105
Fuel Pump/Fuel Level
Sensor
NOTE: Preliminary checks may be performed on
this component using the diagnostic mode on the
LCD gauge (see EFI Diagnostic System in the Electri-
cal System section).
The fuel pump and fuel level sensor are not serviceable
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 fuel rail; 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).
4. Check for any flashing DTC (Diagnostic Trouble
Code) on the digital gauge. A disconnected or faulty
tilt sensor will cause the fuel pump not to run and a
code to flash.
5. If the pump is not running, check the 10 amp FUEL
fuse in the PDM under the passenger seat. Replace as
necessary and check for fuel pump operation.
6. If fuse is OK, check the FUEL relay by swapping with
another relay. If the pump runs, replace the FUEL
relay.
7. If the pump still is inoperative, replace as follows.
REMOVING
1. Remove the seats and battery cover; then disconnect
the negative battery cable.
2. Remove the rear body panel and cargo box (see Steer-
ing/Frame/Controls); then plug or tape over the gas
tank filler hose.
NOTE: The power supply/wiring to the fuel pump
could be checked by reconnecting the battery nega-
tive cable and using a multimeter set to DC volts;
then check for battery voltage by turning the ignition
to ON and checking between the black and red wires.
Disconnect the negative battery cable when finished.
3. Disconnect the fuel pump/fuel level sender connector;
then wrap a shop towel around the gasline connector
and disconnect the gasline from the fuel pump.
4. Mark the components for assembling purposes and
remove the screws securing the fuel pump to the gas
tank.
WC226
5. Carefully remove the fuel pump/fuel level sender
assembly from the gas tank; then tape over the open-
ing.
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 position
without force. If not, replace the fuel level sensor
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).
! 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 fuel pump, the following test
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.
AT THIS POINT
If the pump has failed earlier test and must be
replaced, proceed to INSTALLING.
