2004 Johnson 4-stroke Outboards Fuel Pressure Inspection
Follow these steps to inspect fuel pressure in your 2004 Johnson SR 4-stroke 40 or 50HP outboard:
- Relieve fuel pressure in the fuel feed line.
- Connect special tools (pressure gauge, pressure hose & pressure joint) between the fuel feed hose and 3-way joint pipe. Clamp the hose securely to ensure no leaks occur during checking.
- Special Tools:
- 5000902: Pressure gauge
- 5000900 or 350931: Fuel Pressure Adapter
- Squeeze the fuel primer bulb until you feel resistance. Turn the ignition switch "ON" for 3 seconds, then turn it "OFF". Repeat this procedure 3 or 4 times to pressurize the fuel system, then check fuel pressure.
- Measure fuel pressure in the line at cranking or idle speed operation.
- Fuel pressure: Approx. 240 kPa (2.4kg/cm2, 34.1 psi)
- Stop the engine and wait 5 minutes. There may be a slight pressure drop initially, but it should stabilize and hold for 5 minutes.
- Place a container under the joint to catch fuel.
- Cover the joint with a rag and loosen the joint nut slowly to gradually release fuel pressure.
- After checking fuel pressure, remove the fuel pressure gauge.
- Reconnect the fuel line.
- With the engine not running and the ignition switch "ON", check the fuel system for leaks.
CAUTION: A small amount of fuel may be released when the fuel feed hose is disconnected. Place a container under the fuel feed hose or 3-way pipe with a shop cloth to catch the released fuel. Dispose of the fuel-soaked cloth in an approved container.
CAUTION: As the fuel feed line is still under high fuel pressure, make sure to release fuel pressure according to the following procedures:
