Johnson / Evinrude fuel pump service

In this video I service the fuel pump on my Johnson 30HP outboard motor.
Kit available from MarineEngine.com here: www.marineengine.com/newparts/...
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[@grumpyoldrider1482]

One of the best repair videos I have ever seen. Complete and accurate information without any extra stuff.

[@stevegoodwin803]

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!!!

[@WeedbusterCleanWater]

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!

[@DangarMarine]

You're welcome Jim, glad to hear you boat is running well now. :)

[@jims4539]

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.

[@Radswa_Chikinora]

Thanks bud. Might use this for some preventative maintence on my old Evinrude 👌 love your work!

[@gigmaster31527]

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.

[@DangarMarine]

You're welcome mate. :)

[@James-eq8fs]

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.

[@DangarMarine]

Hey James, that's a great suggestion, makes a lot of sense. Thanks for mentioning it. :)

[@drlangattx3dotnet]

thanks Stu. I enjoy watching you work and explaining things. I think I pick up good mechanic habits by watching you.

[@DangarMarine]

Thanks Donald, glad you enjoyed.

[@anval1257]

Excellent video on a widely overlooked subject !! Thank You Master !!

[@MrMunchbunch83]

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

[@DangarMarine]

Thanks David, glad the vids have been helping you with your boat.

[@agfletch]

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!

[@DangarMarine]

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. ;)

[@agfletch]

Good point!

[@seanporter113]

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

[@mattmuch1]

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!

[@DangarMarine]

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.

[@mattmuch1]

Dangar Marine Thanks again. That would be wonderful. Looks beautiful in Dangar i hope someday to visit. Much love from Chesapeake Maryland U.S.

[@danwebster5439]

Thanks. Just what I needed. Clear and good close ups

[@mitchsixx1896]

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.

[@christopherkellett7579]

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!

[@DangarMarine]

You're welcome mate, good luck with the renovation. :)

[@dloc702]

😊😊😊😊😊😊😊😊😊😊😮😊😊😊😊😊😊😊😮

[@dand4564]

The best, educational outboard videos anywhere.. thanks again dangar stu!!

[@DangarMarine]

My pleasure!

[@richardwright8902]

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!!!!

[@DangarMarine]

Glad to hear it is running well again. :)

[@thomassheehan4193]

Great video, mate! I especially liked the beer bottle repositioning and going down!

[@BaysideShrimp]

Great videos as always. Great service you provide

[@riv1950]

Really great info and a very good video.Thank you Stu!

[@DangarMarine]

Thanks mate, glad you liked it. :)

[@LifesAdventures555]

You're the man, you're the man. Thanks for what you do.

[@DangarMarine]

You’re welcome. :)

[@MrWilliam.Stewart]

Thanks for making these great videos man.

[@gordjones9227]

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!

[@gonzalorauldiaz]

from Argentina. your videos have served me a lot. here the mechanics are a disaster. Thank you very much

[@lyleanderson6284]

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.

[@vetterfellow]

Another excellent video Stu; Thanks again Friend !!!.

[@DangarMarine]

Thanks Angelo!

[@sevenacresofheaven7744]

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.

[@DangarMarine]

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.

[@GenadiSaltikov]

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?

[@PorkBarrel.]

Thanks Stu as always spot on.

[@DangarMarine]

Thanks John!

[@thom7623]

Thank you for another great video

[@rtmiv2030]

Subscribed because your videos are so informative even though I may not need that particular repair.

[@DangarMarine]

Thanks mate, welcome aboard!

[@TimsWorkshopTJY]

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.

[@DangarMarine]

Thanks Tim. Sounds like you've been very busy!

[@storyfirstfilms149]

absolutely fantastic video and help - thank you

[@trevorsmela2754]

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.

[@DangarMarine]

Glad I could help!

[@jimbanks310]

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. :)

[@torbjornpetersson9319]

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?

[@jimbanks310]

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

[@torbjornpetersson9319]

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.

[@jimbanks310]

torbjörn petersson I’ll keep you posted for the mechanics assessment tomorrow 👍

[@wysetech2000]

Well done, Stu.

[@DangarMarine]

Thanks mate. :)

[@lucasruiz10]

Excelente!!! Gracias. Saludos desde Argentina!!!

[@chowmaine]

Excellent and informative. Thank you!

[@jimbogasoline2042]

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

[@DangarMarine]

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.

[@ronpowell2373]

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.

[@HoustonR6ryda]

Always excellent instruction , thanks.

