Fuel Tank: Service and Repair

FUEL TANK




Components

Removal and Installation

REMOVAL

WARNING: Be sure to read "General Precautions" when working on the fuel system. Refer to "General Precautions".
- Drain fuel from fuel tank if necessary.
- Perform work on level place.

1. Perform steps 2 to 7 of "REMOVAL" in " FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY" on main and sub fuel level sensor units.
2. Remove tunnel stay. Refer to "REAR SUSPENSION ASSEMBLY".
3. Remove exhaust front tube, center muffler and main muffler. Refer to "EXHAUST SYSTEM".
4. Remove propeller shaft.
5. Remove parking rear brake cables. Refer to "PARKING BRAKE CONTROL".
6. Remove rear suspension assembly.
7. Remove fuel tank protector.




8. Disconnect fuel filler hose, vent hose and EVAP hoses at fuel tank side.




9. Remove fuel tank mounting band bolts while supporting fuel tank.
10. Remove fuel tank.

INSTALLATION
Note the following, and install in the reverse order of removal.
- Surely clamp fuel hoses and insert hose to the length below.

Fuel filler hose : 35 mm (1.38 in)
The other hoses : 25 mm (0.98 in)

- Be sure hose clamp is not placed on swelled area of fuel tube.
- Tighten fuel hose clamp so that the distance between its lugs becomes to the following.

Fuel tank side : 8 - 12 mm (0.31 - 0.47 in)
Fuel filler tube side : 5.7 - 9.7 mm (0.22 - 0.38 in)

- To connect quick connector, refer to "Quick Connector".

INSPECTION AFTER INSTALLATION
Use the following procedure to check for fuel leaks.
1. Turn ignition switch "ON" (with engine stopped), and check connections for leakage by applying fuel pressure to fuel piping.
2. Start engine and check for fuel leaks at the fuel system tube and hose connections.