Removing The Fuel Tank; Removing The Fuel Pump; Checking The Fuel Pump Body; Installing The Fuel Pump - Yamaha XT1200Z 2010 Service Manual

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EAS26630

REMOVING THE FUEL TANK

1. Extract the fuel in the fuel tank through the
fuel tank cap with a pump.
2. Remove:
• Fuel hose
EWA23P1001
WARNING
Cover fuel hose connections with a cloth
when disconnecting them. Residual pres-
sure in the fuel lines could cause fuel to
spurt out when removing the hose.
ECA23P1090
NOTICE
Although the fuel has been removed from
the fuel tank, be careful when removing the
fuel hose, since there may be fuel remaining
in it.
TIP
• To remove the fuel hose from the fuel rail, slide
the fuel hose connector cover "1" on the end of
the hose in the direction of the arrow shown,
press the two buttons "2" on the sides of the
connector, and then remove the hose.
• Remove the fuel hose manually without using
any tools.
• Before removing the hose, place a few rags in
the area under where it will be removed.
1
3. Remove:
• Fuel tank
TIP
Do not set the fuel tank down on the installation
surface of the fuel pump. Be sure to lean the fuel
tank against a wall or the like.
EAS26640

REMOVING THE FUEL PUMP

1. Remove:
• Fuel pump
email: info@motomatrix.co.uk
2
ECA14720
NOTICE
• Do not drop the fuel pump or give it a
strong shock.
• Do not touch the base section of the fuel
sender.
EAS26670

CHECKING THE FUEL PUMP BODY

1. Check:
• Fuel pump body
Obstruction → Clean.
Cracks/damage → Replace fuel pump as-
sembly.
EAS26700

INSTALLING THE FUEL PUMP

1. Install:
• Fuel pump gasket "1"
• Fuel pump
• Fuel pump bracket
Fuel pump bolt
4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
TIP
• Do not damage the installation surfaces of the
fuel tank when installing the fuel pump.
• Always use a new fuel pump gasket.
• Install the fuel pump gasket with its lip "a" fac-
ing up.
• Align the projection "b" on the fuel pump with
the punch mark "c" on the fuel tank.
• Align the slot in the fuel pump bracket with the
projection "b" on the fuel pump.
• Tighten the fuel pump bolts in the proper tight-
ening sequence as shown.
1
7-3
FUEL TANK
New
a