Gas / fuel leak help on a 1954 25hp Johnson RD-15

[crosbyman]

there is no combustion involved so the mix is fuel and oil already filtered in the glass bowl filter. no harm in playing safe on the return line but it may be overkill to refilter if you plan to recycle and burn it

if you don’t install a pump you are stuck having to empty the extra collector bottle instead of a nice return line to the tank. never forget to empty the bottle !!

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[oldlure]

I think I recall reading somewhere that you may need a vent for the collection bottle.

[crosbyman]

Most likely to prevent pressure build up or some form of safety overflow in the lake to keep fuel away from the bilge area 🙁 🙁

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[Tubs]

Your description of the parts used as well
as your pictures will be really helpful to
anyone else wanting to do this modification.
Nice job on both.
Tubs

A "Boathouse Repair" is one that done without having tools or the skills to do it properly.

[David Bartlett]

Excellent job. I may need to do this on my 1954 Johnson 25hp.

David Bartlett
Pine Tree Boating Club Chapter

"I don't fully understand everything I know!"

[jdean]

I went fishing out on the lake yesterday in my boat with this mod installed. I ran my motor for probably about 30-40 minutes, half of that idling getting out of the marina. After I got home, I was amazed that I collected about a quart of fuel! If you do this mod, make sure you have a large enough can to collect your fuel in. I was using a 1 gallon gas can, which might be too small if running around all day with a larger motor. I think this mod will pay for itself in the first couple of trips. Crazy!

[crosbyman]

install a pump… plug the air nipple keep the 2 line hose send the recovered juices back in the tank via the air hose keep the tank cap open while running .

no more fire hazard or pollution

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[jdean]

After thinking about it crosbyman, you convinced me. I decided that it would be best to install a fuel pump and just dump the gas directly back in the tank. Much better and safer than dealing with loose fuel tanks in the back in proximity to my trolling motor batteries, etc. That is an accident waiting to happen. I have ordered the parts and will report back after I have installed and tested them. Luckily I was able to find all OEM parts for the whole job for about $60. (That was a miracle.) I will report back with results and pictures when I have it all completed. Thanks again!

[crosbyman]

actually 90$ seems high all you need is a few feet of hose and a $25 pump. Of course OEM stuff costs more 🙁

see mod on a 10hp of course a side cover plate with mounting holes all ready to drill and tap are best way to go to mount a pump.

this one in the picture got me going crazy last summer with 5 bad pumps till I realized my pulse hole was not drilled in line with the back end of the pump 🙂 🙂

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• This reply was modified 3 years, 5 months ago by crosbyman.
• This reply was modified 3 years, 5 months ago by crosbyman.

[jdean]

Forgot to drill the hole for the fuel pump? Sounds like the time I spent an hour figuring out why my dishwasher wasn’t draining into my new garbage disposal. I forgot to punch the plug out! 🙂

The total for this mod was about $60, not $90. I looked at a lot of different fuel pumps. For 25hp+ motors, new OEM pumps were $90, Sierra about $75. The Chinese eBay & Amazon knock-off pumps were $12-15. Fearing being stuck in the middle of a lake at some point, regretting purchasing a $12 Chinese fuel pump, I decided to go for a nice-looking used OEM pump and an OEM re-build kit for it. With shipping, the fuel pump and the rebuild kit for it was about $35. I also purchased a 1959 Gale 25hp bypass cover, part 304646, that was set up for a fuel pump for $15 with shipping. As far as I understand, it should fit my RD-15. I could have made an aluminum plate like the one you pictured above, but this sounded easier. Then with hoses, a bypass cover gasket and capping off the intake nipple, we’re at $60. But… I do think this will be worth it.

This is the fuel pump I purchased.

Thanks for the encouragement!

I showed this mod to a neighbor with a 1959 35hp Evinrude Lark over the weekend, and he was excited to make similar modifications ASAP. 🙂

• This reply was modified 3 years, 5 months ago by jdean.
• This reply was modified 3 years, 5 months ago by jdean.

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