FUEL TANK

Removing the fuel tank
Order	Job/Parts to remove	Q’ty	Remarks
	Seat		Refer to GENERAL CHASSIS.
	Side cover (left/right)		Refer to GENERAL CHASSIS.
	Air filter case cover		Refer to CLEANING THE AIR FILTER ELEMENT.
	Shroud (left/right)		Refer to GENERAL CHASSIS.
1	Fuel pump coupler/Fuel hose	1/1	Disconnect.
2	Fuel tank	1
3	Fuel pump bracket	1
4	Fuel pump	1
5	Fuel filter	1
6	Thermistor cover	1
7	Fuel pump gasket	1
8	Fuel tank bracket	2
9	Rubber damper	4
10	Damper	1

REMOVING THE FUEL TANK

1.Extract the fuel in the fuel tank through the fuel tank cap with a pump.

2.Remove:

3.Disconnect:

: Cover the fuel hose connection with a cloth when disconnecting it. This is because residual pressure in the fuel hose could cause fuel to spurt out when the hose is removed.

: Make sure that the fuel hose is disconnected by hand. Do not forcefully disconnect the hose with tools.

To disconnect the fuel hose from the fuel tank, remove the fuel hose connector holder “a”, and then slide the fuel hose connector cover.
To remove the fuel hose, slide the fuel hose connector cover “1” on the end of the hose in the direction of the arrow shown, press the two buttons “2” on the sides of the connector, and then remove the hose.
Before removing the hose, place a few cloths in the area under where it will be removed.
To prevent sand, dust, and other foreign materials from entering the fuel pump, install the included fuel hose joint cover 1 “3” and the fuel hose joint cover 2 “4” onto the disconnected fuel hose and the fuel pump.

4.Remove:

: Do not set the fuel tank down on the installation surface of the fuel pump. Be sure to lean the fuel tank against a wall or the like.

1.Remove:

1.Check:

Fuel pump body

Obstructions → Clean.

Cracks/damage → Replace the fuel pump assembly.

1.Check:

1.Install:

Take care not to damage the installation surfaces of the fuel tank.
Always use a new fuel pump gasket.
Install the lip on the fuel pump gasket upward.
Install the fuel pump as shown in the figure.
Align the projection “a” on the fuel pump with the slot “b” in the fuel pump bracket.
Tighten the fuel pump bolts in the proper tightening sequence as shown.

1.Install:

2.Connect:

Connect the fuel hose securely, and check that the orientation of the installed fuel hose holder is correct.
Take care not to kink or pinch the fuel hose.

Insert the fuel hose into the fuel pipe securely until you hear a “click”.
Slide the fuel hose connector cover “1” at the hose end in the direction of the arrow.
Install the fuel hose connector holder “a”.

3.Connect:

4.Install: