Air injector O ring replacement

[Edgewater225]

2003 optimax 250 xs
While I was checking on the thermostat I noticed one of the o rings is in bad shape. Would pulling off the whole fuel bar be the best way to access and replace the ring?

[XstreamVking]

yep. remove nuts and CAREFULLY remove the whole assembly. If ones toast the others may be. Trick for reinstalling them is to compress the stem and o-rings with a pc of hose from a teleflex steering fill hose, or similar. Lube it up with 2 stroke and slide hose over stem and let sit for a few hrs., then it will slide right in.

[Edgewater225]

yep. remove nuts and CAREFULLY remove the whole assembly. If ones toast the others may be. Trick for reinstalling them is to compress the stem and o-rings with a pc of hose from a teleflex steering fill hose, or similar. Lube it up with 2 stroke and slide hose over stem and let sit for a few hrs., then it will slide right in.

thats great. Really helpful
someone mentioned a Teflon seal when putting them back on. Should I be concerned with as well or is that just an issue with the fuel injectors?

[XstreamVking]

The teflon ring has to be warmed in hot water to make it stretch a little. Unless there is an apparant problem with them, I just let em be. They seem fairly durable.

[InjectorService]

Which o-rings are in question here? The ones on the air injector? Leave those teflon seals alone unless you've got one damaged, they are a complete pain to deal with.

[Edgewater225]

The teflon ring has to be warmed in hot water to make it stretch a little. Unless there is an apparant problem with them, I just let em be. They seem fairly durable.

sounds good
thank you again for the help.

[XstreamVking]

I'm not a tech, I just work on my own optl's. I like helping out others to save money and time. And you are very welcome edgewater. Injector service is the opti x-pert here, he knows them inside and out.

[Edgewater225]

Which o-rings are in question here? The ones on the air injector? Leave those teflon seals alone unless you've got one damaged, they are a complete pain to deal with.

The one I need to replace shows when you pull off for the fuel rail by removing the two nuts. It’s a light brown color and I believe the part number is 804529.

I wasn’t sure if the Teflon seal breaks when I remove the fuel rail. I have no plans I removing anything else. Just pull the rail and whatever hoses need to be detached to the rail. Replace the plug. Gently slide the rails back in with some DFI oil on everything. Then hoses and nuts back on. Someone mentioned a Teflon seal so I figured I’d ask about it.

thanks for the help.

[InjectorService]

That part number would be on the fuel injectors smaller o-ring. I just looked it up, what merc wants for these things is quite a lot. Do you have an injector shop near you? You in a rush? If not Ill send you 6 free of charge.


#11 On This Diagram


The teflon seals would be on the air or direct injector which is not pictured here.

[Edgewater225]

That part number would be on the fuel injectors smaller o-ring. I just looked it up, what merc wants for these things is quite a lot. Do you have an injector shop near you? You in a rush? If not Ill send you 6 free of charge.


#11 On This Diagram


The teflon seals would be on the air or direct injector which is not pictured here.

that’s really nice of you. I agree 100% I couldn’t believe they’re cost. Also needed to wait a up to week for delivery. I don’t know of a shop close by here in CT.

I ended up ordering from here since a buddy of mine was happy with the quality off Amazon - Brand fits Fuel Injector Filter Rebuild Kit for Mercury Optimax & Sport Jet Engines - https://a.co/d/diQg9Bs


If I should be nervous about using something like these I’d be happy to send you a fedex label for your offer if you email me at adamelgert@yahoo.com. I can have fedex come pick them up from you when they’re ready.

if you email me at adamelgert@yahoo.com

[InjectorService]

Ill gladly send some if you like, however chances are you are good to use the ones you found. The ones pictured are Viton (as long as they really are what they are advertising). I use Viton for all of my o-rings.

[Edgewater225]

I’ll gladly send some if you like, however chances are you are good to use the ones you found. The ones pictured are Viton (as long as they really are what they are advertising). I use Viton for all of my o-rings.

I’ll take my chances that they are real since they’ll be here tomorrow. That’s really nice of you though and I appreciate the offer and the help.