Fuel Pump Removal
Caution: Never drop the fuel pump, especially on a hard surface. Such a shock to the pump can damage it.
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. Disconnect the battery (-) terminal. To make fuel spillage minimum, draw the fuel out from the fuel tank when the engine is cold. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.
- Draw the fuel out from the fuel tank with a commercially available electric pump.
- Remove the fuel tank (See Fuel Tank Removal).
Be careful of fuel spillage from the fuel tank since fuel still remains in the fuel tank and fuel pump. Plug the fuel pipe of the fuel tank.
- Turn the fuel tank upside down.
Remove:
- Fuel Pump Bolts [A]
- Fuel Pump [B] and gasket
- Discard the fuel pump gasket.
![](https://motoinstruction.ru/img/kawasaki/23/128343.jpg)
Caution: Do not pull the lead of the fuel pump. If they are pulled, the lead terminals may be damaged.
Fuel Pump Installation
- Remove dirt or dust from the fuel pump [A] by lightly applying compressed air.
![](https://motoinstruction.ru/img/kawasaki/23/128344.jpg)
- Replace the fuel pump gasket [A] with a new one.
![](https://motoinstruction.ru/img/kawasaki/23/128345.jpg)
- Apply a non-permanent locking agent to the threads of the fuel pump bolts.
- Tighten the fuel pump bolts to a snug fit, tighten them alternating diagonally.
Torque - Fuel Pump Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
- Tighten the pump bolts again alternating diagonally to check the tightness.
Fuel Pump Operation Inspection
Note: Be sure the battery is fully charged.
Just listen to the pump sound in the fuel tank to confirm pump operation.
- Turn the ignition switch ON and make sure that the fuel pump operates (make light sounds) for 3 seconds, and then stops.
- Turn the ignition switch OFF.
If the pump does not work as described above, inspect the operating voltage.
Fuel Pump Operating Voltage Inspection
Note: Be sure the battery is fully charged.
- Turn the ignition switch OFF.
- Remove the left side cover (See Side Cover Removal in the Frame chapter).
- Connect the hand tester (x DC 25 V) to the fuel pump connector [A] with needle adapter set.
Special Tools - Hand Tester: 57001-1394
Needle Adapter Set: 57001-1457
![](https://motoinstruction.ru/img/kawasaki/23/128346.jpg)
Pump Operating Voltage at Pump Connections to Pump Connectors
- Tester (+) → W/R Lead
- Tester (-) → BK/Y Lead
- Measure the operating voltage with the engine stopped, and with the connector joined.
- Turn the engine stop switch to run position.
- Turn the ignition switch ON.
The tester needle should indicate battery voltage for 3 seconds, and then 0 V.
Perating Voltage at Pump Connector
Standard: Battery Voltage for 3 seconds, and then 0 V
If the reading stays on battery voltage, and never shows 0 V. Check the ECU for its ground and power supply (See ECU Power Supply Inspection) and fuel pump relay.
If the voltage is in specification, but the pump doesn't work, replace the pump (See Fuel Pump Removal/Installation).
If there is still no battery voltage, check the pump relay (See Relay Box section in the Electrical System chapter).
Pressure Regulator Removal
The pressure regulator [A] is built into the fuel pump [B] and cannot be removed.
![](https://motoinstruction.ru/img/kawasaki/23/128347.jpg)
Pump Screen, Fuel Filter Cleaning
The fuel filter [A] is built into the pump and cannot be cleaned or checked.
If the fuel filter is suspected of clogging or being damaged, replace it with the fuel pump as a set.
![](https://motoinstruction.ru/img/kawasaki/23/128348.jpg)
Fuel Pump Circuit
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1. ECU; 2. Water-proof Joint C; 3. Engine Stop Switch; 4. Ignition Switch; 5. Water-proof Joint A; 6. ECU Fuse 15A; 7. Ignition Fuse 10 A; 8. ECU Main Relay; 9. Fuel Pump Relay; 10. Main Fuse 30 A; 11. Battery 12 V10 Ah; 12. Frame Ground; 13. Fuel Pump; 14. Joint Connector