Honda 90 fuel pump leak

wapiti · Posted: Sun May 08, 2011 11:18 am Post subject: Honda 90 fuel pump leak

I just took my Honda 90 for a tune-up to my local Honda dealer. They told me that when they started the engine they noticed leaks from both fuel pumps. After letting the motor sit for awhile they started it again and didn't see much leakage. The motor ran well. The cost to replace two fuel pumps is around $500.00. Honda does not provide kits for fuel pump repair. Would dry gaskets and seals be the problem? Should I replace the pumps ASAP or should I run the engine and check for fuel leaks?

Captains Cat · Posted: Sun May 08, 2011 3:27 pm Post subject:

If it doesn't appear to be a safety hazard, I'd run it for a few hours without the cowl on so you can watch it closely.

Oh, and keep a fire extinguisher handy. an "ABC" rated type that can put out fuel fires. Wink

Charlie

BrentB · Posted: Sun May 08, 2011 4:53 pm Post subject:

I dont have these OBs. Are they mechanical or electric pumps?
Could they tell if leaking from pumps or hose connectors?

wapiti · Posted: Mon May 09, 2011 11:13 pm Post subject:

Brent;
Not sure if the pumps are electric or mechanical, but the leak is definitely from the pumps not the hose connections. Wouldn't have to replace the pumps if the leaks came from the connections. Is leakage from a Honda 90 fuel pump a common occurrence?
Wapiti

blackfish · Posted: Tue May 10, 2011 12:08 am Post subject:

not sure what year your honda is
but the bf90a have two mechanical fuel pumps
strange that both pumps would start leaking
have you pulled the pumps apart
there's not much to them
I'm looking at the fuel pumps online and I just don't see $500. dollars
but i could be looking at the wrong motor
what year is your honda?

starcrafttom · Posted: Tue May 10, 2011 1:50 am Post subject:

Iam sure most of the $500 is for labor. I bet this job books out at 3 to 5 hours to remove, replace and set the fuel pumps.

wapiti · Posted: Tue May 10, 2011 9:56 am Post subject:

Blackfish;
My Honda 90 is a 1996. The Dealer quoted me $186 per pump and labor to install for a rough total of $500.00. Does this may sense?
wapiti

BrentB · Posted: Tue May 10, 2011 10:23 am Post subject:

What did the dealer recommend?

blackfish · Posted: Tue May 10, 2011 10:38 am Post subject:

boat.net lists each pump at 83.30 plus a 1.74 o-ring
I guess you might replace the fuel lines aswell
+shipping +tax and labour
I googled this and could not find anything about leaking honda fuel pumps also searched the marine engine forums.
Let us know how you make out

wapiti · Posted: Tue May 10, 2011 8:09 pm Post subject:

The dealer recommended replacement of the fuel pumps if the leaks persist. But at $186 per pump versus $83, I can see why he would like to replace them. How difficult is replacement and synchronizing of these fuel pumps?
Thanks!
wapiti

BrentB · Posted: Tue May 10, 2011 9:31 pm Post subject:

do you have a shop manual?

blackfish · Posted: Tue May 10, 2011 9:48 pm Post subject:

www.boats.net
this is the place I have got parts for my honda
you need to register to get shipping rates
check it out , don't forget these prices are american so the standard shipping etc applies
like I said I've got stuff sent up never had to pay extra at the border
some times I got way with no hst it,s all honda parts no aftermarket

another good site is www.marineengine.com find your way to the honda out board forum there are a couple of honda mechanics that post all the time(honda dude and justintime) very helpful guys

http://www.marineengine.com/boat-forum/forumdisplay.php?21-Honda-Outboard-Forum

as for replacing the fuel pumps
the pump is held in place with two bolts thats about it
remove the fuel lines and your done (label the fuel lines there are six of them)
i've had the top one off before but not the bottom I think because its a bit harder to get at

as far as I know you don't synchronize pumps
are you thinking of the carbs maybe?

I still find it strange that your pumps are leaking
can you see where on the pump the leak is coming from
maybe you could just tighten the four screws on the front

wapiti · Posted: Thu May 12, 2011 7:11 pm Post subject:

Blackfish;
Thanks for the most helpful information and suggestions. I was going to order the fuel pumps and install them myself, but after starting my Honda 90 and running it for over 10 minutes, I found no signs of leakage around the fuel pumps. The dealer definitely told me that there was leakage from the pumps???? Will continue to monitor, but replacement of the pumps is now on hold.
Thanks again!
Wapiti

srbaum · Posted: Thu May 12, 2011 8:00 pm Post subject: Leaking fuel pumps

My 90 hp Honda engine started running rough several days ago, so I changed the Racor filter. After the filter change, the engine ran okay for a few minutes and I had to squeeze the primer bulb to make the engine run smooth. I removed both fuel pumps and the in-line fuel filter below them and it took about 15 minutes to get everything removed. The filter was harder to remove than the pumps, as it is located in a bracket below the lower cowling under the linkage. I bench tested the pumps with a vacuum gauge and found that the top pump was not holding a vacuum when depressing the plunger.
I am ordering the pump on line and purchased the replacement fuel filter from Autozone for $3.69 (their part number FF3418). The installation will take about the same time as the removal...

blackfish · Posted: Thu May 12, 2011 9:12 pm Post subject:

boy you're right about that fuel filter it's a real bear to get in or out