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-   General Q & A (https://www.offshoreonly.com/forums/general-q-20/)
-   -   Changing gear oil in mechanical fuel pump in 525EFI... (https://www.offshoreonly.com/forums/general-q/344365-changing-gear-oil-mechanical-fuel-pump-525efi.html)

t500hps 02-03-2017 12:06 PM
Originally Posted by VoodooRob (Post 4525125)
The stock set-up is a P.I.A. for sure. Merc wants you to maintain the fluid but doesn't give any easy way of actually doing it. Poor design. I remember a few years ago there were pictures posted on OSO of a brass drain and using a turkey baster to refill while the assembly is still mounted on the engine un-disturbed.
Wasn't my picture (cause I never took one) but this is basically what I did on a pair of 500EFI's. I've since sold the boat but when I had the pumps off I drilled/tapped into the lower SIDE of the pump to install a brass fitting below the fill. I could drain them without removal and refill using a little hose that was even smaller than the fill hole for air to escape. Was it easy....no, but ALOT easier than removing those dam things every year!!!

stimleck 02-03-2017 05:18 PM
us a turkey baster and suck it all out

pt austin pirate 02-03-2017 10:41 PM
drain plug fuel pump
 
Originally Posted by HyFive578 (Post 4525056)
Any chance you could post a picture? Would like to see where you drilled...
The late Jory of S.o.S marine in Granite Bay C.A. put a drain plug in my pump around 2009 works great, bottom drains out nicely, replace plug, and I use an pump oil can with Merc drive oil to fill from top plug very quick neat en easy, not sure how to post pics, but next time iam in boat I can give you measurements between plugs and from plug to bottom of houseing, if this will help.

Ballistic Beak 02-05-2017 05:16 PM
Here's where I placed my plug:

http://i531.photobucket.com/albums/d...ps1gltdmee.jpg

Ryan

Griff 02-06-2017 12:56 AM
Originally Posted by stimleck (Post 4525798)
us a turkey baster and suck it all out
That does not work well. Even with a thin tube to insert into the fill plug, you can only get about half the lube out.

HyFive578 02-06-2017 06:57 AM
1 Attachment(s)
Originally Posted by Ballistic Beak (Post 4526237)
Here's where I placed my plug:

http://i531.photobucket.com/albums/d...ps1gltdmee.jpg

Ryan
Thanks Ryan. I did mine in the exact same spot. Maybe a little hard to see because plug is black also, but here's where I ended up doing it.

[ATTACH=CONFIG]564478[/ATTACH]

F-2 Speedy 02-06-2017 07:04 AM
With that being a cast housing, any issues tapping it ? Im a bit torn between using these or going electric, I have both

Ballistic Beak 02-06-2017 08:00 AM
No problems tapping.

HyFive578 02-06-2017 08:25 AM
Originally Posted by 33outlawsst (Post 4526333)
With that being a cast housing, any issues tapping it ? Im a bit torn between using these or going electric, I have both
Not at all. Was a piece of cake. Used an 11/32" titanium bit to cut the hole and went very slowly as to not over-drill. The metal is pretty soft, so I was able to turn the 1/8" pipe tap with just a socket wrench, used a little motor oil and test fit the plug a few times to see where it would bottom out and then went deeper with the tap until I found the spot where I wanted it to bottom out. I coated the plugs with a little Mercury Perfect Seal just to make sure they won't turn themselves out. After all, it was pretty easy. Took me about 90 minutes to do all three pumps.

F-2 Speedy 02-06-2017 02:56 PM
Originally Posted by HyFive578 (Post 4526365)
Not at all. Was a piece of cake. Used an 11/32" titanium bit to cut the hole and went very slowly as to not over-drill. The metal is pretty soft, so I was able to turn the 1/8" pipe tap with just a socket wrench, used a little motor oil and test fit the plug a few times to see where it would bottom out and then went deeper with the tap until I found the spot where I wanted it to bottom out. I coated the plugs with a little Mercury Perfect Seal just to make sure they won't turn themselves out. After all, it was pretty easy. Took me about 90 minutes to do all three pumps.
My engines are on stands in the shop, I'll be doing shortly, thanks for the post


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