Sub-Fuel Tank/Fuel Pump Removal/Installation; Sub-Fuel Tank/Fuel Pump Disassembly - Honda TRX500FM Service Manual

FUEL SYSTEM
Wipe
off
spilled
ouf
gasoJine.
REMOVAL/INSTALLATION
Remove the nghl mudguard (page 2-6).
Relieve the fuel pressure and disconnect the quick
connect filling from the sub-fuel lank/fuel pump
assembly (page 7-6).
Clamp the fuel hose (1
J
althe point from the upper hose
end is 55 mm (2.2 in), using the hose dip.
TOOL :
(2] Hose clip
07614-0050101
or
equivalent
commercial ly
available in U.S.A.
Disconnect the fuel hose and fuel vapor return hose (3].
Remove the bolt (4]. collar [5] and the sub-fuel tank/fuel
pump assembly [6] from the frame.
Install the sub-fuel tank/fuel pump assembly [1] onto the , - - - - - - - - - - -- - -- - - - - ,
frame by aligning the bosses with the mounting
grommets.
Install the collar [2J and bolt [3], then tighten the bolt
securely.
Connect the fuel hose [4J and fuel vapor return hose [5]
to the sub-fuel tanklfuel pump assembly.
Remove the hose clip from the fuel hose.
Connect the quick connect fitting to the sub-fuel lank/
fuel pump assembty (page 7-9).
Install the removed paris in the reverse order of
removal.
DISASSEMBLY
NOTE :
To prevent dirt and debris from entering the fuel
pump. always clean
it
before disassembly.
Clean the inside of the fuel pump case, fuel pump
unit and fuel pump filter with clean gasoline. Never
use commercially available carburetor cleaners.
Always replace all O-rings with new ones when the
fuel pump has been disassembled.
Be careful not to damage the fuel pump unit wire.
Align
Drain the fuel from the fuel pump case [1] and store it in
an approved container.
Do not
over-tighten
Set the fuet pump case in a vise with soft jaws as
the VIse
shown.
7-14
L
Setting Positions
1 31
J