Fuel Pump – Fits Johnson/Evinrude 25-140 HP Outboards (Replaces 438559)

Fuel Pump – Fits Johnson/Evinrude 25-140 HP Outboards (Replaces 438559)

This fuel pump assembly is designed for a wide range of Johnson and Evinrude outboard motors from 25 to 140 HP, including both 2-stroke and 4-stroke engines manufactured between 1968 and 2001. It is compatible with both Crossflow and Looper engine models, serving as a reliable replacement for many common applications.

This unit is a direct replacement for Johnson/Evinrude OEM part numbers 438559, 433390, 398385, 395712, 385784, 398678, 395718, 395107, 394716, 393648, 388555, 383765, 382872, 382843, 381600, 765591, and 5005462.

• Installation Style: External pulse-driven mechanical pump
• Connection: Features 3 ports (Inlet, Outlet, Pulse) for straightforward installation
• Fuel Compatibility: Designed for use with standard Gasoline/Petrol fuel

Part Number Cross-Reference

This fuel pump assembly (equivalent to 438559) supersedes and replaces the following Johnson/Evinrude OEM part numbers.

Compatible Engine Models

Confirm your engine model/year in the table below. For Johnson/Evinrude owners, here’s a guide to help you identify your engine’s serial/model: Johnson/Evinrude Serial Number Guide.

Technical Specifications

Package Contents

• 1 x Fuel Pump Assembly (Replaces 438559)
• 1 x Mounting Gasket (0303615) - Note: This gasket is included in some packages but not all. Please verify if it is critical for your installation.

Explosion Diagram

Installation Guide

1. Disconnect the negative battery cable to prevent accidental starting.
2. Shut off the fuel supply valve and place a rag under the existing pump to catch any spills.
3. Carefully note the position of the three hoses (fuel inlet, fuel outlet, and engine pulse) on the old pump.
4. Loosen the hose clamps and disconnect the three hoses.
5. Remove the mounting bolts that secure the old fuel pump to the engine block.
6. Clean the mounting surface on the engine, ensuring it is free of old gasket material and debris.
7. Place the new gasket onto the engine block, aligning it with the mounting holes.
8. Position the new fuel pump and secure it with the mounting bolts. Do not overtighten.
9. Reconnect the fuel inlet, outlet, and pulse hoses to the correct ports on the new pump.
10. Securely tighten all hose clamps.
11. Open the fuel supply valve, reconnect the battery, and prime the fuel system using the primer bulb.
12. Carefully inspect for any fuel leaks before starting the engine.

Troubleshooting & FAQ

Q: How do I confirm this fits my Evinrude V4 engine?

A: First, check the compatibility table on this page to ensure your engine's model, horsepower, and year range are listed. Pay close attention to any notes; for example, some 90 HP and 115 HP V4 models from 1995-1996 require a specific 90-degree Crossflow engine design for this pump to fit.

Q: My original pump is part number 395712. Is this the correct replacement?

A: Yes. This fuel pump assembly is a direct aftermarket replacement for over a dozen OEM part numbers, including 395712. Please see the "Part Number Cross-Reference" section for a complete list.

Q: Can I use this pump to replace or bypass my VRO pump?

A: This fuel pump is a component used in some VRO "delete" or replacement kits. However, converting a VRO system requires a specific process to ensure your engine receives the correct fuel/oil mixture. We strongly recommend purchasing a complete VRO replacement kit that includes all necessary components and instructions rather than using this pump alone for that purpose.

Q: What are the symptoms of a failing fuel pump?

A: Common signs of a faulty fuel pump include the engine having trouble starting, bogging down at higher speeds, stalling, or surging unexpectedly. You might also notice fuel leaking from the pump body, which indicates a seal or diaphragm failure.

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.