Hi All,
I finally got the issue solved!
I ordered a lift pump and installed it (that is a bit of a job, getting that rats-nest of 3/8 rubber hoses aligned "just right" before tightening the clamps).
It ran on the driveway, but the problem was when under load at 3000+ rpm, so needed a full speed run.
Same symptoms...
So on to the VST/injector pump...
The Evinrude replacement is about $1000, and there is a new no-name(copy?) on eBay for about $100, so I thought I would try it.
It is a really nice unit, well made (at least on the outside), but needed a little modification to fit on the existing mounting points:
The original has "slots" cut on the two port side mounting areas that slide onto the rubber bushings. On the replacement, the openings were slightly smaller than the "slots",
so I had to remove a little of the aluminum bracket so it would slide on like the original.
Once I did that, everything went together perfectly.
I pumped up the fuel bulb (I could hear fuel flowing into the VST on each squeeze), and once the bulb was firm, turned the key on, and let the electric pump run until it shut off (a little longer than before, about 15-20 seconds)
Then engaged the starter, and it started right up!
I let it idle for a little while, then shut it down, and checked for leaks.
With none found, I put the cowlings back on and took the boat to the ramp for a test run
(the "speed zone" is about a 15 min, 1500rpm/5kt putt-putt away).
Once inside the "speed zone" I slowly pushed the throttle up to 2000 rpm, 3000, 4000, 5000 up to 5500! and zoomed around the "speed zone" for about 10 minutes.
Convinced it was working normally, I brought it home, took off the cowlings again (I am really good at that now, and can get them all off in about 3min), to double check for fuel leaks.
None found, so put everything back together.
If anyone else (that still has a 23y/o FICHT) has "high rpm" fuel issues, I hope this helps!
Paul