Fuel Tank; Fuel Tank Removal - Pioneer 1200 Maintenance Service Manual

FUEL SYSTEM
4. Install the fuel pump onto the mounting bracket with two thread-rolling screws (25) and tighten to 40 in-
lb (4.5 N·m).
5. Turn the fuel shut-off valve on top of the fuel tank to the open position (Figure 14-21, Page 14-27).
6. Connect the battery cables, positive (+) post first, and tighten terminals to 20 ft-lb (27 N·m). Coat termi-
nals with Battery Terminal Protector Spray (CCI P/N 1014305).
7. With the Forward/Reverse handle in the NEUTRAL position, start the engine and check for fuel leaks. If
the fuel pump leaks, a rebuild kit or new fuel pump must be installed to replace all gaskets and dia-
phragms, or entire pump. See following DANGER.
∆
DANGER
• Repair any fuel leaks before using the vehicle.

FUEL TANK

See General Warning, Section 1, Page 1-1.
∆
WARNING
• If the fuel tank is damaged, replace it. Do not attempt to repair it. See the following tank
removal and disposal procedure.
CAUTION
• Add only unleaded gasoline to the tank. Do not put oil into the fuel tank.

FUEL TANK REMOVAL

1. Turn the key switch to OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock
the wheels.
2. Turn fuel shut-off valve to the closed (OFF) position (Figure 14-20, Page 14-27).
3. Run the engine until fuel remaining in the carburetor, fuel pump, and fuel lines is used up and the engine
stalls.
4. Disconnect the battery cables as instructed. See WARNING "To avoid unintentionally starting..." in
General Warning, Section 1, Page 1-1.
5. Remove the four bolts (8), eight washers (9) and four lock nuts (10) from the seat support and remove
the two armrests (11 and 12) from the vehicle. See Figure 4-3, Section 4, Page 4-6.
6. Carefully remove and rotate the seat support (7) 90° clockwise and allow it to rest on the vehicle body
(Figure 14-14, Page 14-22). See following NOTE.
NOTE: It is not necessary to remove the park brake cable or differential lock cable to service or remove the
fuel tank.
2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
14
Fuel Tank
Page 14-21