The variable-ratio oil injector on the Johnson 60-horsepower, two-stroke outboard motor is triggered by the fuel pump's pulse hose, so that the demand for fuel is matched exactly by the supplied amount of oil. Because the motor will suffer immediate and fatal damage unless the VRO is connected, removing the VRO from the fuel pump is part of fuel pump removal and replacement procedure. Tagging the fuel, pulse and oil lines, to ensure they are reconnected properly, simplifies the process.
Disconnecting the VRO and Fuel Pump
Cut the plastic tie that secures the fuel outlet hose to the top of the pump assembly, using a utility knife. Push the hose from the pump fitting. Tag the hose with a paper tag on which you have written the location from where the hose has been removed.
Squeeze the tabs on the spring clamp that holds the pulse line that runs from the powerhead to the bottom-front of the pump housing, using a pair of pliers. Slide the clamp back onto the hose, then push the hose from the pump's fitting. Tag the hose with the location from where it has been removed.
Compress the spring clamp that holds the fuel inlet line to the bottom-center of the pump. Slide the clamp back onto the hose and push the hose from the pump fitting. Tag the hose with the location from where it has been removed.
Locate the oil inlet line at the bottom-center of the pump. Compress the spring clamp, slide the clamp back onto the hose and push the hose from the fitting on the pump. Tag the hose with the location from where it has been removed.
Release the pump wiring connector from the wire loom retainer. Disengage the pump wiring connector from the wiring harness. Loosen the three screws, located on the back side of the bracket, with a screwdriver. Remove the pump from the manifold bracket.
Reconnecting the VRO and Fuel Pump
Place the pump in the manifold bracket. Thread the retainer screws into the bores on the pump and tighten the screws to between 18 and 24 inch-pounds with a torque driver. Push the pump wiring connector into the wiring harness and work the connector back into the wire retainer.
Push the fuel inlet and pulse hoses onto the fittings indicated on their paper tags. Squeeze the spring connector of the fuel inlet hose and slide it over the nipple on the pump fitting. Compress the spring fitting of the pulse line and fit the hose back onto the bottom of the pump, farthest from the wiring.
Push the fuel outlet hose onto the fitting on top of the pump. Secure the fitting with new plastic ties. Squeeze the spring connector of the oil inlet hose and slide it over the nipple on the pump fitting.
Items you will need
- Utility knife
- Paper tags
- Torque driver
- Plastic wire ties
- Never pull a fuel or oil line from a fitting; rather, push the end of the hose from the fitting. This avoids the damage to the hose as it's pulled over the end of the fitting's nipple.
- Disconnect the negative cable of your battery before performing any maintenance work on your outboard motor, to prevent electrical shock or accidental starting. Remove the nut from the negative post with a 5/16-inch box-end wrench. Lift the cable from the battery, move it outside of the battery box and close the lid of the battery box. After the work is complete, reconnect the negative battery cable.
- "Johnson Outboard Repair Manual -- 2.5 to 250 HP Models, 2002-2007"; Seloc Marine; 2007