Mercury Racing 2.5L Horn motors—including the 260 HP, 280 ROS, 280 Consumer, 300 Drag, and S3000 F1—require precise fuel delivery. One major EFI challenge is air pockets in fuel rails and injectors, causing lean conditions, misfires, and fuel pressure inconsistencies.
Mercury Racing engines use an EFI bleed system to remove trapped air, ensuring stable fuel pressure at all RPMs. The nickel-plated brass elbow fitting (Buckshot Racing #77) replaces Mercury OEM 22-94090, offering superior corrosion resistance and durability. Air disrupts fuel atomization, leading to erratic performance and power loss.
The EFI bleed system, with nickel-plated brass L-fittings (94090), vents air to maintain steady fuel flow, preventing injector hesitation and fuel starvation, especially at high RPM.
These L-fittings install on EFI fuel rail bleed ports, keeping fuel flow uninterrupted while maintaining a sealed system. Unlike standard brass, nickel-plated fittings resist corrosion, ethanol damage, and pressure fluctuations, making them ideal for high-performance marine applications.
Fuel pressure stability is crucial in racing. Fluctuations cause lean misfires, power loss, and increased wear. Nickel-plated brass elbow fittings maintain optimal fuel pressure, ensuring injectors function properly for consistent combustion. This improves throttle response, acceleration, and reliability.
Upgrading to nickel-plated brass fittings enhances both performance and durability. Standard brass fittings wear down from fuel pressure, temperature swings, and corrosive race fuels, leading to leaks. The nickel-plated version eliminates these issues, delivering a stronger, longer-lasting component for competitive racing.
For outboard racers and performance enthusiasts, nickel-plated L-fittings are an essential upgrade, ensuring consistent fuel delivery, preventing air-related issues, and extending fuel system longevity.
Installation Guide: Press Fit & Drill Sizes
Proper installation of the Buckshot Racing #77 nickel-plated elbow fitting requires a secure press fit. Our fitting is ~.060", 1-2 thousandths oversized versus OEM 22-94090, ensuring a solid replacement fit. However, measuring each fitting and hole before installation is crucial, as tolerances can vary slightly.
In aluminum, a #53 drill bit (0.0595") or 1.50 mm metric bit (0.0591") provides a light press fit, while a 1.45 mm drill bit (0.0571") ensures a tighter fit for maximum retention.
In steel, which doesn’t deform as easily, a 0.058"-0.0585" hole offers a secure press fit without excessive force.
If an existing hole is too loose, applying JB Weld or a high-strength retaining compound can restore a tight, leak-free seal. For best results, measure hole diameter with calipers before drilling. Reaming the hole after drilling improves precision, especially in steel, where accuracy is critical.
Choosing the correct drill size and installation method ensures the fitting remains secure under high-performance fuel system conditions.
Includes one (1) L-Fitting, replacing Mercury 22-94090, or select Dealer Buy 6, Save $6
For technical support, contact Mike Hill at +1-714-697-1716 or mike@buckshotracing77.com.