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FUEL SYSTEM
Section 3A - Fuel Pump
Table of Contents
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . 3A-1 Checking Fuel Pump Lift (Vacuum) . . . . . . . . 3A-11
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1 Vacuum Test Troubleshooting . . . . . . . . . . 3A-11
Fuel Pump (Manual) (Design 1) . . . . . . . . . . .
Fuel Pump (Manual) (Design 2)
3A-2 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-12
Troubleshooting Fuel Pump . . . . . . . . . . . . . . 3A-12
3
(Use W/WME-98 CARB) . . . . . . . . . . . . . . . . . 3A-4 Fuel Pump Removal/Disassembly . . . . . . . . . 3A-13 A
Fuel Pump (Electric) (Design 1) . . . . . . . . . . . 3A-6 Fuel Pump – Cleaning/Inspection . . . . . . . . . 3A-15
Fuel Pump (Electric) (Design 2) Check Valve Reassembly . . . . . . . . . . . . . 3A-15
(Use W/WME-97/99 CARBS) . . . . . . . . . . . . . 3A-8 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-16
Theory of Operation . . . . . . . . . . . . . . . . . . . . . 3A-10 Installation of Fuel Pump . . . . . . . . . . . . . . . . . 3A-18
Specifications
FUEL Fuel Pump Pressure
SYSTEM – @ Idle 17.2 - 27.5 kPa (2-1/2 - 4 psi)
– @ W.O.T. 27.5 - 48.2 kPa (4 - 7 psi)
Recommended Gasoline Unleaded Gasoline
with a Minimum Pump Posted
Octane Rating of 87 or Research Oc-
tane Number (RON) rating of 90. Refer
to Operator’s Manual for additional fuel
requirement information
Fuel Tank Capacity 5.4 Imperial Gals.; 24.9 Liters
(6.6 U.S. Gallons)
Break-in Gasoline Ratio
Manual Outboard 25:1
Electric Start Outboard 50:1 (In Fuel Tank)
IMPORTANT: Electric fuel pump pressure, if used, must be limited to no more than
27.4 kPa (4.0 psi.)
19
18 20
19
A
B 21
6
5 22
A 1
10 2
13
4 4
9 2 11
3
8 14
16
7
12 22 17
19
25
15
22
22 C
23
22
22
29
31 24
28
22
27
30
26
19 Perfect Seal
27
19
18 20 26
22
19
22
B 29
A
25
1 A
4 11
7 3
6
2 14
10 5 15
8
13
22
9 4 17
2
12
16
22 24
22 30 23
31
22
C
21
A – To carburetor
B – To intake manifold
C – To crankcase
19 Perfect Seal
A = TO MANIFOLD B = TO CRANKCASE
22
24 38
24
22
18
24
25 37
26 27
A 24
19 A
24
33
29
1
4 11
7 3
6
2 14
10 5 15
8
13
22
9 4 17
2
40 24
12
24 16
24 30
32 28
42 41
24
24 24
36
C
31 34
35
B
A – To intake manifold
B – To oil pump
C – To crankcase
Theory of Operation
The fuel pump is a crankcase pressure operated, diaphragm type pump. Crankcase pulsat-
ing pressure (created by the up and down movement of piston) is transferred to the fuel
pump by way of a passage (hole) between the crankcase and fuel pump.
When the piston is in an upward motion, a vacuum is created in the crankcase, thus pulling
in a fuel/air mixture the from carburetor into the crankcase. This vacuum also pulls in on the
fuel pump diaphragm, opening an inlet check valve in the fuel pump allowing fuel from fuel
tank to be drawn into the fuel pump.
Downward motion of the piston forces the fuel/air mixture out of the crankcase into the cylin-
der. This motion also forces out on the fuel pump diaphragm, which in turn, closes the inlet
check valve (to keep fuel from returning to fuel tank) and opens the outlet check valve, thus
forcing fuel to the carburetors.
WARNING
FIRE AND EXPLOSION HAZARD. Observe fire prevention rules, particularly NO
SMOKING. Before servicing any part of the fuel system, disconnect electrical sys-
tem at the battery. Drain the fuel system completely. Use an approved container to
collect and store fuel. Wipe up any spillage immediately. Materials used to contain
spillage must be disposed of in an approved receptacle. Any fuel system service
must be performed in a well ventilated area.
FUEL LEAKAGE FROM ANY PART OF THE FUEL SYSTEM CAN BE A FIRE AND EX-
PLOSION HAZARD WHICH CAN CAUSE SERIOUS BODILY INJURY OR DEATH.
