Outboard Fuel Line Issues

This page describes an outboard fuel-line starting problem where the engine usually started on the first pull, was not flooded, and would not reliably receive fuel through the squeeze bulb.

Initial checks

• The fuel bulb would not fill consistently.
• Fuel sometimes moved when the line was removed from the engine and opened with a screwdriver.
• Fittings appeared factory-tight.
• No air bubbles appeared when the hose was submerged and the bulb was squeezed.

The first replacement hose temporarily solved the starting issue. The outboard started on the first pull again after the fittings were reinstalled on the new hose with new clamps.

Recurring hose problem

About three weeks later, starting issues returned. The engine was not flooded, which pointed back to fuel delivery. After checking both ends of the hose, the tank end would not pass air. Cutting back the hose revealed a twisted internal plastic liner that was blocking flow.

A later replacement hose showed the same type of liner problem, with the thin plastic liner sticking out at both ends after the outer hose shrank. The source note then replaced the outboard fuel hose with automotive fuel hose and covered it with plastic wire loom to protect it from UV rays.

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