or it is running lean (blocked carburettor jets or a vacuum leak).
Thanks for making these great videos man.
Love these videos, Oh by the way you already have gas all over your hands from removing the hoses, a little late for the gloves.
These videos are the only outboard vids i watch very easy to understand explained in the way i think know special tool improvise
Lol now were back to NO gloves you are a riot mate.
Great video sir.. very detailed👍
Glad you liked it
great stuff, and thanks for sharing. Love the way you explain everything in detail.
I have a 2000 Evinrude 9.9 4-stroke outboard, that I have to keep pumping the fuel bladder to keep the motor running when in high throttle, but sitting still in neutral it can run forever.
I had a local shop work on it, and they replaced the original fuel pump that was designed to work with the crankshaft, which has a deeper diaphragm with one that is much shallower, but the problem still exist. Any idea on how to repair the fuel pump? I don't seem to be able to get any replacement parts for it. I appreciate it if you could help.
Well done, Stu.
Thanks mate. :)
Excelente!!! Gracias. Saludos desde Argentina!!!
Love all your video's
I have a 1987 110 evinrude and after did a carburetor rebuilt the motor keeps dying change all the fuel line..new fuel pump...new fuel primer...but every time your press fuel from primer to the motor it runs until burn all the fuel then motor shuts off...prime fuel back into the motor it starts again until fuel burn out....i did everything everyone say on youtube.....any clue would help.
Thanks
How often should you rebuild your fuel pump?
I have been having full throttle issues. The motor runs fine low speed. Give it full throttle and it acts like its starving for fuel. I noticed that the inline filter is not filling up and that there is only a trickle coming from the tank. I looked at the pump diaphragm and it looks ok but has lost its pliability so I suspect it may be bad. I pump up the primer and it fills the filter but then depletes as the motor runs. I cant see fuel in the filter so I have no idea how it is even running.
Hey man I got the same thing going right now. Ever figure it out??
I'm interested in knowing to
Similar issue with mine right now.
same problem here with my 1988 Johnson 110hp v4 I’m not gettting enough or no fuel unless if I pump it with an electrical pump I adapted
Same same..
1st, I’m a new subscriber & want to thank you for your tutoring. I’ve learned more from watching your video’s than I learned cumulatively through my trials over the years, so thank you again! I do have a question on the fuel pump though. If there is fuel in the carbs & you spray starter fluid in them or in cylinders, should the engine at least fire or show signs of firing, provided there is spark and everything else is in order? I ask because my 150 will not fire and I suspect fuel pump is part of problem if not the problem.
Thank you so much! helped a great deal. I have a question: When do you open the Core Plugs, those little aluminium caps? how do you open them? how do you seal in the new one? What is the purpose of those Core Plugs?
Thanks for telling me how to clean that corrosion
Excellent and instructive video.
I have a 86 85 hp force and it runs for awhile then stalls if you give the bulb a squeeze it will start back sometimes some times it wont .if it cools some it starts back up. I have a glass filter and theirs always got fuel.should I start with rebuilding the fuel pump?? replaced water pump impeller 2 yrs ago.it acts like it runs hard then falls off like you turn the key off. some times you can save it by squeezing the bulb sometimes you cant
Just bought a '91 Johnson fast strike 150 that the previous owner attempted to remove the VRO; no parts left for me so I needed up buying a manual pump that looks like this one. I am assuming the 2 middle ports are for the full rails for each carb/carb bank? The larger top inlet is for the bulb side (main fuel line)?
new johnson fuel pump on ebay is 15. is it better to rebuild or new. love your videos thanks
hello Dangar Marine thanks for all the videos, i have an issue with my 150 evinrude 1983, i think its running too rich and wasting too much gas, but the motr runs good and acelerates perfect, but wasting too much gas, what is the possible issue there?
Could be a carb tuning issue or a problem with the cold-start enrichement system being stuck on, or partially on.
