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1994 Protour 190 Restoration

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  • #16
    Next the fuel cell it had a lot of vapor escaping from it. Removed it from the hull and disassembled. The the gaskets that go around the housing had cracks and NLA.
    I made a aluminum template to cut out replacement gaskets and put sealing washers on all the screws.
    I pressurized the tank with a shop vac and sprayed soapy water on it to check for leaks.
    Problem solved.
    The fuel tank has fuel levels marked on it take a look at the photo as a guess I think they were adjusting the fuel load for the number of people in the boat to keep the pulls consistent.
    Attached Files
    Last edited by RDahler; 05-27-2021, 09:51 AM.

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    • #17
      Nice work.
      1989 Prostar 190 351 sold
      2008 Prostar 197 LY6

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      • #18
        Originally posted by RDahler View Post
        Next the fuel cell it had a lot of vapor escaping from it. Removed it from the hull and disassembled. The the gaskets that go around the housing had cracks and NLA.
        I made a aluminum template to cut out replacement gaskets and put sealing washers on all the screws.
        I pressurized the tank with a shop vac and sprayed soapy water on it to check for leaks.
        Problem solved.
        The fuel tank has fuel levels marked on it take a look at the photo as a guess I think they were adjusting the fuel load for the number of people in the boat to keep the pulls consistent.
        Good thing they put the "F" and "E" on the tank.

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        • #19
          Good thing they put the "F" and "E" on the tank.


          I also thought the 1/2 full mark is useful

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          • #20
            The fuel tank is mislabeled. At least for our 94. Since the pickup is not on the bottom, there is approx 5 gallons you can’t really use. So that is really “E”.

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            • #21
              When I disassembled My fuel cell the 1/2 inch pickup tube was connected to a funnel shaped pickup with a fine screen on the bottom of it by a short rubber hose with two clamps. It was positioned 3/8 inch off the bottom of the tank. With this configuration I would suspect the amount of unusable fuel is between one or two gallons at the most.
              Last edited by RDahler; 05-28-2021, 12:08 AM.

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              • #22
                Originally posted by RDahler View Post
                When I disassembled My fuel cell the 1/2 inch pickup tube was connected to a funnel shaped pickup with a fine screen on the bottom of it by a short rubber hose with two clamps. It was positioned 3/8 inch off the bottom of the tank. With this configuration I would suspect the amount of unusable fuel is between one or two gallons at the most.
                Agree.

                For me and at that point, the screen comes out. One less thing to potentially cause a fuel supply issue.

                I figure anything that comes through will stop at the fuel filter.

                .
                93 190
                (safe click)
                John 14:6
                (safe click)

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                • #23
                  Which Pro Skier had the boat and set a world record at the time, sorry my days offshore have clouded my memory.
                  1993 25th Anniversary Limited ProStar 190, #17

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                  • #24
                    I do agree with your thinking on the screen on the end of the pick up and almost removed it during the rebuild. The rubber hose that is used to connect it was hard to source it had to be rated for fuel submerge. It just fell apart when I touched it I guess 26 years is to long to be submerged in fuel.
                    On this fuel cell the pickup and fuel level probe extend down in to a removable compartment that isolates them from the main fuel supply by a small 1/4 hole used to keep it filled. This is used to keep the fuel pickup submerged and the engine running in hard turns.
                    All the trash that had collected over years had collected out side of the compartment and the screen was clean. The marine anti siphon valve attached at the top of the pick up and is located before the external in line filter.
                    The reason I kept the screen I had a bad experience with trash collecting in the anti siphon valve on my 88 190 the engine would randomly quit and after sitting for about 10 minutes it would restart and run like nothing had happened. The trash would slowly work it's way back down the pickup tube as we sat. Then the process would repeat some times every other trip to the lake some times two or three times wile at the lake a real PITA.
                    Last edited by RDahler; 05-28-2021, 01:52 PM.

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                    • #25
                      Hi Bret
                      1994 Mastercraft Sponsored Pro Skier Jeff Rodgers this was his boat.

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                      • #26
                        1994 Protour 190 Restoration

                        Next I removed the LT1 engine and Power Slot transmission from the hull.
                        Attached Files

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                        • #27
                          1994 Protour 190 Restoration

                          I hung plumb bobs on the front of the engine and rear of the transmission to mark the exact location of the engine. This will let me preset the engine and transmission mounts back to there original position or at least in the ball park.
                          Attached Files

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                          • #28
                            Originally posted by MIskiboat View Post
                            The fuel tank is mislabeled. At least for our 94. Since the pickup is not on the bottom, there is approx 5 gallons you can’t really use. So that is really “E”.
                            My 95 starts sputtering at 3/8s full. Even with a sump, the suction of the fuel pump, causes a vortex and boat runs like crap.

                            Sent from my SM-G955U using Tapatalk
                            sigpic...A bad day water skiing still beats a good day at work...1995 Pro Star 205....

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                            • #29
                              Sounds like the end of pickup tube is to high in the sump, If it is made like my 1994 fuel cell with a rubber coupling and a pick up screen I would suspect the rubber coupling inside the fuel cell has detached from the pickup tube. The quick fix buy a new pickup up tube make sure to cut the length so that it is about 3/8 to 1/2 off the bottom of the sump when installed do a search on moeller marine replacement fuel pickup.

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                              • #30
                                1994 Protour 190 Restoration

                                The engine only had 775 hours it would crank right up and appeared to be running properly. The plan was to do a leak down compression test and a visual inspection now that I had it out of the boat if it passes clean it up and repaint it.
                                Things do not always go as planed it failed the compression test cylinder #1 was low.
                                New plan take the engine apart and figure out what is causing the low compression on #1.
                                Attached Files

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