94
2. Remove the coolant hoses from the water pump; then
remove two cap screws securing the water pump to
the crankcase.
GZ230A
3. Remove the water pump from the engine.
Installing
1. Install a new O-ring onto the water pump and lightly
coat with clean engine oil.
GZ252C
2. Install the water pump assembly onto the engine
aligning the flat drive on the water pump to the slot
in the driveshaft.
GZ252D
3. Secure the water pump with the two cap screws and
tighten securely; then connect the coolant hoses and
secure with hose clamps.
4. Install and tighten the coolant drain plug securely;
then fill the cooling system with the proper amount
of recommended coolant and install the radiator cap.
5. Start the engine and check for coolant leaks; then add
coolant if necessary to proper level.
Electric Fuel Pump/Fuel
Level Sensor
The electric fuel pump and fuel level sensor are not ser-
viceable components. If either component fails, it must
be replaced.
TESTING
1. Turn the ignition switch ON and listen for a momen-
tary “whirring” sound of the pump building pressure.
If the sound is heard (10 seconds), no electrical
checks are necessary. Turn the ignition switch OFF.
2. Disconnect the gasline hose from the throttle body;
then install a suitable pressure gauge.
FI092A
3. Turn the ignition switch to the ON position. The fuel
pressure should build until the pump shuts off. Pres-
sure should read 3.0 kg-cm
2
(43 psi).
CAUTION
Do not force the water pump housing into the crankcase
or severe engine damage may occur.
CAUTION
After operating the ATV for the initial 5-10 minutes, stop
the engine, allow the engine to cool down, and check
the coolant level. Add coolant as necessary.
! 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.
AT THIS POINT
Prior to removing the electric fuel pump, the following
check should be performed to determine that removal
is necessary.
! WARNING
Gasoline may be under pressure. Place an absorbent
towel under the connector to absorb any gasoline spray
when disconnecting.
