
3A-3
90-13645--2
495
FUEL SYSTEM AND CARBURETION
Fuel Pump Removal/Installation
(Design 1)
Remove 4 hoses from fuel pump.
Remove 2 phillips-head screws -- lift off fuel pump.
Remove 2 hex-head bolts to disassemble fuel
pump.
20427
a
b
a
c
a - Fuel Pump
b - Screws (2 Each)
c - Bolts (2 Each)
Remove gasket from backside (fuel pump base) --
replace gasket as necessary -- check gasket in
port area carefully.
20417
a
b
a - Gasket
b - Port Area
Reinstall Fuel Pump (Design 1)
After reinstalling fuel pump, ALWAYS check all
fuel line connections for leaks, with engine
running.
CAUTION
Reinstall fuel pump to powerhead, as shown, with
2 phillips-head screws.
Attach fuel lines (inlet and outlet).
Attach oil injection hose.
Attach pulse hose.
Secure each hose connection with a sta-strap.
a
b
c
d
a - Inlet Fuel Hose
b - Outlet Fuel Hose
c - Oil Injection Hose
d - Pulse Hose
Fuel Pump Cleaning,
Inspection, Disassembly and
Reassembly (Design 1 and 2)
Disassemble by removing 2 hex-head bolts;
remove/disassemble fuel pump parts.
Fuel Pump – Cleaning/Inspection
Clean fuel pump housing, check valves, pulse cham-
ber, and pump base in solvent, and dry all but check
valves with compressed air.
Inspect each check valve (2 ea.), for cracks and/or
holes. Check each black rubber disc (2 ea.) to see
that the black coating is not coming off. Unless dam-
aged while disassembled, replacement is seldom
necessary. Inspect the Check Valve Assembly on
Chamber Plate (check by both pressure and suction
to hose barb), to see that check ball is moving and
functioning (1-3 psi required).
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 chamber Plate Assembly.
Summary of Contents for 100
Page 4: ...GENERAL INFORMATION AND SPECIFICATIONS 1 ...
Page 18: ...IGNITION SYSTEM ELECTRICAL AND IGNITION A 2 ...
Page 30: ...11669 BATTERY CHARGING SYSTEM AND STARTING SYSTEM ELECTRICAL AND IGNITION B 2 ...
Page 58: ...22480 TIMING SYNCHRONIZING ADJUSTING ELECTRICAL AND IGNITION C 2 ...
Page 71: ...WIRING DIAGRAMS ELECTRICAL AND IGNITION D 2 ...
Page 86: ...FUEL SYSTEM AND CARBURETION A 3 ...
Page 118: ...OIL INJECTION SYSTEM B 3 ...
Page 127: ...20032 3 CYLINDER ENGINES POWERHEAD A 4 ...
Page 168: ...791 H GEAR HOUSING LOWER UNIT A 5 ...
Page 170: ...5A 1 90 13645 2 1095 LOWER UNIT Notes ...
Page 205: ...MID SECTION LOWER UNIT B 5 ...
Page 207: ...5B 1 90 13645 2 495 LOWER UNIT Notes ...
Page 218: ...SHOCK ABSORBER LOWER UNIT C 5 ...
Page 223: ...17250 DESIGN I SIDE FILL RESERVOIR POWER TRIM A 6 ...
Page 233: ...6A 9 POWER TRIM 90 13645 2 495 Commander Side Mount Remote Control Wiring Diagram ...
Page 268: ...DESIGN II AFT FILL RESERVOIR POWER TRIM B 6 51344 ...
Page 305: ...SINGLE RAM POWER TRIM C 6 51485 ...
Page 309: ...6C 3 90 13645 2 495 POWER TRIM Notes ...
Page 340: ...50099 ENGINE ATTACHMENTS ENGINE INSTALLATION 7 A ...
Page 369: ...TILLER HANDLE AND CO PILOT OUTBOARD MOTOR INSTALLATION ATTACHMENTS 7 B ...
Page 371: ...7B 1 90 13645 2 495 OUTBOARD MOTOR INSTALLATION ATTACHMENTS Notes ...