[@movietime111]

Thanks for fantastic show! We have Johnson 48 SPL, looks same as engine on this video except little larger.. yesterday I was out with kids and engine studdered a few times then few minutes later stated to smoke a bit and shut down with I think overheat buzzer on. After sitting out in the river for 45 minutes the the engine started back up. Found a bunch of gasoline in the bilge, though can't see any leak from the gas tank. There is a water separating fuel filter in the bilge area but I cant really see any leaking fuel from it. Do these systems pressurize that would cause the fuel filter in bilge to leak? For life of me I can't figure out where fuel came from in bilge except from the fuel/water separator filter. Any suggestions would be appreciated, thanks again!

[@matthewbishop3622]

I enjoy your knowledge, you have helped me a few times. I have a 00 Yamaha 25 Hp, 3cyl. Will it not run better on high octane? Or is 87 better for it?

[@lauramonroe9446]

Thanks so much for this video. If I have a VRO with the VRO removed, can use this fuel pump? Thanks

[@robgoeller265]

Super good vid. Just a note you can purchase the whole fuel pump new on e-bay for around $14

[@rudorc]

Thanks for the video Dangar Marine. This helped me tremendously with my fuel pump rebuild. One question tho, When you removed the pump from the engine, the cap was positioned to the right. When you installed it after the rebuild it was positioned to the left. Which side is the proper position?

[@mehrdadsharifi9081]

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.

[@maxipower6932]

Thank you for this amazing instruction I bought a 1966 Hydro Swift. I know lii about outboard motors. The one on my boat all it says: "Johnson 115." 2 or 4 cycles? How do I tell? Currently not running. Any one with info, it will be very appreciated.

[@vinnitca1990]

One of the best video on KZbin !!! Thanks man ! respects from USA.

[@eastwest1362]

Excellent and instructive video.

[@davehalcomb2258]

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

[@geyang4837]

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

[@zackpylate3494]

Hey stu I have a 50 Evinrud and I got a rebuild kit for the fuel pump and I rebuilt it and put it on my boat and fuel was still spraying out please help

[@craignelson6560]

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]

I have a 140hp 1988 Johnson too and was having the same issue what’s the part number for the new pump?

[@craignelson6560]

@@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.

[@JamesMiller-wt9dk]

How often should you rebuild your fuel pump?

[@JulioPastrana]

Great explanation thank yuou for that, have you ever work in a outboard johnson evinrude motor 90 hp 4 stroke?

[@RichieRouge206]

Interesting to watch and learn how these work. Great video

[@volvogt21]

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!

[@DangarMarine]

Oh well, live and learn. :)

[@roonbooks3227]

Great! Can you advise on if the aftermarket fuel pumps are worth installing or is oem yhe only way to go?

[@fishingfirstthenworkfishin4882]

hey sir i have a 2x 35 hp 3 cylinder johnsons i cant get it to preform it starts and idel gread but the thing is asoon as i open it full taps it only pushing 5 nautical mile . i dit clean the carbs and i dit replace all but it dont have no power so pleas can you advice me what to do pleas sir

[@RoosterStranglr]

How important is it to change the cap for those kind of cracks? Mine has similar ones. Maybe smaller.

[@johnc.wunscheljr2873]

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

[@Fireship1]

Great video Stu! Did you change this pump out for preventive reasons or did it have issues? I'm wondering if I should add this to the list of things to do to my evinrude 48 SPL that has been sitting for many years.

[@DangarMarine]

Hey Jack. In this case I am just using this motor as an excuse to film all these common jobs, but I would certainly consider doing this as a general service job every 5-10 years depending on use.

[@GringoSF]

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

[@adamwhite4787]

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.

[@jaysoutdoors723]

I have a 1983 90hp v4 Johnson I can’t get to run right spits and spotters seems like it’s getting to much gas and flooding out could fuel pump cause this thanks any info helps been working on it for weeks and still in same place with it

[@chillywilly3397]

Thank you very much!

[@TravisInCanada1]

Would that cover have cracked from over tightening? Say if it had been rebuilt in the past?

[@scooterb9162]

Dangar I'm having some trouble with my 1975 85hp Evinrude running just wondering if you can help.

[@norbertocanamar6692]

I have a 2012 115 evinrude motor died and i realized i had water in the fuel .. so i drain the lines and fuel tank replaced filter and spark plugs but everytime i start it outboard misfires for the first 30 seconds or so check engine light turns on then it works fine after that then if i trim the engine up or down it does the same thing then it works fine again ... any suggestions?