Great video Stu! Wild Turkey and coke pre-mixed in a bottle??? I need to get down to Australia!! :)
Thanks Ted. I find these premix bottles really save times when you are trying to get out of the house in a rush in the morning. ;)
Great! Can you advise on if the aftermarket fuel pumps are worth installing or is oem yhe only way to go?
absolutely fantastic video and help - thank you
Good video, usefull. How's the boat building going on. Haven't seen much of that last weeks
Thanks mate. Boat build has stalled a little bit to to money and the availability of plywood but it should be going again within a week or two.
Interesting to watch and learn how these work. Great video
Hello sir what is the difference between the small square fuel pumps and the bigger triangle fuel pumps, Johnson/evinrude
Hi mate, great video. I’ve got a Johnson 35q that’s in reasonable condition for its age but it has been sitting idle on my brother’s boat for 3-4yrs. Was going when put in storage. I’d like to give it a birthday and put it on my boat. What steps would you recommend? I’m thinking Fuel pump service, water pump service and new fluids. Am I missing anything? TIA
Another really good, simple video. You might check the cost of a pump versus a kit & rebuild, sometimes it's less to buy a pump. What kind of brew was that Wild Turkey? Here on the East Coast of the US, that's a name of a bourbon.
Wild Turkey is a US brand sold here.
Yes, it is amazing how cheap entire units can be sometimes. Once for a Tohatsu I was looking into a carburettor kit and it turned out that an entire carburettor was $100 so I just replaced it. This is the same Wild Turkey you know of, it is from the US.
Hi, Great video and really welly explained! I have just subscribed. Does the existing fuel pump have a part number on? How do I know what I need to purchase for my 1991 50HP? (The link for the kit says no longer available by the way, but probbaly can't get to my country anyway). I have located it locally in New Zelaand where I am which says it's for "432962".
Also - Any advice for an engine which mostly starts fine at home but sometimes doesn't like to start on the ocean - Turns over fine but not firing. Spark plugs replaced and no change. Removed fuel line off engine when strandard (after an hour) and basically just plugged it back on, then engine fired up. (Also seems to not like idle/low revs and cut out when idling for no more tha 20 seconds).
Howdy from Sugarland Texas. I have a 90SPL Pre mix. I noticed that I am getting 2-Stroke oil residue all over the inside of engine cover and engine. However the engine runs great and never fouls plugs. What could be the problem ? Is this a sign that its time for a rebuild ? Even though it runs great.
Thanks so much for this video. If I have a VRO with the VRO removed, can use this fuel pump? Thanks
Another stellar video! Do you think the 1980's Honda 7.5 is close enough in construction to use this video as a guide?
The basic principles will be the same. It may not have the second vacuum hose though.
You didn't explain how the engine will act if this fuel pump is having issues, and thus needs a rebuild. How do you test the pump before disassembly? OOPS, you have a diagnostic video called "outboard fuel pumps."
Bruce Wagenberg prime the bulb until stiff. You’ll see a leak in the fuel pump. It’ll be obvious
If those zip ties are not designed for a round surface and are not designated to be used and installed with the proper tool you are asking for trouble. Air will enter your system and create all kinds of issues. I had all kinds of these problems until I replaced them with proper screw type hose clamps. Common zip ties are not to be used for hose clamps according to Mercury certified mechanics. Just saying.
There are special tools for tightening tie-wraps. They pull to a certain force and then cut the remaining part. You can buy then at a good E store. For cutting a tie-wrap flat and save you can use a small, flat bottom pliers. They are sold in E stores but also in Modelmaking stores.
Christina- cable ties are not great hose clamps I agree- I have earned some great money chasing down air leaks in pitot static systems because people used them inappropriately. When you have to pull a wing off to get to some tubes it chews up a lot of hours very quickly. However, on thick wall rubber like those fuel lines, using cable ties above a barbed pipe end, and only tight enough to act as hose retainer, cable ties are ok. It would be preferable to use hose clamps , but Stu isn't even sure that the motor will run yet. A good source for hose camps is car wrecking yards, those ones that let you remove your own bits from the wrecks. Most yards let you have 10-20 fuel hose clamps if you take them when getting some car part or other. I have a small stash of those 'wire ' ones the car people love putting on radiator over flow hoses, windscreen washer lines etc.
