Fuel Pump – Fits Honda Marine 25-90 HP 4-Stroke (Replaces 16700-ZV5-003, 16700-ZW1-004)

Fuel Pump – Fits Honda Marine 25-90 HP 4-Stroke (Replaces 16700-ZV5-003, 16700-ZW1-004)

This fuel pump assembly is designed for a wide range of Honda Marine 4-stroke outboard engines from 25 HP to 90 HP, specifically covering models manufactured between 1997 and 2007. It serves as a direct-fit replacement for the BF25, BF30, BF35, BF40, BF45, BF50, BF75, and BF90 series.

As a direct replacement, this assembly cross-references Honda OEM part numbers 16700-ZV5-003 and 16700-ZW1-004, ensuring compatibility and seamless integration with your existing fuel system.

• Installation: Direct bolt-on replacement for easy setup.
• Compatibility: Designed for gasoline-fueled Honda BF series 4-stroke outboards.
• Connection: Features standard fuel line barb connectors for a secure fit.

Part Number Cross-Reference

Use this table to confirm equivalent part numbers across OEM and aftermarket brands.

Compatible Engine Models

Confirm your engine model/year in the table below.

Technical Specifications

Package Contents

Package contents may vary slightly by manufacturer. A typical kit includes:

• 1 x Fuel Pump Assembly (replaces 16700-ZV5-003 / 16700-ZW1-004)
• Note: Some aftermarket kits may also include the following accessories:
• 3 x Clamps / Clips (replaces 90603-ZV4-000)
• 1 x O-Ring (replaces 91306-921-000)

Installation Guide

1. Safety First: Before starting, disconnect the battery and work in a well-ventilated area away from sparks or open flames.
2. Locate the Pump: Identify the fuel pump on your outboard engine.
3. Relieve Fuel Pressure: Safely relieve any pressure in the fuel system to prevent spills.
4. Disconnect Lines: Carefully disconnect the fuel lines and electrical connectors from the old pump. Have a rag ready to catch any residual fuel.
5. Remove Old Pump: Unbolt and remove the old fuel pump assembly from the engine block.
6. Install New Pump: Mount the new fuel pump assembly, ensuring it is seated correctly. Tighten the mounting bolts to the manufacturer's specified torque.
7. Reconnect Lines: Securely reattach the fuel lines and electrical connectors to the new pump.
8. Prime the System: Prime the fuel system according to your engine’s service manual to fill the new pump and lines with fuel.
9. Check for Leaks: Reconnect the battery. Pressurize the system and meticulously check all connections for any signs of fuel leaks.
10. Test the Engine: Start the engine and let it run, observing its performance to ensure the pump is functioning correctly.

Troubleshooting & FAQ

Q: How do I confirm this fits my engine?
A: The most reliable method is to match your existing OEM part number to our cross-reference list (16700-ZV5-003, 16700-ZW1-004). Additionally, consult the detailed "Compatible Engine Models" table to verify your specific Honda model and year range.

Q: My Honda is a 2007 or newer BF40D/BF50D. Will this fit?
A: No. As noted in the compatibility table, newer models (2007+) like the BF40D and BF50D use an updated fuel pump, OEM part number 16700-ZZ5-003. This pump is not compatible with those engines.

Q: What are common signs of a failing fuel pump?
A: Symptoms of a faulty fuel pump include engine sputtering, hesitation or loss of power at high speeds, difficulty starting, or complete failure to start. The engine may also run rough or stall intermittently.

Q: OEM vs. Aftermarket?
A: This listing is an aftermarket replacement part (not an OEM component). We build to OEM specifications using comparable-grade materials. Production is done in an ISO9002-certified facility, and each batch is inspected for consistent performance.

Q: How fast do you ship and how much does it cost?
A: We offer fast global shipping—typically 5–15 days worldwide—and standard shipping is free. Expedited options are available at checkout depending on your location.

Q: What is your warranty and return policy?
A: This product includes a 1-year warranty against manufacturing defects under normal use. If something goes wrong, contact our support team with your order details. Returns are accepted within our standard return window (unused & in original condition); please see our policy page or reach out for instructions.

Important Notes

• Verify that the product images and specifications match your original part. If discrepancies exist—even if your model is listed—do not proceed with the purchase.
• This product is an aftermarket replacement part and is not an OEM component.
• Professional installation is recommended to ensure safety and optimal performance.

Why Choose JLM MARINE?

• Quality Assured: As a trusted manufacturer for over 20 years, we supply top marine brands globally.
• Fast Global Shipping: Free delivery worldwide in 5–15 days.
• Direct from Manufacturer: Competitive pricing without compromising quality.