Removing The Fuel Tank; Removing The Fuel Pump; Installing The Fuel Pump; Installing The Fuel Tank - Yamaha 2007 XP500 Service Manual

EAS26630

REMOVING THE FUEL TANK

1. Extract the fuel in the fuel tank through the
fuel tank cap with a pump.
2. Remove:
Fuel hose connector cover "1"
G
3. Disconnect:
Fuel hose "2"
G
Fuel pump coupler "3"
G
Fuel tank breather hose "4"
G
ECA15B1031
CAUTION:
Be sure to disconnect the fuel hose by
G
hand. Do not forcefully disconnect the
hose with tools.
Although the fuel has been removed from
G
the fuel tank, be careful when removing the
fuel hoses, since there may be fuel remain-
ing in it.
Do not disconnect the fuel hose except the
G
fuel hose connector of the fuel pump feed-
ing side.
NOTE:
Before removing the hoses, place a few rags in
the area under where it will be removed.
4. Remove:
Fuel tank
G
EAS26640

REMOVING THE FUEL PUMP

1. Remove:
Fuel pump bracket
G
Fuel pump
G
Fuel pump gasket
G
ECA14720
CAUTION:
Do not drop the fuel pump or give it a
G
strong shock.
Do not touch the base section of the fuel
G
sender.
EAS26710

INSTALLING THE FUEL PUMP

1. Install:
Fuel pump gasket
G
Fuel pump
G
Fuel pump bracket
G
NOTE:
Do not damage the installation surfaces of the
G
fuel tank when installing the fuel pump.
Always use a new fuel pump gasket.
G
Align the projection "a" on the fuel pump with
G
the projection in the fuel tank.
Tighten the bolts to the specified torque in the
G
proper tightening sequence as shown.
Install the fuel pump in the direction shown in
G
the illustration.
4
2
EAS15B4013

INSTALLING THE FUEL TANK

3
1. Install:
1
Fuel tank
G
NOTE:
Tighten the bolts to the specified torque in the
proper tightening sequence as shown.
2. Connect:
Fuel hose
G
7-2
FUEL TANK
New
Fuel pump bracket bolt
4 Nm (0.4 m•kg, 2.9 ft • lb)
a
1
FWD
3
5
Fuel tank bolt
10 Nm (1.0 m•kg, 7.2 ft•lb)
2
FWD
1
6
4
2
4
3