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In-tank Fuel Pump (fault Code 45); Fuel Pump Removal; Pump Screen Cleaning - Kawasaki Vulcan 1500 Classic Fi Service Manual

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2-112 FUEL SYSTEM (DFI)

In-tank Fuel Pump (Fault Code 45)

Fuel Pump Removal

Never drop the fuel pump, especially on a hard sur-
face. Such a shock to the pump can damage it.
Gasoline is extremely flammable and can be explo-
sive 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 with a pump as much as possi-
ble when the engine is cold. Be prepared for fuel
spillage; any spilled fuel must be completely wiped
up immediately.
The in-tank fuel pump shortens the DFI fuel lines, and
suppresses vaper lock in the fuel hoses.
Remove the fuel tank (see this chapter).
Draw the fuel out from the fuel tank with a commercially
available pump.
Be careful of fuel spillage from the fuel tank since fuel still
remains in the fuel tank and fuel pump. Plug all the fuel
pipes of the fuel tank.
Turn the fuel tank upside down.
Unscrew the fuel pump bolts [A], and take out the fuel
pump and gasket.
Front [B]
Discard the fuel pump gasket.

Pump Screen Cleaning

Clean the pump screen in a well-ventilated area, and
take care that there are no sparks or flame any-
where near the working area. Because of the dan-
ger of highly flammable liquids, do not use gasoline
or low-flash point solvent to clean the pump screen.
Remove the fuel pump [A] along with the pump screen
[B].
Discard the fuel pump gasket [D].
Prepare a container [C] filled with a high-flash point sol-
vent.
Dip and shake the pump in the solvent to remove dirt and
fuel deposits [E] from the pump screen.
Dry the pump and screen by lightly applying compressed
air.
Replace the fuel pump gasket with a new one.
Install the fuel pump (see this section).
CAUTION
WARNING
WARNING

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Vn1500 classic fi

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