Kawasaki J300 - Service manual > Fuel Pump

Fuel Pump Removal

WARNING Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. 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. Disconnect the battery (-) terminal. To avoid fuel spills, draw it from the tank when the engine is cold. Be prepared for fuel spillage; any spilled fuel must be completely wiped up immediately.

NOTICE Never drop the fuel pump especially on a hard surface.

Such a shock to the injector can damage it.

• Remove:
  Fuel Tank Cap Cover (see Fuel Tank Cap Cover Removal in the Frame chapter)
  Fuel Injector (see Fuel Injector Removal)
• Disconnect the fuel pump connector [A]
• Remove:
  Fuel Pump Mounting Screws [B]
  Fuel Pump [C] with Fuel Hose

Fuel Pump Installation

• Remove dirt or dust from the fuel pump by lightly applying compressed air.
• Replace the O-ring [A] with a new one.
• Install the fuel pump and tighten its screws.

  Torque - Fuel Pump Mounting Screws: 3.4 N*m (0.35 kgf*m, 30 in*lb)

• Tighten the screws again to check the tightness.
• Install the removed parts (see appropriate chapters).

Fuel Pump Operation Inspection

NOTE

• Be sure the battery is fully charged.

 

• Turn the engine stop switch to run position.
• Turn the ignition switch on and make sure that the fuel pump operates (make light sounds) for 3 seconds, and then stops.
• Turn the ignition switch off.

  If the pump does not operate as described above, inspect the operating voltage (see Fuel Pump Operating Voltage Inspection).

Fuel Pump Operating Voltage Inspection

NOTE

• Be sure the battery is fully charged.

 

• Turn the ignition switch off.
• Remove the fuel tank cap cover (see Fuel Tank Cap Cover Removal in the Frame chapter).
• Disconnect the fuel pump connector and connect the measuring adapter [A] between these connectors.

  Main Harness [B]
  Fuel Pump [C]

Special Tool - Measuring Adapter: 57001-1700

• Connect a digital meter [D] to the measuring adapter leads.

Fuel Pump Operating Voltage
 Connections to Adapter:
  Digital Meter (+) → R (main harness R/BK) lead
  Digital Meter (-) → BK (main harness G) lead

• Measure the operating voltage with engine stopped and with the connector joined.
• Turn the engine stop switch to run position.
• Turn the ignition switch on.

Operating Voltage
 Standard: Battery Voltage for 3 seconds, and then 0 V

• Turn the ignition switch off.

  If the reading stays on battery voltage and never shows 0 V, check the fuel pump relay (see Relay Circuit Inspection in the Electrical System chapter).

  If the fuel pump relay is normal, check the ECU for its ground and power supply (see ECU Power Supply Inspection).

  If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).

  If there is still no battery voltage, check the fuel pump relay (see Relay Circuit Inspection in the Electrical System chapter).

  If the fuel pump relay is normal, check the wiring for continuity (see wiring diagram in this section).

  If the wiring is good, check the ECU for its ground and power supply (see ECU Power Supply Inspection).

  If the ground and power supply are good, replace the ECU (see ECU Removal/Installation).

  If the reading is in specification, but the pump does not operate, replace the fuel pump (see Fuel Pump Removal/Installation).

Pressure Regulator Removal

• The pressure regulator [A] is built into the fuel pump and can not be removed.

Fuel Filter Cleaning

• Remove the fuel pump (see Fuel Pump Removal).
• Wash the fuel filter [A] in non-flammable of high flash-point solvent. Use a brush to remove any contaminants trapped in the screens.

WARNING Gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the fuel filter in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area. Do not use gasoline or low flash-point solvents to clean the fuel filter.

If the fuel filter is damaged, replace it.

Fuel Pump Circuit

1. ECU
2. Fuel Pump
3. Engine Stop Switch
4. Fuse Box
5. Ignition Fuse 15 A
6. Charging/ECU Fuse 30 A
7. Ignition Switch
8. Side Stand Switch
9. Fuel Pump Relay
10. Battery
11. Engine Ground
12. Frame Ground 1
13. ECU Relay

See also: