95
4. If the pump is not running, disconnect the fuel
pump/tank sensor connector by reaching under the
rear rack from behind.
5. Connect a multimeter to the power supply leads with
the red tester lead to the red wire and the black tester
lead to the black wire; then turn the ignition switch to
the ON position. The meter should read battery volt-
age. If battery voltage is indicated and the fuel pump
does not run, replace the pump assembly. If no bat-
tery voltage is indicated, check the ECM and the
vehicle tilt sensor.
REMOVING
1. Remove the rear rack and fenders (see Steer-
ing/Frame/Controls); then disconnect the power sup-
ply/fuel hose connector.
2. Remove the spring clamp; then remove the fuel hose.
3. Remove the screws securing the fuel pump to the gas
tank; then make a reference mark on the fuel pump
and tank.
4. Lift out the fuel pump assembly carefully tilting it
forward to clear the voltage regulator; then guide the
pump and float lever through the opening in the gas
tank.
5. Using duct tape or other suitable means, cover the
fuel pump opening.
INSPECTING
1. Inspect the fuel screen and blow clean with low pres-
sure compressed air.
2. Move the float lever and check for free movement.
The float assembly should return to the lower posi-
tion without force. If not, replace the fuel pump
assembly.
3. Test the fuel level sensor by connecting a multimeter
(A) to the fuel level sensor leads (B); then select
OHMS. The multimeter should show 5 ohms at full
fuel position (C) and 95 ohms at empty fuel position
(D).
ATV2116
NOTE: If readings are erratic, clean the resistor
wiper and resistor with clean alcohol and retest. If
still not correct, replace the fuel level sensor.
4. To replace the fuel level sensor, use the following
procedure.
A. Disconnect the two-wire connector (A); then
press the fuel level sensor toward the top of the
fuel pump to release it from the mounting slot
(B).
FI460A
B. Engage the tabs (C) of the fuel level sensor into
the mounting slot (B) and press toward the bot-
tom of the fuel pump to latch in place; then con-
nect the two-wire connector (A).
INSTALLING
1. Mark the new fuel pump with a reference mark in the
same location as the removed pump; then place the
new gasket on the pump.
2. Remove the material covering the fuel pump open-
ing; then carefully guide the fuel pump into position
taking care not to damage the float or float lever.
CAUTION
Take care not to damage the float or float arm or
replacement of the entire assembly will be necessary.
AT THIS POINT
If the pump has failed earlier test and must be
replaced, proceed to INSTALLING.
