Fuel Tank: Service and Repair

FUEL TANK REMOVAL/INSTALLATION[LF, L3]

WARNING:
- Repairing a fuel tank containing fuel is dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.
- A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before draining fuel, make sure to discharge static electricity by touching the vehicle body.

1. Park the vehicle on a level surface.
2. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION[LF, L3].) Before Service Precaution
3. Drain the fuel from the fuel tank using the following procedure:
1. Disconnect the quick release connector (in the engine compartment).
2. Attach a long hose to the disconnected fuel pipe and drain the fuel into a proper receptacle.
3. Start the fuel pump using the following procedure:
Using M-MDS




1. Connect the M-MDS to the DLC-2.
2. Start the fuel pump using the "FP" simulation function.

Without using M-MDS
1. Disconnect the negative battery cable.




2. Remove the fuel pump relay.

CAUTION: Be careful to short the specified terminal as shorting the wrong terminal of the main fuse block may cause a malfunction.




3. Using a jumper wire, short fuel pump relay terminals C and D and connect the negative battery cable to start the fuel pump.

CAUTION: The fuel pump may malfunction if it is operated without any fuel in the fuel tank (fuel pump idling). Constantly monitor the amount of fuel being discharged and immediately stop operation of the pump when essentially no fuel is being discharged.

4. When essentially no fuel is being discharged from the hose, stop the fuel pump using the following procedure:
Using M-MDS
1. Stop the fuel pump using the "FP" simulation function.

Without using M-MDS
1. Disconnect the negative battery cable to stop the fuel pump.

4. Disconnect the negative battery cable, (using M-MDS)
5. Remove the rear seat cushion.
6. Remove the service hole cover.
7. Disconnect the fuel pump unit connector.
8. Remove the charcoal canister protector.
9. Lower the main silencer so that the insulator can be removed.
10. Remove the insulator.
11. Remove the rear under cover (LH).
12. Remove in the order indicated in the table.
13. Install in the reverse order of removal.

California Emission Regulation Applicable Model:

14. Inspect all parts by performing "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTIONS[LF, L3].) After Service Precaution

California emission regulation applicable model

Except For California Emission Regulation Applicable Model:

Except for California Emission Regulation Application Model

Evaporative Hose Removal/Installation Note
- Refer to the "QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION" to disconnect the quick release connector of the front side of the fuel tank.
- Refer to the "QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION" to disconnect the quick release connector connected to the charcoal canister.
- Refer to the "QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION" to reconnect the quick release connector of the front side of the fuel tank.
- Refer to the "QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION" to reconnect the quick release connector connected to the charcoal canister.

Joint Hose Removal Note
1. Remove the fuel-filler pipe installation bolt.
2. Loosen the tie band connecting with the fuel tank.
3. Pull down the fuel-filler pipe to disconnect the joint hose.

Breather Hose Removal Note
- Except for California emission regulation applicable model, refer to the "QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION)" to disconnect the quick release connector connecting to the fuel shut-off valve.

Fuel-filler Pipe Removal Note
1. Remove the rear tire (RH).
2. Remove the rear mudguard (RH).
3. Support the rear crossmember using a transmission jack.
4. Remove the rear shock absorber (RH) lower bolts.
5. Loosen the rear crossmember installation nuts (6 locations) and lower the rear crossmember 30 mm {1.2 in}.
6. Remove the fuel-filler pipe.

Breather Hose Installation Note




California emission regulation applicable model
- Connect the breather hose connecting with the fuel tank and clamp as shown in the figure.

Except for California emission regulation applicable model
- Refer to the "QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION)" to reconnect the quick release connector connecting to the fuel shut-off valve.

Joint Hose Installation Note




1. Install the joint hose and clamp as shown in the figure.