Typical big Corp BS ( Mercury ) they wont admit the had a problem, but you can buy a kit from them to rectify the issue , the key to doing this yourself is to get all the correct components if your replacing the EFI pump and pypass regulator lines fittings ect.

Interesting read, been doing most of the suggestions already, looks like I'll have to start trailering the 15 miles for the only non ethanol station in town

You can get them from several places like CP. http://www.cpperformance.com/c-500-f...s-returns.aspx

This is how my outboard is setup. A lot of racers do this, because they want to run as little fuel as possible and make sure the main pump never cavitates. I have a low pressure Holley red pump that pulls from the main fuel tank and feeds a gallon (+/-) size aluminum canister. Then my high pressure Bosch pump pull from the bottom of this surge tank and feeds the motor. The return line goes into the top of the surge tank with a second "vent" line that goes back to the main tank.

I also have a buddy that recently put one of Aeromotive's submersible pumps into a custom aluminum gas tank (again an outboard setup) Came out very trick, but it wasn't cheap. I want to say the pump was about a grand!!!

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That's cool,guess my idea wasn't very original but it works at least

Will add about the Gen II cool fuel system - It is very important to apply or reapply a coating of Thermal grease on all of the retainer bracket inside surfaces where it contacts the cooler and the high pressure fuel pump. Many people who change the fuel pump forget to do this or over time the thermal grease just wears off in which can add in vapor lock issues, so one more thing added to the mix that can help against vapor lock. Not saying it will completely cure it but one of these little things that will help against it. They all add up.

Thanks for the info

BUP
Been a couple years since your comment here, but i just read it reading up on vapor lock. Well, i quess i will pull the covers to the pumps and put that white grease back on. I wasn't sure what it was and if needed so i cleaned it off on both motors while they were out.

thanks for all the time you put in. Experience and knowledge passed on saves many many headaches for those of us that have some experience, but yet with sooooo many tricks of the trade to learn.

Use this - it helps but not a 100 % cure. This is from and OEM procedure for the bracket and ignition components to transfer heat. Many do not use and it does help against VL but again not a cure all.

Every 3 or so years, it is wise to remove bracket - clean it up 100 % and reinstall the heat transfer compound.

Read the script what and why it is used in link below..

https://www.marinepowerservice.com/B...roductID=39117

The link has the old Merc part number listed as jt has been superseded to a 92-8M0082339

use heat transfer compound on inner side of bracket number 13 in the link below,

http://www.marineengine.com/parts/me...nd-fuel-cooler