4-11
4
4. If the pump is not running, disconnect the fuel
pump/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 ECU and the
vehicle tilt sensor.
REMOVING
1. Remove the key from the ignition switch.
2. Remove the seat, seat back, and seat base; then dis-
connect the negative battery cable.
3. Disconnect the electrical plug from the main harness;
then disconnect the gasline hose from the fuel pump.
4. Mark the fuel pump mounting and gas tank for
installing purposes; then remove the screws securing
the fuel pump to the gas tank and remove the fuel
pump.
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 level sen-
sor 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 bottom
of the fuel pump to latch in place; then connect
the two-wire connector (A).
INSTALLING
1. Place the fuel pump assembly into the gas tank with
a new gasket aligning the match marks; then secure
with the four screws. Tighten securely.
NOTE: It is important to install the fuel pump with
the correct orientation to ensure adequate float
lever clearance.
2. Connect the gasline hose to the fuel pump pipe and
secure with the hose clamp; then connect the electri-
cal plug to the main harness.
3. Connect the negative battery cable; then turn the
ignition switch to the ON position and verify that no
gas leaks are present, the pump runs for 2-3 seconds,
and the gas gauge reading is normal.
4. Start the engine to verify proper engine operation;
then shut off the engine and install the seat base, seat
back, and seat.
! WARNING
Always ensure that power cannot be inadvertently
applied to the ignition/ECU when working on the fuel
system. If the ignition switch is turned on, the elec-
tric fuel pump will start and gas could be rapidly
pumped and spilled resulting in fire and severe
injury.
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.
Manual
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