90 hp Mariner - fuel line issue

Tightlines72

Cadet
Joined
Aug 15, 2015
Messages
18
My learn-to-DIY outboard is once again giving me problems!
I have had my 1999 90 hp Mariner for just about 6 months and have been slowly working through replacing all of the upper unit. I bought the boat cheap and will fix a problem, get her running for a week or two, then have a new problem to diagnose and fix. I can honestly say without sarcasm that I've enjoyed the project, but I'm definitely ready to have a bit more consistent use.
My latest problem was trouble engaging forward gear with the boat running which lead me to my shifter cable. After I adjusted, I ran the boat on muffs to make sure I had fixed the problem and everything went smoothly. However, after about fifteen seconds in neutral after cycling through forward and reverse, my engine started to bog down and eventually cut out. I tried restarting and couldn't get the engine to start until I gave some throttle in neutral before starting. This worked a couple times, but would end up cutting out each time. It then got to the point where I couldn't start at all and my primer bulb wouldn't harden. This being the last system I hadn't reworked, I trimmed all of my fuel lines ~ 1 inch, reattached new hose clamps, bought a new primer bulb. My bulb still wouldn't harden, so I bought a new gas tank to try and account for a loose seal on the brass attachment for the fuel line. Still nothing. Ive pumped with the bulb while vertical, attached and reattached each fuel line connector both from gas tank and engine, and can't seem to find my problem. Went back under the cowling and each time I pump the ball, I hear air being released from somewhere in the internal fuel lines. Is this my issue, or is this typical? Please help! It's tarpon season and each day I miss is a major issue in my life
 

roscoe

Supreme Mariner
Joined
Oct 30, 2002
Messages
21,745
Possibly a rupture inside the fuel pump.
You pump the bulb, fuel goes to the fuel pump, leaks through the torn/ruptured diaphragm, and drains into the crankcase.
This will cause a flooded condition.
The bulb won't get hard because the pressure is constantly being lost through the rupture.
Engine will run, but will eventually become too flooded to run, or restart.

Rebuild kit is about $20 from a Merc dealer.

Worth replacing even if it is not the cause of your problem, as they don't last forever and are often overlooked.
 

DavidMoore

Petty Officer 2nd Class
Joined
Jun 2, 2015
Messages
183
What roscoe said.

Remove the fuel line from either the quick disconnect / where it attaches to the engine and plug the end if necessary. Does the bulb now firm up, if it does the leak is in the engine, most probably the fuel pump diaphragm is torn, but could also be the carbs.
 

Tightlines72

Cadet
Joined
Aug 15, 2015
Messages
18
Thanks for the advice. It still wasn't building pressure after disconnecting from the engine, so I went backed and double checked everything. Turns out one of my fuel lines had collapsed internally. Ethanol free from here on out
 

ondarvr

Supreme Mariner
Joined
Apr 6, 2005
Messages
11,527
If it was stock Merc fuel line there were problems with them, they didn't hold up well
 
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