FUEL SYSTEM (DFI) 3-141

Fuel Tank

Fuel Tank Removal

WARNING

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 and disconnect the battery (–) terminal.

To avoid fire, do not remove the fuel tank when the engine is still hot. Wait until it cools down.

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.

•Turn the ignition switch OFF.

•Wait until the engine cools down.

•Remove:

Front Seat (see Front Seat Removal in the Frame chapter)

Fuel Tank Bolts [A]

•Open the fuel tank cap [A] to lower the pressure in the tank.

○During tank removal, keep the tank cap open to release pressure in the tank. This makes fuel spillage less.

•Draw the fuel out from the fuel tank with a commercially available pump [A].

○Use a soft plastic hose [B] as a pump inlet hose in order to insert the hose smoothly.

○Put the hose through the fill opening [C] into the tank and draw the fuel out.

Front [D]

WARNING

The fuel could not be removed completely from the fuel tank. Be careful for remained fuel spillage.

3-142 FUEL SYSTEM (DFI)

Fuel Tank

•Disconnect:

Battery (–) Terminal [A]

Fuel Pump Lead Connector [B]

•Remove:

Fuel Tank Bolt [C]

Fuel Tank Drain Hose [D] Fuel Tank Breather Hose [E]

•For the California, Southeast Asia and Thailand models, remove the following.

Fuel Return Hose

•Be sure to place a piece of cloth [A] around the fuel hose joint.

•Insert a thin blade screwdriver [B] into the slit [C] on the joint lock [D].

•Turn [A] the driver to disconnect the joint lock [B].

•Pull the fuel hose joint [C] out of the outlet pipe.

WARNING

Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.

When the fuel hose is disconnected, fuel spills out from the hose and the pipe. Cover the hose connection with a clean shop towel to prevent fuel spillage.

•Close the fuel tank cap.

•Remove the fuel tank, and place a it on a flat surface.

FUEL SYSTEM (DFI) 3-143

Fuel Tank

•For the California, Southeast Asia and Thailand models, note the following.

CAUTION

For the California, Southeast Asia and Thailand models, if gasoline, solvent, water or any other liquid enters the canister, the canister’s vapor absorbing capacity is greatly reduced. If the canister does become contaminated, replace it with a new one.

○Be sure to plug the evaporative fuel return hose to prevent fuel spilling before fuel tank removal.

WARNING

For the California, Southeast Asia and Thailand models, be careful not to spill the gasoline through the return hose. Spilled fuel is hazardous.

If liquid or gasoline flows into the breather hose, remove the hose and blow it clean with compressed air.

○Be careful of fuel spillage from the fuel tank since fuel still remains in the fuel tank and fuel pump.

WARNING

Store the fuel tank in an area which is well -ventilated and free from any source of flame or sparks. Do not smoke in this area. Place the fuel tank on a flat surface and plug the fuel pipes to prevent fuel leakage.

Fuel Tank Installation

•Note the above WARNING (see Fuel Tank Removal).

•Run the hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).

•Check that the dampers [A] and pads [B] are in place on the frame and the fuel tank.

If the dampers and pads are damaged or deteriorated, replace them.

3-144 FUEL SYSTEM (DFI)

Fuel Tank

•Install the pads [A] and trim [B] as shown in the figure. Hook [C]

8 mm (0.31 in.) [D] View A [E]

View B [F]

Fuel Tank Bracket [G] Weld [H]

View Upper Side [I]

•For the California, Southeast Asia and Thailand models, note the following.

○To prevent the gasoline from flowing into or out of the canister, hold the separator perpendicular to the ground.

○Connect the hoses according to the diagram of the evaporative emission control system. Make sure they do not get pinched or kinked.

○Run the hoses with a minimum of bending so that the air or vapor will not be obstructed.

•Insert [A] the fuel hose joint [B] straight onto the fuel outlet pipe until the hose joint clicks.

•Push [C] the joint lock [D] until the hose joint clicks.