Arctic Cat 650 Twin2004, Service Manual

Page: 101 / 210

4-18
INSPECTING
1. Inspect the fuel screen and blow clean with low
pressure compressed air.
2. Move the float lever and check for free movement.
The float assembly should return to the lower
position without force. If not, replace the fuel
pump assembly.
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3. Test the fuel gauge tank sensor by connecting a
multimeter (A) to the fuel sensor leads (B); then
select OHMS. The multimeter should show 120
ohms at full fuel position (C) and 3 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 pump assembly.
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
opening; then carefully guide the fuel pump into
position taking care not to damage the float or
float lever.
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3. Rotate the fuel pump counterclockwise 90° or
until the match marks align; then install the
mounting screws and tighten securely using a
crisscross pattern.

NOTE: It is important to install the fuel pump
with the correct orientation to ensure adequate
float lever clearance.
4. Connect the wires, fuel hose, and spring clamp;
then turn the ignition switch to the ON position.
Note that the fuel pump runs momentarily and the
fuel gauge indicates the proper fuel level.
5. With the transmission in neutral and brake lever
lock engaged, start the engine and check for
normal operation. Check for any fuel leaks.
6. Install any wire ties that were removed; then
install the rear fenders, rack, and seat making sure
the seat locks securely.

AT THIS POINT
If the pump has failed earlier test and must be
replaced, proceed to INSTALLING.