Section 10 FUEL SYSTEM
Subsection 02 (FUEL CIRCUIT)
10-02-10 SMR2003-030_10_02A.FM
Pressure Relief Valve
This valve will eliminate fuel spillage when the wa-
tercraft is upside down. If pressure is built up in
fuel system the valve should open at 3.5 kPa (0.5
PSI) for DI, 4-TEC and RFI models and at 10 kPa
(1.5 PSI) for all other models to release the pres-
sure.
NOTE: It is a one-way valve with an arrow to indi-
cate the air flow.
Check Valve
Black side of the one-way check valve no. 7 is the
valve outlet. It allows air to get in reservoir.
Baffle Pick Up Filter
All Models except RFI, DI and 4-TEC
Inspect filter no. 9 of baffle pick up. Clean or re-
place as necessary.
Fuel Tank
All Models
Visually inspect the inside and outside of the fuel
tank necks for crack(s). If crack(s) are existing, re-
place fuel tank no. 14.
Check with your finger to feel the inside and out-
side surfaces of fuel tank. Flex fuel tank necks to
ensure there are no hidden cracks.
1. Tank upper surface
2. Inspect outside, above upper surface
3. Normal molding seam
4. Inspect inside, above upper surface
5. Base of the neck
A. Approx. 4 mm (5/32 in)
NOTE: A fuel tank is comprised of 3 components:
the tank, the fuel pick up neck and the filler neck.
The necks are injection molded and the tank is
then blow molded over the necks. During the
molding process, a small molding seam may ap-
pear on the inner side of the necks at approximate-
ly 4 mm (5/32 in) from the base of the neck. It is a
normal situation to have a molding seam and it
should not be confused with a crack.
ASSEMBLY
Assembly is essentially the reverse of disassem-
bly procedures. However pay particular attention
to the following.
Reinstall fuel pump. Refer to ENGINE MANAGE-
MENT section.
4-TEC Engines
Ensure rubber carpet is in place.
Insert tank, air box and straps.
Place straps in clips (bottom) and in guides of air-
box.
Insert strap ends in hoops. Use tape to hold in
place.
Properly secure harnesses.
Reinstall fuel pump. Refer to ENGINE MANAGE-
MENT section.
Baffle Pick Up
All Models except RFI, DI and 4-TEC
Slide adapter no. 11 onto baffle pick up no. 8 until
it stops on rib. Install clamp no. 12.
Install baffle pick up no. 8 into fuel tank and push it
until it sits on fuel tank neck. Install clamp no. 10
and torque both clamps to 3 N•m (27 lbf•in).
FUEL SYSTEM PRESSURIZATION
WARNING
If pressure relief valve is stuck, the pressure
in fuel system will build up and it may cause
fuel leakage in engine compartment.
WARNING
Whenever doing any type of repair on water-
craft or if any components of the fuel system
are disconnected, a pressure test must be
done before starting engine. Ensure to verify
fuel line ends for damage. Always cut dam-
aged end before reinstallation.
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