How to Change a Fuel Filter on a BRP 90 HP Outboard

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"BRP," also known as Bombardier Recreational Products, Inc., bought Outboard Motor Corporation in 2001. OMC included two outboard motor brands, Johnson and Evinrude. One, Johnson, has been inactive for several years. The other, Evinrude, is still in production, powering both recreational and public service vessels on waterways around the world. In its current form, the Evinrude 90-horsepower motor has two fuel filters -- one for its low-pressure pump and one serving its high-pressure pump.

Things You'll Need

  • Pre-wired paper tags
  • Locking pliers
  • Spring-type hose clamps
  • Shop rags
  • Replacement fuel hoses
  • Low-pressure compressed air
  • New low-pressure filter
  • 1/2-inch socket
  • Remove the black negative cable from your boat's battery using a 5/16-inch wrench, before removing the low-pressure filter, to avoid potential fires.

  • Locate the low-pressure fuel filter, a nylon canister secured by a clamp bracket on the front, port side of the powerhead, directly below the intake manifold. Tag the fuel hoses on the top and side of the filter, using pre-wired paper tags, and find the arrow on the filter canister that indicates the fuel line running to the fuel vapor separator. Normally, this is the line on the side of the filter; the top line is coming from the low-pressure fuel pump.

  • Squeeze the tabs on the spring-type hose clamps with a pair of locking pliers and slide the clamps past the raised nipple on the fuel fitting. Check the clamps for corrosion or worn springs as you work with them and replace those that look suspicious. Slip a shop rag below the filter and pull the hoses from the fittings, allowing fuel to drain back into the hose as much as possible. Inspect the hoses and replace those that are brittle or worn.

  • Pry the canister from the bracket on the powerhead with your hands. Remove the filter and, unless the filter is damaged, clean it with denatured alcohol. Blow-dry the filter with low-pressure compressed air. Return the new or newly cleaned filter to the bracket on the powerhead and reattach the hoses, according to the information on the tags. Reposition the hose clamps to secure the hoses to the filter. Prime the low-pressure fuel system by squeezing the motor's priming bulb until it is hard to the touch and inspect the system for leaks. Reconnect the negative cable to the battery.

  • Remove the high-pressure fuel pump's 15-amp fuse from its fuse holder. Start the engine and let it run until it it stalls out. Crank the engine three times, to ensure fuel system pressure is depleted. Remove the negative cable from the battery once more. Follow the fuel line that serves the fuel rail back to the filter canister on the middle, port side of the powerhead, just below the manifold. Tag the fuel lines -- even though the filter has the words "In" and "Out" embossed on the filter -- to avoid later confusion and remove them from the pump. Unbolt the filter from the powerhead with a 1/2-inch socket and drain any residual fuel from the filter.

  • Bolt the filter back into place. Reconnect the hoses according to the information on the tags. Return the 15-amp fuse to its holder and pressurize the system by cranking the engine three times, without starting it. Check the fuel system for leaks once more.

Tips & Warnings

  • Disconnect the negative cable of your battery before performing any maintenance work on your outboard motor, to prevent electrical shock, fire or accidental starting. Remove the nut from the negative post with a 5/16-inch box-end wrench. Lift the cable from your battery, move it outside of the battery box and close the lid of the battery box.

References

  • "Evinrude Repair Manual -- 2.5 to 250 HP Models, 2002-2007"; Seloc Marine; 2007
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