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FUEL PUMP

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.)

90-826148R03 JULY 2003 Page 3A-1


FUEL PUMP

Fuel Pump (Manual) (Design 1)

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

A = TO CARBURETOR B = TO INTAKE MANIFOLD C = TO CRANKCASE

Page 3A-2 90-826148R03 JULY 2003


FUEL PUMP

Fuel Pump (Manual)(Continued)(Design 1)


TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 FUEL PUMP ASSEMBLY
2 2 CHECK VALVE
3 1 DIAPHRAGM
4 2 RETAINER
5 1 SPRING
6 1 CAP
7 1 SPRING
8 1 CAP
9 1 DIAPHRAGM
10 1 GASKET
11 1 GASKET–BOOST
12 1 GASKET–PULSE
13 1 BASE
14 1 PLATE
15 2 SCREW–PUMP 55 6.2
16 2 SCREW–PUMP TO CRANKCASE (M6 x 1 x 50) 55 6.2
17 1 FITTING
18 1 PRIMER BULB
19 2 HOSE (9-1/2 IN.)
20 1 SLEEVE
21 1 HOSE
22 AR CABLE TIE (8 IN.)
23 1 HOSE (3-1/4 IN.)
24 1 INSULATOR
25 1 HOSE (MOLDED)
26 1 FUEL FILTER
27 1 BRACKET
28 1 NUT (M6 x 1) Drive Tight
29 1 HOSE (14-1/4 IN.)
30 1 FUEL CONNECTOR
31 1 SCREW 100 11.3

90-826148R03 JULY 2003 Page 3A-3


FUEL PUMP

Fuel Pump (Manual) (Design 2) (Use W/WME-98 CARB)


28

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

Page 3A-4 90-826148R03 JULY 2003


FUEL PUMP

Fuel Pump (Manual) (Design 2) (Use W/WME-98 CARB)


(Continued)
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 FUEL PUMP ASSEMBLY
2 2 CHECK VALVE KIT
3 2 DIAPHRAGM
4 2 RETAINER
5 1 SPRING
6 1 CAP
7 1 SPRING
8 1 CAP
9 1 DIAPHRAGM
10 1 GASKET
11 1 GASKET–BOOST
12 1 GASKET–PULSE
13 1 BASE
14 1 PLATE
15 2 SCREW–PUMP (M5 x 40) 55 6.2
16 2 SCREW–PUMP TO CRANKCASE (M6 x 1 x 50) 55 6.2
17 1 FITTING
18 1 PRIMER BULB
19 2 HOSE (9-1/2 IN.)
20 1 SLEEVE
21 1 HOSE– MOLDED
22 AR CABLE TIE (8 IN.)
23 1 HOSE (3-1/4 IN.)
24 1 INSULATOR
25 1 HOSE (MOLDED)
26 1 FUEL FILTER
27 1 BRACKET
28 1 NUT (M6) Drive Tight
29 1 HOSE – MOLDED
30 1 FUEL CONNECTOR
31 1 SCREW (M6 x 35) 100 11.3

90-826148R03 JULY 2003 Page 3A-5


FUEL PUMP

Fuel Pump (Electric) (Design 1)

19 Perfect Seal
A = TO MANIFOLD B = TO CRANKCASE

Page 3A-6 90-826148R03 JULY 2003


FUEL PUMP

Fuel Pump (Electric)(Continued)(Design 1)


TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 FUEL PUMP ASSEMBLY
2 2 CHECK VALVE
3 1 DIAPHRAGM
4 2 RETAINER
5 1 SPRING
6 1 CAP
7 1 SPRING
8 1 CAP
9 1 DIAPHRAGM
10 1 GASKET
11 1 GASKET–BOOST
12 1 GASKET–PULSE
13 1 BASE
14 1 PLATE
15 2 SCREW–PUMP (M5 x 0.8 x 40) 55 6.2
16 2 SCREW–PUMP TO CRANKCASE (M6 x 1 x 50) 55 6.2
17 1 FITTING
18 1 SCREW (M6 x 16)
19 1 CLAMP
20 1 SOLENOID VALVE
21 1 GROMMET
22 2 HOSE (11 1/2 IN.)
23 1 SLEEVE (1/2 x 5 IN.)
24 AR CABLE TIE (8 IN.)
25 1 TEE FITTING
26 1 HOSE (4 IN.)
27 1 HOSE (3-1/4 IN.)
28 1 HOSE
29 1 HOSE (3-1/4 IN.)
30 1 INSULATOR
31 1 TUBING (9 IN.)
32 1 CONNECTOR
33 1 TUBING (4 IN.)
34 1 CHECK VALVE
35 1 HOSE (1-1/2 IN.)
36 1 TUBING (1-1/2 IN.)
37 1 FUEL FILTER
38 1 BRACKET
39 1 NUT (M6 x 1) Drive Tight
40 1 HOSE (14 1/4 IN.)
41 1 FUEL CONNECTOR
42 1 SCREW