I agree the curved back type are better, but when the hose is in good condition I've just never had any trouble to worry about them. Having said that, I mostly use stainless steel hose clamps for the bulk of the work we do but I just avoid using them to unless they are really needed to keep the cost down. I should find a back of proper fuel ties to keep in the workshop one day though.
Thank you for the comments, but, when I pay a pro I expect a proper job. I should not have to have taken the boat back two times to have me told nothing was wrong. I found the problem on my own. Dealer never received any business from me again even after I informed him of what was going on he denied it and I told him in a very nice way. So if it cost me another 20 dollars so what I paid him 350 dollars for the job, what is another 20 dollars to have it right'
Would that cover have cracked from over tightening?
Say if it had been rebuilt in the past?
Thank you for another great video
Have a question if you don't mind... I broke off the stem that goes in the bottom of the carburetor bowl. I'm pretty sure it's the return from the fuel pump is this necessary or can I delete it and plug the hole in the bowl? Or is it necessary for keeping a constant pressure in the carburetor?
All your videos are very informative. I removed the carbs. from a J50PLSTD 2003 outboard and can't figure out where some of the fuel hoses connect to. Any help would be greatly appreciated.
Ken Prevette I try to mark mine, had the same problem one time.
I have a question. I'm trying to replace the water pump and impe.lor on a 89 48hp johnson. Now I have ordered three water pump kits and each one of them have come with an impeller that's inside diameter was larger then the shift. Now shouldn't that inside diameter of the impeller fit snug onto the drive shaft? The Impellers I am getting are about one inch in diameter and the drive shift is about 5/8 in diameter. I keep giving the part number giving by evenrudd but they keep sending the same one
I've been having issues recently and no one seems to know how to help. When I'm underway with my 20hp johnny anything after 16knts the outboard violently jerks and the revs drop right down. If you give it throttle, the outboard then misses profusely. It's running clean, new fuel, a serviced carb, new fuel lines. I checked the pump and found a crack when the inlet housing screws into the main body. Could this be causing the issues I'm having? Apologise for asking on here, running out of ideas.
Stu , I’ve seen that there are 2 diff sizes of replacement fuel pump for removing vro unit , would my Johnson gt 150 v6 take the larger or smaller one ? And I’m getting a lot of unburnt oil on the inside of the cowl and running down the front of the motor . And ideas on that as well sir?
Hello Stu. I love you videos, and I have a 60hp Evinrude E60TLETD. It will not get up to speed. Only to about 15 mph. The VRO was removed by the previous owner and I am wondering where I mount the new fuel pump I purchased. My mechanic removed the pulse limiter and replaced it with a hose barb and connected it to the pulse line off the pump. I do not see anywhere to connect the pump housing to the motor to get the middle hole on pump the oscillating pressure. I have a solenoid where all of the videos I have watched show to mount the pump. Please help!! Thank you very much in advance!! 🚤
Looks like the same fuel pump as on my (what I suspect is a) 15hp Evinrude.
I had alot of trouble getting the holes in the gasket and diaphragm to line up because of the presure from the springs on each side. I had to use a feeler gauge on each side to keep the springs from deforming it. Or was I just being to picky ?
Yes, that can be a problem. Good idea to use a feeler gauge to keep them in place. :)
This is a great video. I have the exact same Johnson outboard. Recently the outboard start up fine, but when I push the gear to forward or reverse, it doesn’t trigger the throttle and the boat travelling at idle speed (about 2.4knot). Any idea what could be the issue? The last thing I did before this happen was changing the lower unit lube oil, which I don’t think causing the throttle issue.
Found the problem. Throttle cable seized
Awesome video. Very small parts. I see yee we’re enjoying a bundy aye!
Thanks Bob, glad you enjoyed. :)