1. Seat 6. Side cover 11. Fuel pump retainer. 4. Mud guard 9. Fuel pump gasket : Do not reuse.
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1 LT-A450** K8 ~ L0 LT-A500** K9 ~ L1 LT-A750** K8 ~ L1 Fuel Tank Removal, Inspection and Installation Procedure Necessary Tools Ratchet handle (9.5 sq) Socket wrench (10 mm, 9.5 sq) Socket wrench (12 mm, 9.5 sq) Extension bar (150 mm, 9.5sq) Flat-end screwdriver Phillips screwdriver Hexagon wrench (5 mm) Small needle nose pliers Torque wrench (9.5 sq) Component Location 1. Seat 6. Side cover 11. Fuel pump retainer 2. Rear carrier 7. Fuel tank outer cover : 45 N m (4.5 kgf-m, 32.5 lbf-ft) 3. Rear fender 8. Fuel tank : 23 N m (2.3 kgf-m, 16.5 lbf-ft) 4. Mud guard 9. Fuel pump gasket : Do not reuse. 5. Engine side cover 10. Fuel pump : Use new one in case any parts 1 are damaged.
2 Replacement parts Campaign Parts Set Part Number Contents Q ty Note Packing Set, Fuel Tank RX0 Packing, Fuel Tank 1 Rear carrier Bolt (8 16) 6 mounting bolts. Tank Assy, Fuel G12-RX0 Tank Assy, Fuel 1 Depend on the inspection result. Clip & Nut Set, Fuel Tank RX0 Clip A ( ) 17 If necessary. Clip B ( ) 2 Clip C ( ) 6 Nut ( ) 3 Special tools Campaign Parts Set Part Number Contents Q ty Note Ring, Locknut Wrench RX0 Ring, Locknut Wrench 1 Alternative for Tool Set, Fuel Tank RX0 Plate, Fuel Tank Check 1 Wire, Fuel Tank 1 Wiring Harness Routing Diagram 1. ECM 3. Fuse box 5. Starter relay 2. Neutral relay 4. Fuel pump relay 6. 4WD/diff-lock relay 2
3 Removal WARNING Keep away from fire or spark. Spilled gasoline should be wiped off immediately. Work in a well-ventilated area. 1) Turn the ignition switch OFF position. 2) Pull the seat lock lever (1) upward, and remove the seat (2). 3) Remove the battery stay (1) and the collars. 4) Remove the battery (4). NOTE Be sure to disconnect the battery ( ) lead wire (2) first, then disconnect the battery (+) lead wire (3). 3
4 5) Pull the starter relay (1). 6) Disconnect the starter relay coupler (2) and remove the starter relay cover (3). 7) Disconnect the starter motor lead wire (4) and coupler (5). 8) Disconnect the couplers and remove the ECM (1), neutral relay/fuse box (2), fuel pump relay (3), 4WD/diff-lock relay (4) and tool (5). 9) Remove the engine side cover (1). 4
5 10) Remove the side covers (1), left and right. A : Left side B : Right side 11) Remove the rear carrier bolts (2). A : Left side B : Right side 5
6 12) Remove the fasteners (1) and screws (2). A : Left side 13) Remove the parking brake cable (5) from the cable guide. B : Right side 14) Remove the fuel tank cap (6). CAUTION To prevent the fuel tank from contamination with foreign particles, install the fuel tank cap after removing the rear fender. 15) Remove the rear fender together with the rear carrier (7). 6
7 16) Remove the fasteners (3), bolt (4) and screw (5). 17) Remove the fuel tank outer cover (6). 18) Place a rag under the fuel feed hose and disconnect the fuel feed hose (1) from the fuel pump. 19) Disconnect the fuel tank coupler (2) and fuel tank breather hose (3) 20) Remove the fuel tank mounting bolts. 21) Remove the fuel tank from the left side. 22) Remove the fuel pump retainer (1) with the special tool (A). Note: Drain a certain amount of fuel to avoid overflow before removing the retainer. Special tool (A): RX0 (Ring locknut wrench) Or ) Remove the fuel pump assembly (2) and fuel pump gasket. 7
8 Inspection 1) Check the fuel tank inlet width P at the 8 points by the special tool as shown in the illustration. If the width P is bigger than the groove on the special tool, go to the next step. If the width P is smaller than the groove, replace the fuel tank assy. Inside Outside Inside Outside OK OK Inside Outside Inside Outside Retry at other points. NOTE If the special tool (A) can not put deeply as shown in the illustlation, please check at the closest points which can be checked deeply. Special tool (A): RX0 (Fuel Tank Check Plate) 2) Trace the fuel tank inlet inside edge 3 turns along the edge by the special tool to remove burr. Please refer to the illustration. (B) CAUTION Do not push the tool strongly onto the edge otherwise it might be deformed. Special tool (B): RX0 (Fuel Tank Wire) (B) 8
9 Installation Install the fuel pump assembly in the reverse order of removal. Pay attention to the following points: Install the new fuel pump gasket (2). Make sure that the fuel pump gasket lip is properly installed and not deformed. CAUTION Fuel may leak if the fuel pump gasket lip (1) is not properly installed. Install the fuel pump. Make sure that the fuel pump is installed properly onto the fuel pump gasket (2). Align the fuel pump nipple (3) with the alignment mark A on the fuel tank. Install the fuel pump retainer (5) with pushing the fuel pump (4) downward. Tighten the fuel pump retainer with the special tool to the specified torque. Special tool (A): RX0 (Ring locknut wrench) Or Tightening torque Fuel pump retainer (a): 45 N m (4.5 kgf-m, 32.5 lbf-ft) Install the fuel tank. Install the new carrier bolts. Tighten the new carrier bolts to the specified torque. Tightening torque Carrier bolt (b): 23 N m (2.3 kgf-m, 16.5 lbf-ft) Tighten the bolts and screws securely. When connecting a connector, be sure to push it until a click is felt. Install the removed parts in the reverse order of removal. 9
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