Fuel Pump – Fits Johnson Evinrude 6-235 HP Outboards (Replaces 438559)

Fuel Pump – Fits Johnson Evinrude 6-235 HP Outboards (Replaces 438559)

This mechanical fuel pump assembly is designed as a direct replacement for Johnson and Evinrude (OMC) two-stroke outboard engines ranging from 6 HP to 235 HP, manufactured between 1968 and 2001. It is compatible with a wide array of models, including various V4 and V6 crossflow and looper engines that require a mechanical, pulse-operated fuel pump.

This unit directly replaces Johnson/Evinrude OEM part numbers 438559, 0438559, 388555, 433390, 398385, 398678, 382843, 395712, 381600, 382872, 395718, 383765, 385784, 395107, 394716, 393648, and 765591.

• Installation Method: Direct replacement for a straightforward installation.
• Fuel Compatibility: Designed for use with gasoline and can be used with either premix fuel or oil injection systems.
• Versatile Use: This pump can be used to replace a VRO pump when converting an engine to a premix fuel system. Note that some V6 engines may require two pumps.

Part Number Cross-Reference

Use this table to confirm equivalent part numbers. This pump is a direct replacement for the following OEM parts.

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 (Replaces OEM Part 438559)
• Note: Gasket, fuel filter, and clip are included in some retail packages but not all. Please verify the product images to confirm the contents of your specific purchase.

Installation Guide

1. Safety First: Shut off the fuel supply at the tank and disconnect the battery terminals.
2. Locate the Pump: Find the existing fuel pump on the side of the engine block.
3. Prepare for Spills: Place an absorbent rag or towel beneath the pump to catch any gasoline that may spill.
4. Disconnect Lines: Carefully loosen the clamps and disconnect the inlet, outlet, and pulse port fuel lines from the pump.
5. Remove Old Pump: Unscrew the mounting bolts that secure the pump to the engine crankcase.
6. Clean Surface: Thoroughly clean the mounting surface on the engine, removing any old gasket material or sealant.
7. Position New Pump: If a new gasket is provided, place it onto the engine block before positioning the new pump.
8. Secure Pump: Align the new pump and tighten the mounting bolts evenly and securely. Do not overtighten.
9. Reconnect Lines: Re-attach the fuel lines to the correct barbed fittings and secure the clamps.
10. Prime System: Reconnect the battery. Use the primer bulb on the fuel line to pump fuel into the new pump until firm.
11. Check for Leaks: Start the engine and carefully inspect the pump and all connections for any signs of fuel leaks.

Troubleshooting & FAQ

How do I confirm this fits my engine?
First, check if your original pump has the part number 438559 or any of the other superseded numbers listed in our cross-reference table. Second, verify your engine's horsepower and year falls within the ranges listed in the compatible models chart. When in doubt, consult your service manual or a professional mechanic.

Can I use this to replace a VRO pump?
Yes, this non-oiling mechanical pump is commonly used to replace the original VRO (Variable Ratio Oiling) pump when converting an engine to run on a premixed fuel/oil mixture. This conversion is a common modification on older Johnson and Evinrude outboards.

My V6 engine has two fuel pumps. Do I need to replace both?
Yes, many V6 Crossflow and Looper engines were designed with two fuel pumps. It is highly recommended to replace both pumps at the same time to ensure balanced fuel delivery and prevent issues caused by one new pump working with one old, weak pump.

What are common signs of a failing fuel pump?
A weak or failing fuel pump may cause the engine to have trouble starting, bog down or lose power at higher speeds, sputter, or stall unexpectedly. These symptoms occur because the carburetor is not receiving a consistent supply of fuel.

OEM vs. Aftermarket?
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.

How fast do you ship and how much does it cost?
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.

What is your warranty and return policy?
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.