Fuel pump repair 9.5hp

I have a pair of 9.5 hp motors, a 1966 Johnson and a 1972 Evinrude, both motors die after 10 seconds or so at wide open throttle. I can keep them running by squeezing the fuel line primer bulb when this happens so it seems like I have a fuel delivery issue. I recently extended the fuel line so that I can place the fuel tank in the front of the boat but only did so after reading on this forum that doing so would not adversely affect fuel delivery. Since both of these motors were in storage for many years I figure the fuel pumps likely require an overhaul but I cant seem find rebuild kits for them. Can anyone tell me if they are available and if so where to buy them?
BTW the 1966 has a larger fuel pump than the 1972 so I'm looking for 2 different kits.

Re: Fuel pump repair 9.5hp

Been a while since I have worked on a 9.5, but The '72 has the small square pump no? That one can be rebuilt, I know you can get one here.

http://www.laingsoutboards.com/newpage4.htm#JOHNSON EVINRUDE Includes Gale, Sea King up to 1963, and others

The older one I think is not rebuildable, but someone correct me if Im wrong.

Another option is to buy a sheet of diaphragm material from mcmaster for dirt cheap and make a whack of rebuild kits. Get the 0.5mm, 50A Duro. Tip compliments of F_R

http://www.mcmaster.com/#catalog/118/3532/=j8ea9g

Note: They dont ship to Canada, might need a friend/relative in the US to pass it along, or find a supplier near you with suitable material.

You may also want to try a short run of line before rebuilding just to rule that out.

Re: Fuel pump repair 9.5hp

Thanks High Trim.
So it looks like I may be euchred on the 66. I think I have a pump from an old 40 hp somewhere in my junk box, is there any issue with using a pump that's over rated?

Re: Fuel pump repair 9.5hp

If you can make it fit, I cannot see why it wont work.

You could also go aftermarket, and get a little 10 buck Briggs and Stratton or Mikuni.

Re: Fuel pump repair 9.5hp

HighTrim said:

...
Another option is to buy a sheet of diaphragm material from mcmaster for dirt cheap and make a whack of rebuild kits. Get the 0.5mm, 50A Duro. Tip compliments of F_R

http://www.mcmaster.com/#catalog/118/3532/=j8ea9g

...

Click to expand...

All the membranes I have seen did have fiber reinforcement, the above does not have.
The simple rubber sheet might fail catastrophically as opposed to gracefully.

Peter

Re: Fuel pump repair 9.5hp

F_R posted this info on another forum, Id say he classifies as an expert. If he says it will work, that is good enough for me.

Re: Fuel pump repair 9.5hp

http://www.leeroysramblings.com/Rebuilding_fuelpump.htm
Not sure if you were aware of this but it will be handy if you get a kit. I am currently using a 9.9 pump on my 4 HP. Not sure your idea will work but it won't hurt to try. Best of luck. Rick.

Re: Fuel pump repair 9.5hp

I fixed my '66 using that type of bulk diaphragm material and it still works after 12 years.

Re: Fuel pump repair 9.5hp

Thanks for all the help folks.
I checked out the article on Leeroys ramblings, there's a lot of great info there and Ill refer to it when I do the rebuilds. The pump that he used in the article appears to be the same as the one on my 72. The pump on the 66 is larger and spotlessly clean so I'm wondering if it's been replaced at some point in time? I was able to put a mirror behind it and found 304088 in the casting but I cant find a reference to that as a good part number.
Before getting started on the pumps I'm going to run the motors using a different hose and tank, the fact that I have identical problems with 2 motors just has me wondering.

Re: Fuel pump repair 9.5hp

The orginal part number for your pump was 380016, and was replaced by 388685. I don't think I have ever found a rebuild kit for this pump.
Look below, pages 4 & 5.
http://www.marineengine.com/parts/v...ntage-evinrude-johnson/381413/38141300001.htm

Re: Fuel pump repair 9.5hp

Good call on the different hose/tank. I thought about suggesting that. You can also elevate the tank so it becomes a gravity feed to further reinforce the bad pump theory. Rick.

Re: Fuel pump repair 9.5hp

If you are using the same tank for both motors, I'd definitely start there.
The end fittings (especially if they are the originals) are prone to wear and can allow air to enter the system....which mimics the symptoms of a failing fuel pump.