Pioneer 1200, Maintenance Service Manual

Page: 237 / 300

FUEL SYSTEM Fuel Tank
2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 14-25
14
FUEL TANK STORAGE OR DISPOSAL
1. Remove the cap from the tank and thoroughly rinse it with water. The cap may be discarded or kept as
a spare.
2. Flush the fuel tank with water to remove any remaining gasoline. Use a well-ventilated area.
3. Set the tank upside down so that the water can drain. Use a well-ventilated area. Allow the tank to sit for
24 hours to dry. See following WARNING.
∆
WARNING
• Dispose of wastewater and fuel tank in accordance with federal, state and local laws and
ordinances.
4. Store the tank upside down, with the cap installed. Use a well-ventilated area.
FUEL TANK INSTALLATION
1. Pioneer 1200:
1.1. Position the retaining straps (13 and 10) and install the fuel tank (Figure 14-15, Page 14-23).
1.1.1. Position the straps in the indentions on the tank.
1.2. Install the screws (12 and 14) into the speed nuts (11) and tighten screws to 25 in-lb (2.8 N·m)
(Figure 14-15, Page 14-23).
2. Pioneer 1200 SE:
2.1. Position the retaining strap (13) and install the fuel tank (Figure 14-16, Page 14-24).
2.2. Install the nut (12) onto the J-bolt (8) and tighten to 25 in-lb (2.8 N·m). Return the seat support (1)
to its original position by rotating it 90° counterclockwise (Figure 14-14, Page 14-22).
2.3. Install the seat support and seat handles and tighten bolts (8) to 13 ft-lb (17.6 N·m).
See Figure 4-3, Section 4, Page 4-6.
3. Connect the vent tube (6) to the fuel tank vent and secure with a new clamp (7) (Figure 14-15,
Page 14-23 or Figure 14-16, Page 14-24).
4. Connect fuel line (1) to the fuel tank shut-off valve (15) and secure with a new clamp (16).
Figure 14-17 Fuel Level Sending Unit
TANK
CONNECTION
BLACK
WIRE
ORANGE
WIRE
FRAME
CONNECTION