1996 9.9 Four stroke fuel pump problem

[rcb130]

I have a 1996 Evinrude four stroke Model E10FEXEDR, S/N G04015605. Took the fuel pump apart to install rebuild kit. Check valves and springs popped out. I check valve disc no where to be found. Does anyone know order of assembly for the check valves, springs and discs? I can find nothing in factory service manual.
Does anyone have a an extra used one for sale? How do check valves, retainers, and springs fit together?
Thanks in advance for any and all help
rcb130

 

[rcb130]

Thoughts anyone? Racerone, what is your advice, you seem to be on top of this stuff?

 

[racerone]

I would make a disc if the vacuum cleaner could not find it.------Was the fuel pump acting up ?-----What was the motor doing / not doing ?-----Failing all that I would simply take a pump of one of the other orphan motors I have like that

 

[rcb130]

Motor would not take throttle under load. Would idle all day with muffs. compression is 150, 145. Had a lot of gas in crankcase. T'stat tested good in a pot of hot water. Diaphragm had small tear and what looks like a pin hole. I do not have an orphan motor to rob a pump from. How do I go about making a disc?
Thanks
rcb130

 

[rcb130]

Motor would not take throttle under load. Would idle all day with muffs. compression is 150, 145. Had a lot of gas in crankcase. T'stat tested good in a pot of hot water. Diaphragm had small tear and what looks like a pin hole. I do not have an orphan motor to rob a pump from. How do I go about making a disc?
Thanks
rcb130

 

[rcb130]

Racerone,
How do I go about making a disc? What material to use?
rcb130

 

[rcb130]

racerone, please respond to above post #6

 

[aquamundi]

Hi I have just dismantled my fuel pump for 9.9 evinrude 4 stroke and found the valves dislodged. they consisted of disc, spring and a small ring lock plate. The disc appears to be made of s/steel with a soft black coating on one side. The coating I presume is to make the seal more effective. The disc goes black side down in the valve location followed by the sping then the small locking ring with the tags facing up. These locking tabs are supposed to hold the spring in place but I found they would not engage and the valve kept springing out. What I did to hold them in was to locate the small locking ring and the used a model makers small soldering iron to melt a few tags over the plate to firmly hold the assembly togther. Be careful not to overdo the melting. as for the disc I'm sure any wafer thin s/s metal without the coating would do.

 

[rcb130]

aquamundi,
Thanks for the tip. I wound up replacing my pump with a used one.

 

[PhrozeN_FisH]

I know this is an older post, but thought I would share something I did last fall. After finding out that OMC had discontinued the fuel pump for the 4 stroke engine I started thinking about how to save these motors from the scrap yard. After checking the dimensions of the 2 stroke and 4 stroke fuel pumps I found they were the same size.

Here is a link showing how I converted the fuel pump and a short video of it running after the conversion. Hopefully, this will help save a few motors from the scrap heap.

https://drive.google.com/open?id=0B0...S1JVG10OG1ET2s

https://drive.google.com/open?id=0B0...jdpMU54X2dkaUE

 

[irv9990]

I also have had to modify a 1996 evinrude fuel pump. when I disassembled fuel pump I found the retainer clips that held the check valves would no longer stay in. I went to Lowes and purchased 2 external tooth lockwashers about the same size as the retainer clips and they pushed in tightly and that was 2 years ago. No more problem.