Katerina Swanson
Mercury Marine offers a range of outboard motors for fishing boats, speed boats, pontoons, and tenders. The Mercury Fuel Line Assembly from T-H Marine is a popular choice for connecting the fuel tank to the engine. It is designed to be durable and efficient, with a kink-free design for seamless fuel flow and easy installation. Before connecting the fuel line, it is important to ensure that the connections are tight to prevent air leaks, which can cause the engine to lose prime and lead to potential safety hazards. This is applicable to all engines, including those manufactured by Honda, Yamaha, Suzuki, and Mercury.
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What You'll Learn
Mercury Fuel Line Assembly
The Mercury Fuel Line Assembly from T-H Marine is a durable and efficient solution for connecting your fuel tank to the engine. It is designed to withstand harsh marine conditions and offers a reliable fuel delivery system. The assembly is equipped with a universal primer bulb and stainless steel clamps for added convenience and security. It also includes a pre-connected fuel fitting that is compatible with Mercury boat engines.
The fuel line is made from sturdy materials and features a kink-free design for seamless fuel flow and easy installation. It is EPA-approved and features a double-check valve and speed prime technology.
When connecting the fuel line to the engine, ensure that it is tight and not loose to prevent air leaks, which can cause problems with the engine's performance. The general rule of thumb is that any engine above 115 HP requires a 3/8" fuel line, while most smaller outboards use a 5/16" hose.
For Mercury FourStroke outboards 60hp and below, the primer bulb is located in the fuel line between the fuel tank and the engine. To prime the fuel system, connect the fuel line to the engine and pump the bulb repeatedly until it is firm. This usually takes a few pumps. Once the bulb is firm, the line is charged, and you can start the engine.
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$48.7 $69.24
Clearing air from the fuel line
Clearing the air from the fuel line is essential for starting your engine. Here is a step-by-step guide on how to do it:
First, locate the primer bulb. This is a rubber spheroid, roughly the size and shape of a chicken egg, and it is found in the fuel line between the fuel tank and the engine. If you have a Mercury FourStroke outboard that is 75hp or greater, the onboard electric fuel pump will prime the fuel system for you. Simply turn the key to the “run” position and wait. You’ll hear a beep, followed by the sound of the fuel pump running. In just a few seconds, the pump will clear the air out of the fuel line, and you’ll be ready to start the engine.
If you have a Mercury FourStroke outboard that is 60hp or below, you will need to manually pump the primer bulb. First, connect the fuel line to the engine if it is not already attached. Then, pump (squeeze) the bulb repeatedly until it’s firm. It usually only takes a few pumps. When the bulb is firm, the line is charged and you can start the engine.
If you are unsure about the source of the air leak, you can try running clear tubing between the bulb and the tank to see if the bubbles are coming from the tank. If you have a plastic portable fuel tank, you may need to check the tank fittings or the fuel tank pickup itself as these can be sources of air leaks.
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Hose barbs
To connect a hose barb to a Mercury outboard fuel line, you will need a hose and a female hose connector with a 3/8 inch rubber hose barb. The hose barb is used to connect the fuel line to the engine harness.
Firstly, locate the engine harness. This is where you will connect the hose between the two hose barbs. The engine harness is connected to the kill switch. The black wire with a yellow stripe goes to the kill switch, and the black and black/yellow wires from the key will tie into the engine's black and black/yellow wires before the kill switch.
Next, take your hose and connect it to the two hose barbs on the engine harness. Ensure that the hose is secure and will not leak.
Once the hose is connected, fill it with oil. It is important to note that you will also need to block off the port where the check valve is located, as it may send raw fuel out when the engine is running.
Finally, connect the fuel line to the engine if it is not already attached. If you have a Mercury FourStroke outboard that is 60hp or below, you will need to pump the primer bulb repeatedly until it is firm. This will only take a few pumps. Once the bulb is firm, the line is charged, and you can start the engine.
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Fuel line size
The fuel line size depends on the model of your Mercury outboard motor. For instance, the fuel line size for a 2007 Mercury 60hp 4-stroke outboard is 3/8", which is the standard size for all Mercury outboards with 40hp and above. The manual for a Johnson 120 2-stroke also specifies a 3/8" ID fuel hose. This size is also recommended for a 250 EFI outboard.
However, there is some discrepancy in the information provided for the 250 EFI outboard. One source mentions that the Mercury EFI 250 Official Service Manual specifies a minimum of 5/16", which is the size typically used for 50-90 horse outboards. This size is also mentioned by another source, who claims that 5/16" is what was installed at the factory.
For Mercury FourStroke outboards 60hp and below, the engine is equipped with a primer bulb, which is located in the fuel line between the fuel tank and the engine. The primer bulb is a rubber spheroid the size and shape of a chicken egg.
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Fuel pump issues
Firstly, it's a good idea to check your entire fuel system for clogs and blockages. If you're using a Mercury outboard, the fuel filter (VST filter) can clog over time, so it's worth checking that first. You should also check your battery, as fuel pump issues can sometimes be caused by a faulty battery.
If you have a Mercury FourStroke outboard that is 60hp or below, you can try manually priming the fuel system. First, connect the fuel line to the engine, then pump the primer bulb repeatedly until it is firm. This will only take a few pumps, and you can then start the engine. For outboards of 75hp or more, the onboard electric fuel pump will prime the system for you. Turn the key to the "run" position and wait for the beep, followed by the sound of the fuel pump running.
If you're still having issues, it's worth checking your fuel water separator and your inline fuel filter. If you have low hours on your engine, it could be a good idea to change your fuel water separator and sensor, as this can be affected by the way your boat is rigged.
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Frequently asked questions
The process of connecting the fuel line depends on the type of engine. For Mercury FourStroke outboards 60hp and below, first connect the fuel line to the engine, then pump the primer bulb repeatedly until it’s firm. For Mercury FourStroke outboards 75hp or greater, simply turn the key to the “run” position and wait for the onboard electric fuel pump to prime the fuel system for you.
Any engine that is above 115 HP requires you to use a 3/8" fuel line. Most smaller outboards have fittings or quick connects set for a 5/16" hose, which is considered the standard hose for smaller engines.
The Mercury Fuel Line Assembly from T-H Marine is a durable and efficient solution for connecting your fuel tank to the engine. It is EPA approved and comes with a universal primer bulb and stainless steel clamps for added convenience and security.
When connecting the fuel line to the engine, ensure that the connection is tight and not loose. A loose connection will cause an air leak, leading to problems such as the engine losing prime and running roughly.
