How to Repair a Leaking Male Outboard Fuel Hose Connection
Fuel line leaks are dangerous at best and disastrous at worst--a boater faces the mariner's worst nightmare, a fire at sea, or an explosion. Quick and accurate troubleshooting is required to prevent either. As with any other troubleshooting situation, you must prevent the situation from worsening, evaluate the causative factors and take the appropriate remedial action. The construction of marine fuel lines is such that, should a leak occur in a fuel line, there are only two potential causes.
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Instructions
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Turn off the fuel supply to the engine. This will minimize the amount of fuel going to the site of the leak.
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2
Examine the hose. Determine if the leak is coming from a crack, cut or slit in the fuel line. If it appears that the hose has been damaged, set a plastic drip tray under the leak. Unscrew the quick connect at the "motor" end of the old fuel line. Screw the quick connect of the new fuel line in place. Trace the old fuel line to the fuel tank. Remove the quick connect for the old fuel line and replace it with the new.
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3
Examine the quick connects on the ends of the fuel hose. If the fuel is leaking from around a quick connect, set a plastic tray under the leaking connection. The O-rings that seal the quick connect are leaking. Unscrew the quick connect fitting and allow the fuel in the line to drain into the tray.
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Remove the O-rings in the quick connector. Seat the new O-rings in the female part of the quick connector. Pour the fuel from the plastic drip tray back into the fuel tank.
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