FUEL PUMP REPAIR KIT, P/N 5008368 INSTALLATION INSTRUCTIONS
Use this instruction sheet when installing the above kit on 1995-2003 Evinrude® and Johnson® 4-stroke 5 and 6 HP (128cc); or 8 and 9.9 HP (211cc) outboards only. DO NOT install on any other models.
The following symbols and/or signal words may be used in this document:
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
Indicates a hazardous situation which, if not avoided, could result in death or serious injury
Indicates a hazardous situation which, if not avoided, could result in minor or moderate personal injury.
Indicates an instruction which, if not followed, could severely damage engine components or other property.**
These safety alert signal words mean:
YOUR SAFETY IS INVOLVED!
For safety reasons, this kit must be installed by an authorized Evinrude®/Johnson® dealer. This instruction sheet is not a substitute for work experience. Additional helpful information may be found in other service literature.
DO NOT perform any work until you have read and understood these instructions completely.
Torque wrench tightening specifications must strictly be adhered to.
Should removal of any locking fastener (lock tabs, locknuts, or patch screws) be required, always replace with a new one.
When replacement parts are required, use Evinrude/Johnson Genuine Parts or parts with equivalent characteristics, including type, strength and material. Use of substandard parts could result in injury or product malfunction.
Always wear EYE PROTECTION AND APPROPRIATE GLOVES when using power tools.
Unless otherwise specified, engine must be OFF when performing this work.
Always be aware of parts that can move, such as flywheels, propellers, etc.
Some components may be HOT. Always wait for engine to cool down before performing work.
If you use procedures or service tools that are not recommended in this instruction sheet, YOU ALONE must decide if your actions might injure people or damage the outboard.
This instruction sheet may be translated into other languages. In the event of any discrepancy, the English version shall prevail.
TO THE INSTALLER: Give this sheet and the operating instructions to the owner. Advise the owner of any special operation or maintenance information contained in the instructions.
TO THE OWNER: Save these instructions in your owner's kit. This sheet contains information important for the use and maintenance of your engine.
FUEL PUMP REPAIR KIT
To prevent accidental starting while servicing, disconnect spark wires from the spark plugs. On electric start models, disconnect and the battery cables at the battery to prevent starter activation.
Fuel Pump Removal
Remove hoses from fuel pump nipples. Remove screws retaining pump to powerhead and remove pump.
Make an alignment mark on the fuel pump before disassembly. Use mark to align fuel pump base, housing, and cover during assembly.
Remove O-ring from fuel pump base and remove fuel pump screws.
Disassemble fuel pump.
Push the plunger and diaphragm assembly together while rotating the base to separate.
Spring pressure will separate plunger, springs, and diaphragm from base.
Inspect all components for wear. Replace damaged components.
Position large spring between the diaphragm and base. Align the stem of diaphragm with the slot in the base.
Position small spring on plunger and align plunger slot with stem of diaphragm.
Push the plunger and diaphragm assembly together while rotating the base to assemble.
Place reed valve in position between cover and housing.
Attach cover and housing to base. Apply Nut Lock to screws and torque to 35 to 56 in.lb. (4 to 6 N·m).
Lubricate O-ring with Triple-Guard grease. Install O-ring on base of fuel pump.
Assembly spacers, lock washers, and screws with fuel pump bracket. Apply Nut Lock to screws.
Install fuel pump and bracket on powerhead. Torque screws to 30 to 35 in. lbs. (3.4 to 4 Nm).
Connect the fuel hose to motor and squeeze the primer bulb until definite resistance is felt.
Check fuel pump assembly and hose connections for leaks. Repair all leaks.
Do this test with the motor in a test tank or on the boat.
Before testing, loosen fuel tank gas cap momentarily to release any pressure that may have built up. Fuel tank must not be more than 30 in. (76 cm) below fuel pump.
Remove carburetor to fuel pump hose. Connect a fuel pressure gauge between the carburetor and fuel pump.
Start motor and monitor gauge. Pump pressure must be as specified below.
|600||1 psi||7 kPa|
|2500 to 300||1.5 psi||10 kPa|
|4500||2.5 psi||17 kPa|
Fuel pump must meet these specifications after repair kit installation.
Failure to check for fuel leaks could allow a leak to go undetected, resulting in fire or explosion and may cause personal injury or property damage.