Fuel Pump for Johnson/Evinrude 6–235 HP Outboards – Replaces 438559, 433390, 398385

Product Details

This aftermarket fuel pump for Johnson/Evinrude 6–235 HP outboards is designed for a broad range of Johnson and Evinrude 2-stroke outboard engines manufactured from 1968 through 2005, subject to the specific model and year conditions shown below. It is a pulse-driven mechanical pump that uses engine crankcase pressure to provide fuel delivery to the engine.

This replacement pump is listed for multiple Johnson/Evinrude references, including 438559, 433390, 398385, 395712, 385784, 398678, 395718, 395107, 394716, 393648, 388555, 383765, 382872, 382843, 381600, 765591, and 5005462. Confirm the original pump, connection layout, and exact engine application before ordering.

• External pulse-driven mechanical fuel pump.
• Three-port layout for fuel inlet, fuel outlet, and engine pulse connection.
• Metal housing suitable for marine fuel-system service.
• Aftermarket replacement component; not an OEM Johnson/Evinrude part.

Part Number Matrix

Use the following references to compare the replacement with your original pump. Part-number matching alone does not replace verification of the exact engine model, year, stroke, and configuration.

Engine & Model Compatibility

Confirm the exact engine model, rated horsepower, stroke, year, and configuration before purchase. The applications below are the listed coverage for this replacement pump.

Technical Specs

Product Type

Fuel pump

Installation

External pulse-driven mechanical pump

Fuel Type

Gasoline/Petrol

Connection

3-port: inlet, outlet, and pulse

Housing Material

Metal

Housing Color

Black/Silver

Dimensions

Approximately 103 × 62 × 89 mm (4.06 × 2.44 × 3.5 inches)

Weight

Approximately 0.22 kg (7.8 ounces)

Fitting Type

Hose barb

Warranty

1 year against manufacturing defects under normal use

Operating Principle

Mechanical diaphragm pump operated by engine pulse pressure

What’s in the Box

• 1 × fuel pump assembly
• Mounting gasket where supplied; gasket inclusion may vary by supplier.

Installation Notes

1. Disconnect the battery and work in a well-ventilated area away from ignition sources.
2. Relieve fuel-system pressure and place an absorbent rag beneath the existing pump to catch fuel.
3. Before disconnecting the old pump, identify the inlet, outlet, and pulse-line routing.
4. Remove the mounting bolts and the old pump and gasket from the engine.
5. Clean the mounting surface and remove old gasket material and debris.
6. Install the replacement gasket if supplied, position the new pump, and tighten the mounting bolts to the engine manufacturer’s recommended specification.
7. Reconnect the inlet, outlet, and pulse lines to the corresponding ports and secure the clamps.
8. Reconnect the battery, prime the fuel system according to the engine service manual, and check carefully for leaks before starting the engine.

Troubleshooting & FAQ

Safety & Important Information

• Verify the original part number, pump appearance, port arrangement, and engine application before purchase.
• Do not install a fuel-system component that differs from the original application or cannot be securely connected.
• Fuel is flammable. Work in a ventilated area, keep the system away from sparks and open flames, and clean spills immediately.
• Professional installation is recommended when you are not familiar with marine fuel systems.

About Sea Sierra

• Pro-Grade Standards — Marine replacement parts selected for dependable service in real-world conditions.
• Global Fulfillment — Standard and expedited delivery options are available where offered at checkout.
• Manufacturer-Direct Value — Practical aftermarket replacement parts at competitive prices.