90-826148R03 JULY 2003 Page 3A-7


FUEL PUMP

Fuel Pump (Electric) (Design 2) (Use W/WME-97/99 CARBS)


20 21 39
23

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

Page 3A-8 90-826148R03 JULY 2003


FUEL PUMP

Fuel Pump (Electric)(Continued)(Design 2)


(Use W/WME-97/99 CARBS)
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
1 1 FUEL PUMP ASSEMBLY
2 2 CHECK VALVE
3 1 DIAPHRAGM
4 2 RETAINER
5 1 SPRING
6 1 CAP
7 1 SPRING
8 1 CAP
9 1 DIAPHRAGM
10 1 GASKET
11 1 GASKET–BOOST
12 1 GASKET–PULSE
13 1 BASE
14 1 PLATE
15 2 SCREW–PUMP (M5 x 0.8 x 40) 55 6.2
16 2 SCREW–PUMP TO CRANKCASE (M6 x 1 x 50) 55 6.2
17 1 FITTING
18 1 SCREW (M6 x 16)
19 1 CLAMP
20 1 SOLENOID VALVE
21 1 GROMMET
22 2 HOSE (11 1/2 IN.)
23 1 SLEEVE (1/2 x 5 IN.)
24 AR CABLE TIE (8 IN.)
25 1 TEE FITTING
26 1 HOSE (4 IN.)
27 1 HOSE (3-1/4 IN.)
28 1 HOSE (3-1/4 IN.)
29 1 HOSE MOLDED
30 1 INSULATOR
31 1 HOSE MOLDED
32 1 CONNECTOR
33 1 HOSE MOLDED
34 1 CHECK VALVE
35 1 HOSE (1-1/2 IN.)
36 1 TUBING (1-1/2 IN.)
37 1 FUEL FILTER
38 1 BRACKET
39 1 NUT (M6 Drive Tight
40 1 HOSE MOLDED
41 1 FUEL CONNECTOR
42 1 SCREW (M6 x 35)

90-826148R03 JULY 2003 Page 3A-9


FUEL PUMP

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.

CHECKING FOR RESTRICTED FUEL FLOW CAUSED BY ANTI-SIPHON VALVES


While anti-siphon valves may be helpful from a safety stand point, they clog with debris, they
may be too small, or they may have too heavy a spring. Summarizing, the pressure drop
across these valves can, and often does, create operational problems and/or powerhead
damage by restricting fuel to the fuel pump and carburetors. Some symptoms of restricted
(lean) fuel flow, which could be caused by use of an anti-siphon valve, are:
• Loss of fuel pump pressure
• Loss of power
• High speed surging
• Preignition/detonation (piston dome erosion)
• Outboard cuts out or hesitates upon acceleration
• Outboard runs rough
• Outboard quits and cannot be restarted
• Outboard will not start
• Vapor lock

Page 3A-10 90-826148R03 JULY 2003


FUEL PUMP

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.

Checking Fuel Pump Lift (Vacuum)


The square fuel pump is designed to lift fuel (vertically) about 1.524 m (60 in.) if there are
no other restrictions in the system using a fuel hose that is 7.9 mm (5/16 in.) minimum diame-
ter. As restrictions are added, such as filters, fittings, valves etc., the amount of fuel pump
lift decreases.
Fuel pump vacuum and air bubbles in the fuel supply can be checked with a vacuum gauge,
a t-fitting and a clear piece of fuel hose. Connect the clear hose between the inlet fitting on
the pulse driven fuel pump and the vacuum gauge t-fitting; keeping the t-fitting as close as
possible to the pump. Connect the fuel line from the fuel tank to the remaining connection
on the t-fitting.

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

Normal Reading Below 2.5 in. of vacuum (mercury)

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

90-826148R03 JULY 2003 Page 3A-11


FUEL PUMP

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.

Troubleshooting Fuel Pump


PROBLEM: AIR BUBBLES IN FUEL LINE
Possible Cause Corrective Action
Low fuel in fuel tank. Fill tank with fuel.
Loose fuel line connection. Check and tighten all connections.
Fuel pump fitting loose. Tighten fitting.
A hole or cut in fuel line. Check condition of all fuel lines and
replace any found to be bad.
Fuel pump anchor screws loose. Tighten all screws evenly and securely.
Fuel pump gaskets worn out. Rebuild fuel pump.