Careful periodic inspection of the entire fuel system is mandatory, particularly after
engine storage. All fuel components, including fuel tanks (plastic, metal or fiber-
glass), fuel lines, primer bulbs and fittings must be inspected for cracks, swelling
and/or corrosion. Any sign of leakage or deterioration necessitates replacement
before further engine operation.
Since any type of anti-siphon device must be located between the outboard fuel inlet and
fuel tank outlet, a simple method of checking [if such a device (or bad fuel) is a problem
source] is to operate the outboard with a separate fuel supply which is known to be good,
such as a remote fuel tank.
If, after using a separate fuel supply, it is found that the anti-siphon valve is the cause of the
problem, there are 2 solutions to the problem; either 1) replace the anti-siphon valve with
one that has lighter spring tension or 2) replace it with a solenoid operated fuel shutoff valve.
b
a
57721
a - Clear hose c - Vacuum gauge
b - T-fitting
Vacuum Test Troubleshooting
This test is normally performed at an idle speed. As engine rpm increases, there will be a
slight increase in vacuum. The increase should not exceed specification
Reading above 2.5 in. of vacuum (mercury) Restriction within the fuel system –
• Restricted anti-siphon valve
• Restriction within the primer bulb
• Kinked or collapsed fuel hose
• Plugged water separating fuel filter (in the
boat)
• Restriction in fuel line thru-hull fitting
• Restriction in fuel tank switching valves
• Plugged fuel tank pick-up screen
Testing
Install clear fuel hose between fuel pump and carburetors. Run engine and inspect fuel
passing through hose for air bubbles. If air bubbles are found, see Air Bubbles in Fuel Line,
below. If air bubbles are NOT found, see Lack of Fuel Pump Pressure.
ob00894
c b
a
d
f
ob01138
51549
a - M5 assembly screws
b d
c
a
a
Design II Design I
a - Retainer
b - Plastic check valve
c - Plastic disc
d - Rubber check valve
a
b
50161
a - Retainer
b - Plastic check valve
3. Reinstall rod into retainer cap and, use a small hammer or hammer and punch to tap
rod down into retainer until flush with top of retainer.
a - Rod
b - Retainer cap
Reassembly
IMPORTANT: Always replace gaskets.
After reassembling check valve in fuel pump body, using the following procedure will help
insure proper reassembly:
1. Insert two 76 mm (3 in.) minimum length 1/4 in. screws (not the fuel pump screws) OR
1/4 in. dowels, through the opposite large holes (6 mm screw holes) in the chamber plate
(l), as locating dowels, and turn plate upside down so that the inner side is facing up.
2. Insert coil spring (k) and cap (j) in place.
3. Place boost chamber diaphragm (i) over dowels (screws) and lower onto chamber plate
-- verify that gasket directional alignment is correct and that V-tabs are aligned.
4. Place boost gasket (h) over dowels, and lower to assembly.
5. Place fuel pump body (a) over dowels, and lower to assembly.
6. Insert coil spring (f) and cap (g) in pump body.
7. Place fuel pump gasket (m) over dowels, and lower to assembly.
8. Place pulse chamber diaphragm (i) over dowels, and lower to assembly.
9. Place fuel pump base (n) over dowels, and lower to assembly.
10. Grasp assembly firmly and clamp together with hands--turn over, and insert the 5mm
fuel pump screws (r) (hex-head). Tighten to specified torque. After tightening, remove
dowels (1/4 in. screws) used for locators.
11. Check that the directional alignment of all parts is correct and that the V-tabs are aligned.
q e d
c
DESIGN I
g
f a DESIGN II
b
c
h
d i
b j
k
l
p
r
n s
m
51549
a - Fuel pump body k - Spring
b - Plastic check valve (2) Design II l - Chamber plate
c - Check valve retainer (2) m - Gasket - pulse
d - Plastic disc (2) Design I n - Fuel pump base
e - Rubber check valve (2) Design I o - Base gasket
f - Boost spring p - Alignment tabs
g - Cap q - Opposite side view
h - Gasket – boost r - Screw (2)- fuel pump
i - Diaphragm (2) (M5 x 40)
j - Cap s - Screw (2) - fuel pump to block
(M6 x 50)
d
c
b e
a
ob01138
a - Fuel pump
b - Inlet fuel hose
c - Outlet fuel hose to carburetors
d - Pulse hose
e - Screws (M6)
5. Reattach trim relays to mounting bracket.
ob00894
a - Trim relays
g b
c
f
d
e
a
ob01136
d
c
g
b
f e
a
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