3-94 FUEL SYSTEM (DFI)
Fuel Tank
Fuel Tank Removal
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch OFF. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.
•Remove:
Seats (see Frame chapter)
Fuel Tank Bolt [A]
• Fuel Tank Drain Hose
Disconnect the battery (–) terminal.
•Turn both ignition switch, and engine stop switch OFF.
•Wait until the engine cools down.
•Opentank. the fuel tank cap [A] to lower the pressure in the ○During tank removal, keep the tank cap open to release
pressure in the tank. This makes fuel spillage less.
•Draw the fuel out from the fuel tank with a commercially available pump [A].
○Use a soft plastic hose [B] as a pump inlet hose in order to insert the hose smoothly.
○Put the hose through the fill opening [C] into the tank and draw the fuel out.
Front [D]
WARNING
The fuel could not be removed completely from the fuel tank. Be careful for remained fuel spillage.
•Raise the fuel tank and disconnect the fuel pump lead connector [A] and fuel level sensor lead connector [B].
FUEL SYSTEM (DFI) 3-95
Fuel Tank
•Be sure to place a piece of cloth [A] around the fuel hose
•pump outlet joint [B].
While pinching the hose joint locks [C] with fingers, pull the joint out along the delivery pipe.
WARNING
Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.
When the fuel hose is disconnected, fuel spills out from the hose and the pipe because of residual pressure. Cover the hose connection with a piece of clean cloth to prevent fuel spillage.
•Close the fuel tank cap.
•Remove the fuel tank, and place it on a flat surface. ○Do not remove the pump inlet hose [A].
Fuel• Tank Installation
•Note the above WARNING (see Fuel Tank Removal).
•Route the hoses correctly (see Appendix chapter). Check that the rubber dampers [A] are on the frame and the fuel tank.
•Checkas well.that the dampers [A] are in place on the fuel tank If the dampers are damaged or deteriorated, replace them.
3-96 FUEL SYSTEM (DFI)
Fuel Tank
•Insert the pump outlet hose joint [A] straight onto the delivery pipe [B] until the hose joint clicks [C].
Front [D]
•Push and pull [A] the hose joint [B] back and forth more than two times and make sure it is locked and doesn’t come off. When the hose joint is correctly installed, it should slide on the delivery pipe about 5 mm (0.2 in.).
WARNING
Make sure the hose joint is installed correctly on the delivery pipe by sliding the joint, or the fuel could leak.
•If it does not slide, reinstall the hose joint.
Connect the fuel pump and the fuel level sensor connectors and the battery (–) lead terminal.
Fuel• Tank and Cap Inspection
Visually inspect the gasket [A] on the tank cap for any damage.
•Replace the gasket if it is damaged.
Check to see if the water drain pipe [B] and fuel breather pipe [C] in the tank are not clogged. Check the tank cap breather also.
If they are clogged, remove the tank and drain it, and then blow the breather free with compressed air.
CAUTION
Do not apply compressed air to the air vent holes [D] in the tank cap. This could cause damage and clogging of the labyrinth in the cap.
Fuel Tank Cleaning
WARNING
Clean the tank in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area. Because of the danger or highly flammable liquids, do not use gasoline or low-flash point solvents to clean the tank.
•Remove the fuel tank (see Fuel Tank Removal).
•Remove the fuel pump inlet hose and the fuel pump (see
•Fuel Pump section in this chapter).
Pour some high flash-point solvent into the fuel tank and
•shake the tank to remove dirt and fuel deposits.
•Draw the solvent out of the fuel tank.
•Dry the tank with compressed air.
•Install the fuel pump (see Fuel Pump Installation). Install the fuel tank (see Fuel Tank Installation).