PROBLEM: LACK OF FUEL PUMP PRESSURE


Possible Cause Corrective Action
Anti-siphon valve. Read Checking for Restricted Fuel
Flow, Caused by Anti-Siphon Valves
preceding.
Air in fuel line. Air Bubbles in Fuel Line, preceding.
A dirty or clogged fuel filter. Clean or replace fuel filter.
The fuel pickup in fuel tank clogged or Clean or replace pickup.
dirty.
Worn out fuel pump diaphragm. Rebuild fuel pump.
Defective (hole or crack) check valves in Rebuild fuel pump.
fuel pump.
Broken check valve retainer. Rebuild fuel pump.
Pulse hole plugged. Remove fuel pump and clean out hole.
Hole in pulse hose (1 pulse hose). Replace pulse hose.
Loose pulse hose. Tighten connection.
Boost diaphragm gasket distorted or out of Check seal between mating surfaces
place. where rib divides pulse chamber – gasket
must align with rib; check for distorted
gasket. Align or replace gasket if
necessary.

Page 3A-12 90-826148R03 JULY 2003


FUEL PUMP

Fuel Pump Removal/Disassembly


CAUTION
Disconnect fuel source from engine. Gasoline is extremely flammable and explo-
sive. The procedures described must be done in a well ventilated and spark free
area, and all gasoline wiped up immediately.
IMPORTANT: Fuel pump diaphragm and gaskets should not be re-used once fuel
pump is disassembled.
1. Remove power trim relay screws and move relays to access fuel pump.
2. Disconnect fuel hoses from fuel pump.
3. Disconnect pulse hose.
4. Remove two M6 mounting screws.
5. Remove fuel pump from engine.

ob00894

c b

a
d
f

ob01138

a - Fuel inlet d - Mounting screw, M6


b - Fuel hose to carburetors e - Relay screws
c - Pulse hose f - Fuel pump

90-826148R03 JULY 2003 Page 3A-13


FUEL PUMP

6. Remove M5 fuel pump assembly screws.

51549

a - M5 assembly screws

Page 3A-14 90-826148R03 JULY 2003


FUEL PUMP

Fuel Pump – Cleaning/Inspection


Clean fuel pump housing, check valves, pulse chamber, and pump base in solvent, and dry
all but check valves with compressed air.
Inspect each check valve for cracks and/or holes. Check each black rubber disc to see that
the black coating is not coming off. Unless damaged while disassembled, replacement is
seldom necessary.
Inspect fittings on fuel pump housing for looseness or any signs of fuel or air leaks. Replace
or tighten fitting if leak is found, or replace fuel pump assembly.
Check Valve Reassembly
1. Insert retainer through check valve.

b d
c
a
a

Design II Design I
a - Retainer
b - Plastic check valve
c - Plastic disc
d - Rubber check valve

2. Install check valves and retainers into fuel pump body.

a
b
50161

a - Retainer
b - Plastic check valve

90-826148R03 JULY 2003 Page 3A-15


FUEL PUMP

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.

Fuel Pump Screw (M5 x 40) Torque


6 Nm (55 lb in.)

Page 3A-16 90-826148R03 JULY 2003


FUEL PUMP

FUEL PUMP REASSEMBLY

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)

90-826148R03 JULY 2003 Page 3A-17


FUEL PUMP

Installation of Fuel Pump


Electric Start Models
1. Position fuel pump with new base gasket on cylinder block. Secure pump to block with
two screws. Torque screws to 6 Nm (55 lb. in.)
2. Connect inlet fuel hose to fuel pump. Secure hose with cable tie.
3. Connect outlet fuel hose to fuel pump. Secure hose with cable tie.
4. Connect pulse hose to fuel pump. Secure hose with cable tie.

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

Page 3A-18 90-826148R03 JULY 2003


FUEL PUMP

Installation of Fuel Pump


Manual Start Models (Design 1)
1. Position fuel pump with new base gasket on cylinder block. Secure pump to block with
two screws. Torque screws to 6 Nm (55 lb. in.)
2. Connect inlet fuel hose to fuel pump. Secure hose with cable tie.
3. Connect outlet fuel hose to fuel pump. Secure hose with cable tie.
4. Connect pulse hose to fuel pump. Secure hose with cable tie.

g b

c
f
d
e
a
ob01136

a - Inlet fuel hose to filter e - Outlet fuel hose to carb


b - Fuel filter f - Screws (M6)
c - Inlet fuel hose to pump g - Pulse hose
d - Fuel pump
Manual Start Models (Design 2)

d
c
g
b

f e
a

ob01137

a - Inlet fuel hose to pump d - Fuel filter


from fuel tank e - Outlet fuel hose to carb
b - Fuel pump f - Screws (M6)
c - Inlet fuel hose to filter g - Pulse hose

90-826148R03 JULY 2003 Page 3A-19

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