108
DE647B
4. Bleed any air from the system by turning the ignition
switch to the ON position and pumping the manual
primer pump until resistance is felt.
DE031A
5. Start the engine and check for leaks; then shut off the
engine and install the inner fender splash panel,
right-side engine cover, and seat. Make sure the seat
latches securely.
Fuel Tank
REMOVING
NOTE: Fuel tank removal should only be necessary
if the tank is leaking fuel or has been contaminated
with water, dirt, or inadvertently filled with gasoline.
1. Remove the seat.
2. Remove the rear rack and fenders (see Steering/
Frame/Controls).
3. Disconnect the hose from the fuel tank to the lift
pump; then disconnect the vent hose and fuel return
hose.
4. Remove the cap screws securing the gas tank to the
frame.
5. Disconnect the fuel gauge connector; then remove
the fuel tank.
CLEANING AND INSPECTING
1. Remove the fuel level sensor and fuel pick-up
screen. Account for a seal.
2. Completely drain all contaminated fuel from the fuel
tank; then thoroughly wash the tank out with hot,
soapy water.
3. Dry the tank interior with compressed air.
NOTE: Repeat steps 2 and 3 until all contaminants
are removed.
4. Back-flush the fuel screen with hot, soapy water and
dry with compressed air.
NOTE: If any “pin-holes” are noted in the fuel
screen, replace the fuel level sensor assembly.
5. Inspect the tank cap and filler neck for chipped or
broken threads.
6. Inspect the fuel tank mountings for security, signs of
cracking, or wearing through the tank.
7. Inspect all fuel and vent hoses for cracks, softening,
or deterioration. Replace as required.
INSTALLING
1. Place the fuel tank into position in the frame; then
install the cap screws. Tighten securely.
2. Connect the fuel hose from the lift pump; then con-
nect the fuel gauge connector.
3. Install the vent hose and fuel return hose; then fill the
fuel tank with clean diesel fuel.
4. Replace the fuel filter (see Periodic Maintenance/
Tune-Up).
5. Pump the manual primer pump 12-20 strokes; then
start the engine and inspect for leakage.
6. Install the rear fenders and rack (see Steering/Frame/
Controls); then install the seat making sure it latches
securely.
Fuel/Vent Hoses
Replace the fuel hoses every two years. Damage from
aging may not always be visible. Do not bend or obstruct
the routing of the vent hose or fuel return hose.
Oil Filter/Oil Pump
NOTE: Whenever internal engine components wear
excessively or break and whenever oil is contami-
nated, the oil pump should be replaced. The oil pump
is not a serviceable component.
! 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.
