Fuel Pump 438559 – Fits Johnson/Evinrude 6–235 HP 2-Stroke Outboards (Replaces 385784, 433390, 395712, 765591)

Product Details

This is a direct-replacement fuel pump for Johnson/Evinrude outboard engines using the 438559-style pump and a three-nipple connection. It is listed for 6–235 HP 2-stroke outboard applications manufactured between 1968 and 1996. The pulse-operated diaphragm design uses an external pulse hose to draw fuel from the tank and deliver it to the engine.

This replacement corresponds to Johnson/Evinrude part number 438559 and may replace additional references including 385784, 433390, 395712, 765591, 388555, 398385, 398678, 382843, 381600, 382872, 395718, 383765, 394716, 393648, and 395107. Always compare the original pump, mounting pattern, hose arrangement, model, horsepower, and year before ordering.

• Flange-mount installation.
• Three-nipple design for fuel inlet, fuel outlet, and external pulse hose.
• Marine-grade metal housing for corrosion resistance.
• Designed for gasoline-fueled 2-stroke outboard applications.

Part Number Matrix

Use this matrix to compare the listed OEM and replacement references. Part-number correspondence does not replace model- and year-specific fitment verification.

Engine & Model Compatibility

Confirm your exact engine model, horsepower, stroke, and year before purchase. The following applications are the listed compatibility references for this fuel pump.

Technical Specs

Product Type

Pulse-operated diaphragm fuel pump

Installation

Flange mount

Fuel Type

Gasoline

Connection

Three-nipple design

Housing Material

Marine-grade metal

Housing Color

Silver/metallic

Dimensions

4.53 × 3.62 × 2.44 inches (115 × 92 × 62 mm)

Weight

8.1 ounces (0.23 kg)

Fitting Type

Fuel-line connection

Operating Principle

External engine crankcase pulses actuate the internal diaphragm

What’s in the Box

• 1 × Fuel pump
• 3 × Straps/bands, reference 320107
• 1 × Mounting gasket, reference 303615
• 1 × Installation instructions

Installation Notes

1. Ensure the engine is switched off and cool. Disconnect the battery where applicable.
2. Turn off the fuel supply and place an absorbent rag beneath the old pump to catch fuel.
3. Disconnect the fuel inlet, fuel outlet, and pulse hose. Note the position of each hose before removal.
4. Unbolt and remove the old fuel pump. Discard the old gasket.
5. Clean the mounting surface on the engine block.
6. Position the new gasket over the mounting holes.
7. Install the replacement pump in the correct orientation and secure it with the mounting bolts.
8. Reconnect the fuel inlet, fuel outlet, and pulse hose to the corresponding nipples.
9. Restore the fuel supply and prime the system if necessary.
10. Reconnect the battery where applicable, start the engine, and check carefully for fuel leaks.

Troubleshooting & FAQ

Safety & Important Information

• Verify the part number, mounting pattern, hose arrangement, dimensions, and application against your original pump before purchase.
• Do not work on the fuel system near open flames, sparks, or other ignition sources.
• Allow the engine to cool, relieve fuel-system pressure where applicable, and clean up spilled fuel immediately.
• This is an aftermarket replacement, not an OEM component.
• Professional installation is recommended when you are not experienced with marine fuel systems.

About Sea Sierra

• Pro-Grade Standards — We supply marine replacement parts designed for dependable fit and function in real-world conditions.
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