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

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

This aftermarket fuel pump is designed for a wide range of Johnson/Evinrude 6-235 HP, 2-stroke and 4-stroke outboard engines manufactured between 1968 and 2001. It serves as a reliable replacement for maintaining proper fuel delivery and engine performance.

This component directly replaces Johnson/Evinrude OEM part numbers: 438559, 433390, 398385, 395712, 385784, 398678, 395718, 395107, 394716, 393648, 388555, 383765, 382872, 382843, 381600, 765591, and 5005462.

• Installation: External pulse-driven mechanical pump
• Fuel Compatibility: Designed for use with standard gasoline/petrol.
• Connection: Features a 3-port design (Inlet, Outlet, Pulse).

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 (438559)
• 1 x Mounting Gasket (0303615) - Note: Gasket inclusion varies by supplier and is not guaranteed.

Installation Guide

Follow these general steps to replace your external fuel pump. Professional installation is recommended.

1. Safety First: Disconnect the negative battery terminal to prevent electrical shorts.
2. Locate Pump: Find the existing fuel pump on the engine block.
3. Prepare for Spillage: Place a rag or container beneath the fuel pump to catch any spilled fuel.
4. Disconnect Lines: Carefully disconnect the inlet, outlet, and pulse fuel lines from the pump. Note their positions.
5. Remove Old Pump: Unbolt the mounting bolts holding the pump in place and remove the pump and old gasket.
6. Clean Surface: Thoroughly clean the mounting surface on the engine block to ensure a good seal.
7. Install New Pump: Place the new gasket on the engine block, then position the new fuel pump over it.
8. Secure Pump: Tighten the mounting bolts evenly and securely. Do not overtighten.
9. Reconnect Lines: Re-attach the inlet, outlet, and pulse lines to their correct ports on the new pump.
10. Final Checks: Reconnect the battery. Prime the fuel system using the primer bulb until firm. Check all connections for leaks before starting the engine.

Troubleshooting & FAQ

Q: How do I confirm this fuel pump will fit my engine?
A: The best way to ensure compatibility is to match your engine's original part number to one of the numbers listed in our description (438559, 433390, 398385, etc.). Additionally, verify your engine's model, HP, and year fall within the ranges specified in the "Compatible Engine Models" table.

Q: What are common signs of a failing fuel pump?
A: Symptoms of a bad or failing fuel pump include difficulty starting, engine bogging down at high speeds, hesitation or sputtering during acceleration, and inconsistent engine performance.

Q: Is the mounting gasket included with the pump?
A: Package contents can vary. While a mounting gasket is often included, we cannot guarantee its presence in every package. Please be prepared to reuse your old gasket if it is in good condition or purchase one separately if needed.

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 Fitment: Before purchasing, please verify that the product images and specifications match your existing part. Even if your model is listed, discrepancies can exist. Do not proceed if the parts do not match.
• Aftermarket Part: This product is a high-quality aftermarket replacement part and is not an original equipment manufacturer (OEM) component.
• Professional Installation: Professional installation is highly recommended to ensure safety, proper function, and optimal engine performance.

Why Choose JLM MARINE?

• Quality Assured: As a trusted manufacturer for over 20 years, we supply top marine brands globally and adhere to strict quality control standards.
• Fast Global Shipping: We offer free, reliable delivery worldwide, with most orders arriving within 5–15 days.
• Direct from Manufacturer: By selling directly to you, we eliminate middlemen, offering competitive pricing without compromising on quality.