Kawasaki J300 - Service manual > Fuel System

Fuel Hose Inspection (fuel leak, damage, installation condition)

• If the motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak [A] or the hose to burst. Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) and check the fuel hoses.

Replace the fuel hose if any fraying, cracks [B] or bulges [C] are noticed.

• Check that the fuel hose is routed according to Cable, Wire, and Hose Routing section in the Appendix chapter.

  Replace the hose if it has been sharply bent or kinked.

  Hose Clamps [A] Fuel Hose [B]

• Check that the fuel hose clamps are securely installed.
  • Push and pull [A] the fuel hose [B] back and forth, and make sure it is locked.

WARNING Leaking fuel can cause a fire or explosion resulting in serious burns. Make sure the hose clamp is installed correctly.

If it does not locked, reinstall the new hose clamp.

Fuel Hose Replacement

• Remove the fuel tank cap cover (see Fuel Tank Cap Cover Removal in the Frame chapter).

NOTE

• Ensure the fuel hose without any pressure, and then remove the fuel pump.

STEP 1: Disconnect the fuel pump connector.
STEP 2: Turn the ignition switch on. Starting the engine until the engine stop working.

• Be sure to place a piece of cloth [A] around the fuel hose connection.
• Wipe off the dirt of the surface [B] around the connection using a cloth or a soft brush.

• Clear the hook [A] of the hose clamp with a suitable tool [B] and flat tip screwdriver [C], and remove the hose clamp.
  • Insert the flat tip screwdriver under the hook while clamping the hose clamp with the suitable tool.

Recommend Tool: OETIKER 1098

WARNING Fuel is flammable and explosive under certain conditions and can cause severe burns. 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 because of residual pressure. Cover the hose connection with a piece of clean cloth to prevent fuel spillage.

• Clean the fuel pipe [A].
• If the new hose is not installed soon, cover the fuel pipe with the vinyl bag [B] to keep it clean.

• Remove the vinyl bag on the pipe.
• Check that there are no flaws, burrs, and adhesion of foreign materials on the fuel pipe [A].

• Replace the fuel hose and hose clamps with new ones, and install them.
• Run the fuel outlet hose correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).
• Pinch the new hose clamp [A] with a suitable tool [B] to install it.

Recommend Tool: OETIKER 1098

• Push and pull [A] the fuel hose [B] back and forth, and make sure it is locked and does not come off.

WARNING Leaking fuel can cause a fire or explosion resulting in severe burns. Make sure the fuel hose joint is installed correctly on the delivery pipe and that it doesn't leak.

If it comes off, reinstall the hose together with the new hose clamp.

• Start the engine and check the fuel hose for leaks.

See also: