Getting the right setup for your evinrude outboard gas tank makes the difference between a relaxing day on the lake and being stuck rowing back to the dock. If you've spent any time around old boats, you know that Evinrude has a long, storied history, and with that history comes a lot of different fuel systems. Whether you're rocking a vintage 1950s "Big Twin" or a more modern E-TEC, how you store and deliver fuel to that motor is everything.
The Evolution of the Evinrude Fuel System
It's actually pretty wild how much things have changed over the decades. Back in the day, specifically before the late 1950s, many Evinrude motors used a pressurized fuel system. These old-school setups didn't have a fuel pump on the engine. Instead, the motor would pump air into the evinrude outboard gas tank, which would then force the gas up into the carburetor.
You can spot these easily because they have two hoses instead of one. While they're built like tanks—literally, they are heavy steel—they can be a bit of a headache to maintain. If the seal on the tank cap isn't perfect, the system won't pressurize, and your motor won't run. If you're using one of these vintage setups, never try to swap it for a modern plastic tank without installing a fuel pump conversion kit on the motor first. It just won't work.
Choosing the Right Modern Tank
For most of us, we're dealing with the standard suction-style systems. When you're shopping for a new evinrude outboard gas tank, you basically have two choices: portable or permanent.
Most people with smaller aluminum fishing boats or runabouts stick with the 3-gallon or 6-gallon portable tanks. They're easy to lug to the gas station, and you can swap them out in seconds. These days, almost all of them are made of high-density polyethylene (that's just a fancy word for tough plastic). Plastic is great because it doesn't rust, which was the number one killer of old metal tanks.
Why Venting Matters
One thing that trips up a lot of boaters with newer tanks is the "EPA-compliant" ventless designs. The older tanks had a little screw on the cap that you'd open to let air in as the fuel was sucked out. The new ones? Not so much. They're designed to stay sealed to prevent fumes from escaping, but this can cause the tank to swell up like a balloon in the sun or collapse under a vacuum as you run the engine.
If your motor starts bogging down after ten minutes of running, check your tank's venting. Sometimes you have to slightly crack the cap just to let the engine breathe, even if the manufacturer says you don't have to.
The All-Important Fuel Line and Connector
You can have the best evinrude outboard gas tank in the world, but if your fuel line is junk, you're going nowhere. Evinrude (and Johnson/OMC) uses a specific type of quick-connect fitting. It's got two prongs—one for the fuel and a locking pin to hold it in place.
The Primer Bulb
Don't cheap out on the primer bulb. A good one should feel firm when you pump it and stay that way until the motor starts. If the bulb stays flat or feels "mushy," you've probably got a vacuum leak or a bad check valve. Also, pro tip: when you're priming the system, try to hold the bulb vertically with the arrow pointing up. It helps the internal valves work better and gets the fuel to the carb faster.
Ethanol: The Silent Killer
We have to talk about ethanol. Most gas you get at the local station is E10 (10% ethanol). For an older evinrude outboard gas tank, ethanol is bad news. It acts like a solvent, eating away at old rubber fuel lines and attracting water. If you can find ethanol-free "REC-90" fuel, use it. Your engine will thank you. If you can't, make sure you're using a high-quality fuel stabilizer every single time you fill up.
Cleaning and Maintaining an Old Metal Tank
If you've scored a vintage boat and it came with an original metal evinrude outboard gas tank, don't toss it just because it looks a bit crusty. As long as it's not rusted through, you can usually save it.
The "BB method" is a classic for a reason. You dump a handful of BBs or small nuts and bolts into the tank with a bit of degreaser or white vinegar, and you shake it like you're mixing a giant cocktail. It knocks the loose rust and varnish off the inside walls. Just make sure you get every single BB out before you put gas in it! After cleaning, check the pickup screen inside the tank. If that little mesh screen is clogged with old gunk, your motor will starve for fuel at high RPMs.
Troubleshooting Fuel Flow Issues
Sometimes you're out on the water, and the motor just dies. It's frustrating, but usually, it's something simple related to the evinrude outboard gas tank setup.
- Check the O-rings: Those little rubber rings inside the fuel connector wear out. If they're cracked, the pump will suck air instead of gas. It's like trying to drink through a straw with a hole in it.
- Fuel Filter: Most Evinrudes have a small filter under the cowling, but having a water-separating filter between the tank and the motor is even better.
- Tank Position: Make sure the tank isn't sitting way lower than the motor. While fuel pumps are pretty good, they aren't miracle workers. Keeping the tank on a level surface helps maintain a steady flow.
Storing Your Tank for the Winter
When the season ends, how you treat your evinrude outboard gas tank determines how much you'll struggle next spring. Some guys swear by keeping the tank bone-dry, while others prefer to keep it completely full with stabilized fuel to prevent condensation.
Personally, I'm a fan of the "mostly full" method. If there's no air in the tank, water can't condense out of the air and settle at the bottom of your gas. Just make sure you run the engine for a bit after adding the stabilizer so it gets into the lines and the carburetor.
Safety First
It sounds obvious, but gas is dangerous. Always pull your evinrude outboard gas tank out of the boat and set it on the dock or the ground when you're filling it up. This prevents static electricity build-up and ensures that if you spill a little, it doesn't end up in your bilge.
Also, keep an eye on the color of your fuel. If you look into your tank and the gas looks like cloudy apple cider, you've got water in there. Stop right there. Drain it, clean it, and start fresh. It's much cheaper to throw away five gallons of bad gas than it is to rebuild a powerhead because of a lean-run condition caused by water.
Wrapping Things Up
At the end of the day, an evinrude outboard gas tank is a pretty simple piece of equipment, but it's the heart of your boat's life support system. Treat it well, keep it clean, and don't ignore the small things like cracked hoses or worn-out connectors.
Whether you're restoring a classic or just trying to get the family out for a weekend of tubing, a solid fuel setup is your best friend. There's nothing quite like the sound of an old Evinrude humming along perfectly because it's getting a steady, clean supply of fuel. Take care of your tank, and it'll take care of you out on the water.