4-8
1. Turn the ignition switch ON and listen for a
momentary “whirring” sound of the pump build-
ing pressure. If the sound is heard (2-3 seconds),
no electrical checks are necessary. Turn the igni-
tion switch OFF.
2. Disconnect one gasline hose from one of the fuel
injectors; then install a suitable pressure gauge on
the hose.
FI092A
3. Turn the ignition switch to the ON position. The
fuel pressure should build until the pump shuts off.
Pressure should read 3.0 kg-cm
2
(43 psi).
4. If the pump is not running, disconnect the fuel
pump/tank sensor connector by reaching under the
rear rack from behind.
5. Connect a multimeter to the power supply leads
with the red tester lead to the red wire and the
black tester lead to the black wire; then turn the
ignition switch to the ON position. The meter
should read battery voltage. If battery voltage is
indicated and the fuel pump does not run, replace
the pump assembly. If no battery voltage is indi-
cated, check the ECU and the vehicle tilt sensor.
REMOVING
1. Remove the rear rack and fenders (see Section 8);
then disconnect the power supply/fuel ok connec-
tor.
2. Remove the spring clamp; then remove the fuel
hose.
3. Remove the screws securing the fuel pump to the
gas tank; then make a reference mark on the fuel
pump and tank.
4. Lift out the fuel pump assembly carefully tilting it
forward to clear the voltage regulator; then guide
the pump and float lever through the opening in
the gas tank.
5. Using duct tape or other suitable means, cover the
fuel pump opening.
INSPECTING
1. Inspect the fuel screen and blow clean with low
pressure compressed air.
2. Move the float lever and check for free movement.
The float assembly should return to the lower posi-
tion without force. If not, replace the fuel pump
assembly.
3. Test the fuel level sensor by connecting a multime-
ter (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 level sensor.
4. To replace the fuel level sensor, use the following
procedure.
A. Disconnect the two-wire connector (A); then
press the fuel level sensor toward the top of the
fuel pump to release it from the mounting slot
(B).
! WARNING
Gasoline may be under pressure. Place an absor-
bent towel under the connector to absorb any gaso-
line spray when disconnecting.
! WARNING
Whenever the gasline hoses are removed (other
than for pressure testing), the battery must be dis-
connected to prevent inadvertent activation of the
electronic fuel pump.
! 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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