4-4
Gas Tank
REMOVING
1. Remove the seat.
2. Remove the rear rack and fenders (see Section 8);
then remove the right-rear tire.
3. Disconnect the hose from the fuel pump to the
throttle body.
4. Remove the cap screws securing the gas tank to
the frame.
5. Disconnect the fuel gauge connector; then remove
the gas tank.
CLEANING AND INSPECTING
NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.
1. Clean all gas tank components with parts-cleaning
solvent.
2. Inspect all hoses for cracks or leaks.
3. Inspect tank cap and tank for leaks, holes, and
damaged threads.
4. Remove the fuel level sensor/fuel pick-up assem-
bly and inspect the fuel level sensor and fuel
screen.
NOTE: If the fuel level sensor has failed or may
be faulty, see Electric Fuel Pump/Fuel Level Sen-
sor in this section.
INSTALLING
1. Install the fuel level sensor/fuel pump assembly.
2. Place the gas tank into position in the frame; then
install the cap screws. Tighten securely.
3. Connect the gas hose from the throttle body; then
connect the fuel gauge/fuel pump connector.
4. Install the vent hose; then fill the gas tank with
gasoline.
5. Start the engine and inspect for leakage.
6. Install the rear fenders, right-rear tire, and rack;
then install the seat making sure it latches
securely.
Oil Filter/Oil Pump
NOTE: Whenever internal engine components
wear excessively or break and whenever oil is con-
taminated, the oil pump should be replaced.
Testing Oil Pump
Pressure
NOTE: The engine must be warmed up to the
specified temperature (cooling fan cycling) for this
test.
1. Connect Tachometer to the engine or utilize the
ATV gauge.
2. Connect the Oil Pressure Test Kit to the oil cooler
to oil filter line.
GZ388
NOTE: Some oil seepage may occur when install-
ing the oil pressure gauge. Wipe up oil residue
with a cloth.
3. Start the engine and run at 3000 RPM. The oil
pressure gauge must read 0.7-1.4 km
2
(10-20 psi).
NOTE: If the oil pressure is lower than specified,
check for low oil level, defective oil pump, or
restricted oil cooler.
NOTE: If the oil pressure is higher than specified,
check for clogged oil passage, clogged oil filter, or
improper installation of the oil filter.
! WARNING
Whenever any maintenance or inspection is made
on the fuel system during which there may be fuel
leakage, there should be no welding, smoking, open
flames, etc., in the area.
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