FUEL TANK(w/ Canister Pump Module) REMOVAL

PROCEDURE


  1. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE

    Click here

  2. REMOVE FUEL TANK VENT TUBE ASSEMBLY

    Click here

  3. DRAIN FUEL

  4. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

  5. DISCONNECT FUEL TUBE


    1. A000SM7E03
      Text in Illustration
      *1 Retainer
      *2 Fuel Tube Connector
      *3 Nylon Tube
      *4 O-Ring
      *5 Pipe

      Detach the 2 claws of the fuel tube connector retainer, push down the retainer and disconnect the fuel tank main tube sub-assembly and fuel tank return tube as shown in the illustration.

      Note


      • Remove any dirt and foreign objects on the fuel tube connector before performing this work.

      • Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tube connector has O-rings that seal the pipe.

      • Perform this work by hand. Do not use any tools.

      • Do not forcibly bend, twist or turn the nylon tube.

      • Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel pump tube.

      • If the fuel tube connector and pipe are stuck, push and pull on them to release them.

  6. DISCONNECT FUEL TANK TO FILLER PIPE HOSE


    1. A000RUR

      Loosen the hose clamp bolt and disconnect the fuel tank to filler pipe hose.

  7. DISCONNECT FUEL CUT OFF VALVE TUBE


    1. A000NS6

      Disconnect the quick connector and clamp Click here.

  8. DISCONNECT FUEL TANK BREATHER TUBE


    1. A000OX4

      Disconnect the quick connector and clamp Click here.

  9. REMOVE REAR SUSPENSION MEMBER BRACE

    Click here

  10. REMOVE FUEL TANK ASSEMBLY


    1. A000QFG

      Using an engine lifter and attachments, support the fuel tank assembly.

      Text in Illustration
      B002B6O Bolt
      B002BBR Nut

    2. Remove the 2 nuts, 4 bolts and 2 No. 1 fuel tank bands.

    3. Using an engine lifter, lower the fuel tank assembly and remove it.

  11. REMOVE FUEL TUBE


    1. A000MX7E03
      Text in Illustration
      *1 Fuel Tank Return Tube
      *2 Fuel Tank Main Tube Sub-assembly

      Detach the No. 5 fuel tube clamp and remove the fuel tank return tube and fuel tank main tube sub-assembly from the fuel tank assembly.

    2. Remove the No. 5 fuel tube clamp from the fuel tank assembly.

  12. REMOVE FUEL TANK CUSHION


    1. A000PA4

      Remove the 5 No. 6 fuel tank cushions from the fuel tank assembly.

    2. A000SHCE03
      Text in Illustration
      *1 Fuel Tank Bracket
      *2 Fuel Tank Cushion
      *3 Fuel Tank Cushion Set
      *a RH side
      *b LH side

      Remove the fuel tank bracket, 2 fuel tank cushions and fuel tank cushion set from the fuel tank assembly.

  13. REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY


    1. A000SUQE01
      Text in Illustration
      *1 No. 1 Fuel Tank Protector Sub-assembly
      *2 No. 2 Fuel Tank Protector
      *3 No. 3 Fuel Tank Protector

      Remove the No. 1 fuel tank protector sub-assembly from the fuel tank assembly.

    2. Remove the No. 2 fuel tank protector and No. 3 fuel tank protector from the fuel tank assembly.