[@randy1ization]

my 65 evinrude idles very high sometimes, wont idle sometimes,. when I first started it, it was almost wide open, even though the throttle plates were in idle position. carbs were rebuilt.. im thinking my fuel pump diaphram is rotten and has a hole in it, does this sound right? thanks

[@brianhamm7297]

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

[@bigbublildrupfishin]

I have 115 Johnson I've changed everything lines carbs and primer bulb and line fuel pump I have not change will it make my new bulb go soft and motor dies

[@cona730]

hey what size screws are they what go into the block?

[@pickfreak]

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.

[@richardwright8902]

Ken Prevette I try to mark mine, had the same problem one time.

[@user-ym9wb2mk5e]

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)?

[@Cutty77]

I have a 96 johnson 15. Have you repaired the idle control knob on the tiller handle? Mine just spins with no changes.

[@halsmith7642]

With replacement of VRO on xp150 with two 3 line pumps, Is it necessary to plug top center hole connection or is the center hole even used?

[@ronnieeevans6633]

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.

[@DangarMarine]

Have all the fuel and vacuum l lines been checked for leaks. Either could be sucking air.

[@morgangassman5375]

Why does my Johnson 25 only run with choke. Fuel tank vent open, new bulb and hose. Could enough air possibly leak at fuel line connectors to need choke?

[@bdonzi]

Thanks for all this information on the fuel pump and carb rebuild ! , I'll be doing these jobs on my 89 30hp Johnson , would you recommend installing an inline fuel filter for extra protection ? can the fuel pump handle the added resistance ?? thanks again for all your detailed videos

[@SoundzAlive1]

Won't hurt and with the boats with inbuilt tanks they always have a larger fuel filter with a fine cartridge to avoid cleaning the tank regularly.

[@leonardclark3147]

Hi Stu, I have a problem with a 90 HP Johnson we were going about half an hour at half throttle and the motor stopped. We had to crank several times with full choke to get the motor to start. It would only run a little and stop, which we did for 4-5 minutes. Finally it started to run without choke. The motor has a new pump and plenty of gas, new filter and hoses. What would cause this?

[@alanpickering946]

Thanks for the video, helped me, my 1975 70 HP johnson fuel pump was playing up, the air dome was stuck

[@DangarMarine]

You're welcome. :)

[@jamesringler987]

How was it running with that problem

[@teslacube]

can you do a video on this on a 115 ficht 1999 johnson?

[@cecedragsund5411]

I was sent the wrong pump, the one I really should have, there are only 2 hoses to connect, it is possible to block the intake that comes from the bottom of the cylinder.?

[@anomie1040]

Thanks for telling me how to clean that corrosion

[@Yasserflehan1970]

Hi Thanks for ever bro., What kind of oil is suitble that i can use it for lower unit for yamaha 200hp Thanks regards

[@DangarMarine]

Just about any 75w-85 gl-5 gear oil is fine.

[@anomie1040]

Lol now were back to NO gloves you are a riot mate.

[@chrissmits3215]

What r the symptoms ...I can’t find a fuel filter .../would this also be the cause of rough idle /shut off?!?!?!

[@jasonbruce2514]

i have a 1996 Johnson/Evinrude 9.9 the fuel filter is to close to the side wall and i cant get to the bottom screw. The lower covers the bottom screw. So how to get to the bottom screw. One person told me to drill a hole in the side of the plastic and the seal it up when i am done. What do you think?

[@sloanclick]

Stu, thanks for uploading this. This is great but what do you think of replacing the fuel pump completely instead of a rebuild? I have a 1973 Evinrude 50 Lark I am trying to get running again and fuel supply seems to be the issue right now.

[@DangarMarine]

If you can get a new one for a good price it is certainly a valid way to go.

[@georgewilliams7723]

How do replace fuel line hook up at motor on 1978 30 hp motor

[@joshuamunoz5036]

Hello sir what is the difference between the small square fuel pumps and the bigger triangle fuel pumps, Johnson/evinrude

[@Badwolf6466]

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.

[@spyker_aileron]

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.

[@elwoodanderson4149]

I wish you were my neighbor

[@rebel_cash]

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

[@tpainter81]

I’ve got a 82 evinrude 25 and my new fuel pump is squirting fuel out the back from a little hole when I start it and it pops and coughs then dies. Is it my pump or another cause ? Thanks

[@politicallyincorrect9027]

Will it hurt the carb if I let it soak in a Chemtool B12 vat overnight?

[@josea81829]

If the fuel pump is not working properly can that cause the motor to bog?