Fuel Pump: Service and Repair

Fuel Pump

REMOVAL

WARNING: Place "NO FIRE" signs near the working area.

CAUTION:
- Be careful not to spill fuel.
- When the fuel meter indication is higher than two third of the total, perform the work after draining the fuel not to spill the fuel.

NOTE: Fuel pump assembly consists of fuel pump, fuel filter and fuel level sensor.

1. Release the fuel pressure.
2. Drain fuel.
3. Remove the second seat.
4. Remove the service hole cover.






5. Disconnect the connector from fuel pump.






6. Disconnect the quick connector, and then disconnect the fuel delivery hose and jet pump hose.
7. Remove the nuts which install fuel pump assembly onto fuel tank.






8. Remove the fuel pump assembly from the fuel tank.

INSTALLATION
Install in the reverse order of removal while being careful of the following.
- Make sure the sealing portion is free from fuel or foreign matter before installation.
- Install with the protrusion (A) of gasket aimed at the front side of the vehicle.
- Insert the protrusion (B) of gasket to the upper plate. (3 places)
- Align the protrusion (C) of fuel pump assembly with the cutout portion of the upper plate.
- Tighten the nuts to the specified torque in the order as shown in the figure.

NOTE: Use a new gasket and retainer.

Tightening torque: 4.4 N.m (0.4 kgf.m, 3.2 ft.lb)