Suzuki Burgman 400 - Service manual > Fuel Pump Disassembly and Assembly

Disassembly

1) Remove the fuel pump assembly.

Refer to "Fuel Pump Assembly Removal and Installation".

2) After removing the clamp screw (1), ground wire (2) and lead wire (Bl) (3), remove the fuel pump assembly (4).

3) Detach the fuel mesh filter (5) and remove the fuel pump (6).

4) Disconnect the lead wire (gray) (7) and remove the fuel level gauge assembly (8).

5) Remove the fuel guide (9) and fuel pressure regulator (10).

Assembly

Refer to "Fuel Mesh Filter Inspection".

Assemble the fuel pump assembly in the reverse order of the disassembly. Pay attention to the following points:

! CAUTION

• To prevent fuel leakage, each O-ring must be replaced with a new one.
• Apply engine oil lightly to each of the O-rings.

 

• Connect all wiring couplers securely so as not to cause contact failure.
• With the engine oil lightly applied to the O-ring, install the fuel pump to the fuel tank.

• After the fuel pump mounting bolts have been tightened temporarily, tighten them to specification in the specified torque.

Tightening torque
Fuel pump mounting bolt: 10 N*m (1.0 kgf-m, 7.0 lb-ft)

Fuel Pressure Inspection

Inspect the fuel pressure in the following procedures:

1) Remove the fuel tank bolt and move the fuel tank for vehicle backward.

2) Place a rag under the fuel feed hose and disconnect fuel feed hose (1) from the fuel tank.

! WARNING

• Use caution to minimize spillage of gasoline.
• Keep away from fire or spark.
• Spilled gasoline should be wiped off immediately.
• Work in a well-ventilated area.

3) Install the special tools to the fuel tank.

Special tool
(A): 09940-40211 (Fuel pressure gauge adapter)
(B): 09940-40230 (Fuel pressure gauge hose attachment)
(C): 09915-77331 (Meter (for high pressure) )
(D): 09915-74521 (Oil pressure gauge hose)

4) Turn the ignition ON and check for fuel pressure.

Fuel pressure
Approx. 300 kPa (3.0 kgf/cm2, 43.5 psi)

If the fuel pressure is lower than the specification, check for the followings:

• Hose leakage
• Filter clogging
• Pressure regulator
• Fuel pump

If the fuel pressure is higher than the specification, check for the followings:

• Pump check valve
• Pressure regulator

! CAUTION

• Prior to removing the special tool, turn the ignition switch to OFF position and gradually release fuel pressure.

! WARNING

• Use caution to minimize spillage of gasoline.
• Keep away from fire or spark.
• Spilled gasoline should be wiped off immediately.
• Work in a well-ventilated area.

5) After finishing the fuel pressure inspection, reinstall the fuel tank. Refer to "Fuel Tank Removal and Installation".

Fuel Pump Relay Inspection

Refer to "Electrical Components Location".

Inspect the fuel pump relay in the following procedures:

1) Remove the front leg shield. Refer to "Front Leg Shield Removal and Installation".

2) Remove the fuel pump relay (1).

3) First, check for insulation with the tester between terminals (2) and (3). Next, check for continuity between (2) and (3) with 12 V voltage applied, positive (+) to terminal (4) and negative (-) to terminal (5). If continuity does not exist, replace the relay with a new one.

Fuel Mesh Filter Inspection

Inspect the fuel mesh filter in the following procedures:

1) Remove the fuel mesh filter. Refer to "Fuel Pump Disassembly and Assembly".

2) If the fuel mesh filter is clogged with foreign particles, it hinders smooth gasoline flow resulting in loss of engine power. Such a filter should be cleaned by blowing with compressed air.

NOTE When the fuel mesh filter is dirtied excessively, replace the fuel filter cartridge with a new one.

3) After finishing the fuel mesh filter inspection, reinstall the fuel mesh filter. Refer to "Fuel Mesh Filter Inspection".

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