How to maintain and repair an outboard fuel system
With todays outboards, an immaculate fuel system is
essential. To keep a clean system, you need a good high quality fuel tank made
of minimum .090" aluminum and preferrably .125". All fuel lines which run under
decks or through bulkheads must be reinforced FIRE-ACOL hose or equivalent to
meet coast guard requirements. Fire ACOL hose is resistant to the 10% alcohol in
todays fuels so you will not have problems with hose deterioration. A remote
mounted fuel filter should be placed in an accessable area which is not below
deck or in the bilge. Racor is by far the best fuel filter bar none and an
outboard filter element has a clear sight bowl which will allow you to see water
contamination as well as give you the ability to drain it. It is because of this
plastic site bowl that you must mount the filter in an exposed area like a
splash well. From the outlet of the fuel filter run either standard alcohol
resistant fuel line or more fire acol hose. Always use OEM hose clamps from the
filter to the engine and standard all stainless clamps from the tank to the
filter.
You should change the filter element at 100 hours of engine
use or every year, whichever comes first. Replacement elements do not include
the plastic viewer bowl but can be purchased if needed. To remove the filter,
use an oil filter or strap wrench. Remove the plastic bowl by locking it in a
vise so it can not turn - caution do not tighten bowl in vise, just close the
jaws enough that it will not spin freely. Use a filter or strap wrench to remove
the element from the bowl. Remove the new element and the two orings and
reinstall on the bowl. Reinstall the new filter on the base and tighten as per
the instructions on the new filter. Fill with fuel and check for leaks. If no
leaks are present then you have successfully installed your new fuel filter.
If you ever find yourself out on the water and need to remove
a fuel filter to drain it of water, here is a neat trick which I myself have
used several times. If no filter wrench is available and you must remove a
contaminated filter while out on the water, take a dock line which is
preferrably 1/2" diameter, wet it, then wrap the filter canister four or five
times. Hold both ends in your hands and pull the end of the rope which will make
the filter turn clockwise when looking down on it from the top. I have never
found a filter this method will not remove. Be aware however, once the filter
has been removed the gasket will not fit back in its place due to fuel swelling.
You will be required to clean the seal and wait for it to shrink before you can
safely reuse it.
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