5.FUELSYSTEM
5-2
on injection system high pressure hoses. Replace any damage or deteriorated fuel lines.
When the repair is completed, ensure that all hoses are connected and secured.
Always perform the fuel pressure test if any component has been removed. A pressure test must be done before
turning the ignition key to ON and setting the engine stop switch to RUN. The fuel pump is activated each time in
these conditions.
To locate a leak, pressurize the system. Check for leaking fuel or fuel odor. Spray soapy water on all hose
connections and injectors. Air bubbles will show the leaking area.
Inspect the fuel lines, fuel tank, fuel tank cap for damage, clogging and leakage of fuel. If any damages are found,
replace the defective parts with the new ones.
FUEL PRESSURE TEST
The pressure test will show the available pressure at the fuel pump outlet. It validates the pressure regulator, the
fuel pump and leaks in the system.
Before proceeding to the pressure test ensure the battery is fully charged. Battery voltage must be over 12 volts.
Ensure there is enough gas in fuel tank.
Remove left seat.
Disconnect outlet hose.
Install fuel pressure gauge and T-fitting between
disconnected hoses.
Turn ignition key ON and set engine stop switch to
RUN and observe fuel pressure. Turn ignition key off
then back on. Repeat the test.
Standard fuel pressure: 350kpa.
A rapid pressure drop indicates leakage is from the fuel rail, If there is not leaking then replace fuel pump.
A slow pressure drop indicates leakage either from the fuel injector or from the fuel pressure regulator. Check fuel
injector and the fuel pressure regulator for leaks. If it is not leaking then replace fuel pump module.
If no leakage, start engine and observe fuel pressure. The fuel pressure should be the same as above.
If pressure is within limits, fuel pump and the fuel pressure regulator are working adequately.
Remove pressure gauge from inlet hose. Reconnect inlet hose.
FUEL FILTER
Replace fuel filter as per amintenance schedule.
Filter Removal
Remove oetiker clamps and pull hoses off. Detachfilter
from body.
Filter inspection
If fuel filter is suspected to be clogged, it may be checked as follows:
Using low compressed air, check if fuel filter is clogged. Air should flow easily through filter. In doubt, install a
new filter.
Filter installation
Use arrow on filter to position it according to fuel flow.
