4-8
Installing
1. Using a new gasket, install the two alignment pins
and gasket onto the magneto cover; then install the
water pump housing and secure with the six cap
screws. Finger-tighten only at this time.
2. Install the water pump cover with a new O-ring
and secure with four cap screws.
3. Tighten the cap screws from steps 1 and 2 using a
crisscross pattern to 8 ft-lb.
4. Fill the engine/transmission with the proper
amount of recommended oil.
5. Fill the cooling system with the proper amount of
recommended coolant.
NOTE: While the cooling system is being filled,
air pockets may develop; therefore, run the engine
for five minutes after the initial fill, shut the engine
off, and then fill the cooling system.
6. Check the entire cooling system for leakage.
Electric Fuel Pump/
Fuel Level Sensor
The electric 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
momentary “whirring” sound of the pump build-
ing 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 body; then
install a suitable pressure gauge.
FI527A
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 hose con-
nector.
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.
CAUTION
After operating the ATV for the initial 5-10 minutes,
stop the engine, allow the engine to cool down, and
check the coolant level. Add coolant as necessary.
! WARNING
Whenever any maintenance or inspection is made on
the fuel system during which there may be fuel leak-
age, there should be no welding, smoking, open
flames, etc., in the area.
AT THIS POINT
Prior to removing the electric fuel pump, the following
check 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.
CAUTION
Take care not to damage the float or float arm or
replacement of the entire assembly will be necessary.
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