90
Removing Fuel Pump Assembly
1. Remove the key from the ignition switch.
2. Remove the passenger seat; then disconnect the neg-
ative battery cable.
3. Disconnect the electrical plug (A) from the main har-
ness; then disconnect the fuel hose (B) from the fuel
pump.
XX342
4. Mark the fuel pump mounting and gas tank for
installing purposes; then remove the cap screws
securing the fuel pump to the gas tank and remove
the fuel pump.
XX342A
5. Using duct tape or other suitable means, cover the
fuel pump opening.
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 posi-
tion without force.
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).
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.
Replacing Fuel Level Sensor
To replace the fuel level sensor, use the following proce-
dure.
1. Cut the two blue wires (A) in the location shown.
2. Slide the existing sensor assembly (B) up and off the
fuel pump assembly housing.
XR257A
3. Keeping the float attached to the float arm, remove
the float arm from the existing fuel level sensor.
Press the float arm into the new fuel level sensor
assembly. Ensure it locks into place.
! WARNING
Always ensure that power cannot be inadvertently
applied to the ignition/ECM when working on the fuel
system. If the ignition switch is turned on, the electric
fuel pump will start and gas could be rapidly pumped
and spilled resulting in fire and severe injury.
CAUTION
Take care not to damage the float or float arm or
replacement of the entire assembly will be necessary.
AT THIS POINT
If the pump has failed earlier test and must be replaced,
proceed to INSTALLING.
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