Join Date: Mar 2008
Location: Kapuskasing Ontario Canada
Mentioned: 7 Post(s)
According to manual:
Fuel Pump Removal
Never drop the fuel pump, especially on a hard surface. Such a shock to the pump can damage it.
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, Fuel Pump, and gasket •Discard the fuel pump gasket.
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 by lightly applying compressed air.
•Replace the fuel pump gasket with a new one.
•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: 87 in·lb (7.25 ft-lbs)
•Tighten the pump bolts again alternating diagonally to check the tightness.
Kawasaki part # for the gasket (O-ring): 92055-0185. ($1.36 from Cheap Cycle Parts)
Last edited by invader; 12-28-2009 at 12:17 AM.