Warning! Do not use solvents or other products that contain chlorine on plastic fuel system components. Chlorine can degrade plastic fuel system components, which can cause a loss of fuel system pressure or engine stalling and could result in death or serious injury.
The fuel filter element is located in the fuel pump assembly inside the fuel tank.
Check fuel system hose and fittings for leaks.
Removal
Warning! To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury.
1. Purge the fuel supply hose of high pressure gasoline. Disconnect fuel supply hose from fuel pump module. See 4.4 FUEL TANK: XL MODELS or 4.5 FUEL TANK: XR 1200X.
2. Remove seat.
Warning! To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding.
3. Remove main fuse.
4. Drain and remove fuel tank. See 4.4 FUEL TANK: XL MODELS or 4.5 FUEL TANK: XR 1200X.
5. Remove fuel pump assembly from fuel tank. See 4.16 FUEL PUMP.
6. See Figure 4-80. Remove and discard cover plate seal (6).
Figure 4-80. Replacing fuel filter element: 1. Fuel pump assembly; 2. O-ring; 3. Fuel filter element; 4. Retaining clip; 5. Filter housing; 6. Cover plate seal; 7. Cover plate
7. Remove retaining clip (4) and lift filter housing (5) off fuel pump assembly (1).
8. Remove and discard filter element (3).
Installation
FASTENER | TORQUE VALUE | |
Fuel pump module mounting screw | 40-45 in·lbs | 4.5-5.1 Nm |
1. See Figure 4-80. Install a new O-ring (2).
2. Install new filter element (3) into filter housing (5).
3. Install filter housing onto base of fuel pump assembly (1). Secure with retaining clip (4), making sure that clip is oriented right side up, exactly as shown in the figure.
4. Install new cover plate seal (6) into groove in cover plate (7).
5. Install fuel pump assembly into fuel tank. Tighten mounting screws in a cross pattern to 40-45 in·lbs (4.5-5.1 Nm). See 4.16 FUEL PUMP.
6. Install fuel tank and reconnect fuel hose. See 4.4 FUEL TANK: XL MODELS or 4.5 FUEL TANK: XR 1200X. Fill fuel tank and carefully check for leaks.
7. Install main fuse.
8. Install seat.
9. Turn ignition switch ON. Verify fuel pump operation.