Fuel connection mod

[Mark42]

The 1985 Force 85hp had no disconnect on the fuel line. The fuel line passes through a plastic fitting that also holds the shift and throttle cables, and is clamped to the fuel filter.

I recently added a permanent fuel tank and new Acol 5/16" marine fuel lines. Turns out the fuel line is way too thick to pass through the hole originally intended for the fuel line.

So I decided to add a quick disconnect like my Evinrude has. All that is needed is:

A standard brass male fitting:

A female connector:

A 5/16" 1/4 hose barb:

and a 1/4" NPT 90 elbow:

The plan is to drill a 1/2" hole in the lower motor cowl and insert the male fuel connector. Thread on the 90 elbow from the inside. As they tighten, the cowl is compressed between the two (a few stainless 1/2" washers will take up any slack to make it tight). The the hose barb screws into the elbow. A length of 5/16" fuel hose connects the motor to the hose barb, and the female connector makes the connection to the fuel line.

If it ever stops raining, I'll take some pictures of the real thing.

 

[john from md]

Re: Fuel connection mod

Mark,

I recently installed USCG fireproof alcohol resistant fuel line to my 85hp Force. I had to open the plastic insert up using a Dremel sanding drum. It worked out well.

John

 

[Mark42]

Re: Fuel connection mod

Mark,

I recently installed USCG fireproof alcohol resistant fuel line to my 85hp Force. I had to open the plastic insert up using a Dremel sanding drum. It worked out well.

John

I started to open up the plastic fitting too, but I soon realized I would have to cut away the center "rib" separating the fuel line and the control cables because the 5/16" hose I have is FAT, much fatter than the 5/16" hose I used on the MFG. Not sure why its so thick, but decided against cutting out the rib and having the cables rub the hose.

 

[Mark42]

Re: Fuel connection mod

Here are the photos the finished mod.

This one came out a little fuzzy, but it shows the elbow on the inside.

I went with the Johnson connection because I know I can find this at any Walmart if I need one in an emergency. These parts I had on hand already, except for the elbow which I got from Lowes. Will pick up another female connector next time I'm in Walmart.

 

[harkawy]

Re: Fuel connection mod

Mark42, your pictures made it look like a breeze to install. But once again, ol' man Murphy popped up his evil head. I purchased the 50052342 1/4" NPT Male Tank Connector and the Female Barb Fuel Line connectors made by Seasense. I found what looked to be the same spot on my cowling as you did on yours and drilled a very nice 1/2" hole. I used a stainless washer and rubber gasket on the outside and inside and attempted to mount the 90 degree elbow. Hello, Mr. Murphy, you pain in the posterior. The elbow won't fit because the linkage to the tranny is in the way.

Soooo........

To find a better location....

The port side still has the linkages coming through, the starboard side has the battery wires coming through. But dead center, below the hook for the top cowl is a perfect area to mount the unit. It is almost 2" sq. with nothing in the way. Looks like I'll be working on the boat on Sunday as the Missus, says that Saturday is the fourth...."You will Bar B Que early. Your hands will be clean and without crud under your fingernails."

I'm looking on taking the boat out on Thursday....

 

[harkawy]

Re: Fuel connection mod

The weather cooled down a bit so I decided to work on the boat again. It took me about 20 minutes to complete the job. Attached are some pictures.

 

[Mark42]

Re: Fuel connection mod

It looks like the Merc version of Force is different from the Chrysler version. I have an extra 1/2" hole in the bottom of the cowl. Though there was clearance for the fitting to point straight down, but after drilling the hole and tilting the motor, the Johnson male connector hits the transom bracket. So it sticks out the side.

Yours looks good!