When removing the fuel filter fuel spillage will occur. Be
sure to work in a well ventilated area away from
anything which may cause the fuel to ignite such as an
open flame, heaters, trouble lights or cigarettes.
1. The fuel filter should be replaced as outlined in the
periodic maintenance table.
2. Open the left and right door panels. Remove the hood
and drive belt.
3. Disengage the rubber strap securing the oil tank to the
clutch cover. Remove the oil tank mount screw.
4. Remove the two harness connectors from the ECU.
Remove the oil tank fill cap, and then the ECU bracket.
5. Remove the four nuts that mount the clutch cover to
the chassis. Slide the oil tank down to open access to
the two rear nuts.
6. Carefully release the clutch cover from the studs and
then pull it away from the airbox.
7.
Depressurize the fuel system. Remove the filter from
the airbox bracket. Disconnect the fuel supply hose
from the fuel pump flange using a disconnect tool.
8. Remove the bottom fuel fitting clamp on the fuel rail.
9. Carefully remove the fuel hose fitting from the fuel rail.
Have a clean shop rag at hand to absorb any fuel that
leaks from the fitting. Dispose of rag properly when
finished.
10. Drain any fuel in the hoses/filter into an appropriate
container, and then discard filter in accordance with
local rules and regulations.
11. Apply a light film of two stroke engine oil to the new
fuel supply hose fitting. Carefully install the fitting back
into the fuel rail. Torque screw to specification.
Fuel Hose Fittings-to-Fuel Rail Clamp Screws: 3.3 ft-lb (4.5 Nm)
12. Reconnect the supply hose to the fuel pump flange.
Verify an audible “click” is heard and the connections
are secure by firmly pulling on the two hose
connections. Push the filter cartridge back into the
bracket.
13. Inspect the hoses making sure none are worn or
damaged.
14. Reinstall the clutch cover. Torque cover nuts to
specification.
15. Reconnect the ECU wiring harness connectors.
16. Install the ECU bracket onto the oil tank. Reinstall the
oil tank. Torque mount screw to specification.
17. Reinstall the drive belt. Replace the hood and door
panels.
