1994 Johnson/Evinrude Outboards 40 thru 55 Service Manual, Page 73Get this manual
Connector Housing rgllf O-ring in fuel connector becomes damaged, air may enter the fuel line, resulting in motor surging andor stallingr,Qllnstaliation of the O-ring in the fuelhose connector requires the use of two instruments, one to hold the plunger down and one to remove the O-ringBoth instruments are illustrated and can be made easily of 16 gauge 116 in(1,59 mm) diameter steel wireA piece of discarded remote control wire may be usedForm small hook on the bottom end of the longer tool of about 116 in(1,59 mm) radiusAfter cutting the wires to length, be sure the ends are rounded off to prevent scratching or damaging the O-ring seat on the plungerrgl To remove the O-ring from the connector, proceed as 1Grip the connector gently in vise between two wooden blocks2Push the plunger down with the straight instrument rgl3Insert the hooked instrument between the O-ring and its seat with the hook in flat or horizontal position4Twist the hook around to grasp the O-ring, then pull outDiscard O-ringTo install new O-ring in the connector, proceed as follows: 1Place drop or two of oil on the O-ring 2Place the O-ring on face of the connector3Push the plunger down with the straight instrument4Pinch the O-ring together and gently push into position with fingersWhen reassembling the fuel hose, check for cracks in the primer bulb or in the hoseThe primer bulb must be attached so that fuel flow is from the" shorter to the longer hose lengthFuel flow through the primer bulb is indicated by an arrow"" Check for leaks by connecting fuel tank hose to motor and squeezing primer bulb until definite pressure is felt in the bulb O-Ring