88
XR172
NOTE: The fuel pump will cycle 5-10 seconds after
the ignition key is turned on.
5. If the pump is producing fuel pressure that is out of
specification, check all electrical connectors and verify
the pump is getting proper voltage (battery voltage).
6. Connect a meter 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 posi-
tion. The meter should read battery voltage.
NOTE: Low voltage will produce a low fuel pressure
reading.
7. If normal battery voltage is present and the ground
wire has been checked for continuity to chassis,
replace the fuel pump. If no voltage is present, deter-
mine if the fuel pump fuse, relay, wiring, tilt sensor,
or ECM is causing no voltage.
NOTE: If the gauge is flashing FUEL OFF, the tilt sen-
sor system has intentionally deactivated the fuel system.
Removing
1. Disconnect the gasline hose and fuel pump connectors.
2. Remove the screws securing the fuel pump to the gas
tank; then make a reference mark on the fuel pump and
tank.
3. Lift out the fuel pump assembly; then guide the pump
and float lever through the opening in the gas tank.
4. 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. If not, replace the fuel pump
assembly.
3. Test the fuel level sensor by connecting a meter to
the fuel level sensor leads; then select OHMS. The
meter should show 5 ohms at full fuel position and
95 ohms at empty fuel position.
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.
Installing
1. Mark the new fuel pump with a reference mark in the
same location as the removed pump; then place the
new gasket on the pump.
2. Remove the material covering the fuel pump open-
ing; then carefully guide the fuel pump into position
taking care not to damage the float or float lever.
KX190
3. Rotate the fuel pump until the match marks align;
then install the mounting screws and tighten securely
using a crisscross pattern.
NOTE: It is critical to install the fuel pump with the cor-
rect orientation to ensure adequate float lever clearance.
4. Connect the wires, fuel hose, and spring clamp; then
turn the ignition switch to the ON position. Note that
the fuel pump runs momentarily and the fuel gauge
indicates the proper fuel level.
5. With the transmission in neutral and brake lever lock
engaged, start the engine and check for normal oper-
ation. Check for any fuel leaks.
TILT SENSOR
Tilt sensor is located on front of the steering post frame
bracket. Remove seat, front fender and storage box to
access.
Supply Voltage
1. Disconnect the three-wire connector from the sensor;
then select DC Voltage on the meter and connect the
red tester lead to the orange wire (C) and the black
tester lead to the pink/black wire (A).
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.
! WARNING
Incorrect installation of the tilt sensor could cause sud-
den loss of engine power which could result in loss of
vehicle control resulting in injury or death.
CAUTION
Do not drop the tilt sensor as shock can damage the
internal mechanism.
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