honda shadow spirit fuel pump

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YAMAHA Road Star Fuel Pump Relocation Kit INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 08-11-2010

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1. Remove seat and disconnect battery. Remove fuel tank along with both left and right side battery covers, and remove air box from carburetor (all per Yamaha standard shop manual procedures). 2. Remove chrome plastic cover over fuel pump and disconnect choke cable/knob from lower pump bracket. Remove pump-to-carb fuel line from fuel pump. Disconnect fuel pumps electrical lead connector. 3. Remove two (2) hex-head pump mounting bracket bolts and remove pump assembly from motorcycle. Slide fuel pump up and off bracket mounting posts (Caution: excess fuel may drain from pump and/or fuel lines and fuel filter!). Remove heat shield. Remove remaining fuel line from pump. Pull all fuel lines from filter and remove steel springs and hose clamps from these lines (these will be reused on the kits fuel lines). With a sharp knife or box cutter, trim off the top portion of the fuel pumps rubber isolation/mount system per Photo A. Next cut pumps wiring harness approximately half way between connector and pump. Strip the insulation from the ends of these wires as well as from the supplied Baron harness extension wires. Using the supplied electrical butt connectors, crimp Baron harness extensions red wire to pumps black-w/blue-strip wire, and Baron harness extensions black wire to pumps black wire. Repeat this process on other side of wire harness extension with pumps connector. Now, referring to Photo B, you will need to cut off the square tube that runs along the side of the fuel pump with a hack saw. Cut down toward pump body in a straight cut, then cut tube off by cutting along the body. This will allow you to twist pump in the rubber mount so the curved spigot is facing up (clockwise approx 1/4 turn). 4. Remove pump-to-carb fuel line from carb and separate electrical wires from this line. Remove this fuel line from engine. Re-route choke cable to right side of engine (toward carb) and rotate it up and over rear cylinder head back toward left side of bike. Mount new Baron choke bracket to the choke cable and tighten plastic nut. New choke bracket will mount to rear fuel tank mounting location (Photo C). 5. 99~03 models – Remove electrical relay bracket (found under the right side cover) from the bike and slide each relay off of this bracket. Install fuel pump onto new Baron Fuel Pump Bracket and install bracket in the same location as the stock bracket you just removed, using stock mounting hardware. Refer to Photo F for proper installation. 6. 04~07 models Remove electrical relays from stock bracket and remove relays from rubber holder. Cut rubber holder per Photo E and replace one of the relays into the rubber and install on to new Baron bracket. The second relay will be placed to the right of the tool bag under the seat and secured with the provided two-sided tape pad. Reconnect plugs to the relays. (Photo F)

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2003 SUZUKI SV 650 FUEL SYSTEM AND THROTTLE BODY SERVICE MANUAL

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Filed Under (Suzuki) by admin on 26-02-2011

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FUEL PUMP The electric fuel pump is mounted at the bottom of the fuel tank, which consists of the armature, magnet, impeller, brush, check valve and relief valve . The ECM controls its ON/OFF operation as controlled under the FUEL PUMP CONTROL SYSTEM . When electrical energy is supplied to the fuel pump, the motor in the pump runs and together with the impel- ler . This causes a pressure difference to occur on both sides of the impeller as there are many grooves around it . Then the fuel is drawn through the inlet port, and with its pressure increased, it is discharged through the outlet port . The fuel pump has a check valve to keep some pressure in the fuel feed hose even when the fuel pump is stopped . Also, the relief valve is equipped in the fuel pump, which releases pressurized fuel to the fuel tank when the outlet of the fuel pressure has increased up to 450 -600 kPa (4.5- 6.0 kgf/cm2,64- 85 psi) . Relief valve Brush , ∎ I,’ Check valve Magnet L Armature When the impeller is driven by the motor, pressure differential occurs between the front part and the rear part of the blade groove as viewed in angular direction due to fluid friction . This process continuously takes place causing fuel pressure to be built up . The pressurized fuel is then let out from the pump chamber and discharged through the motor section and the check valve . FUEL SYSTEM AND THROTTLE BODY 5- 3 Inlet port I I Impeller 5-4 FUEL SYSTEM AND THROTTLE BODY FUEL PRESSURE REGULATOR The fuel pressure regulator consists of the spring and valve . It keeps absolute fuel pressure of 300 kPa (3.0 kgf/cm2,43 psi) to be applied to the injector at all times . When the fuel pressure rises more than 300 kPa (3 .0 kgf/cm2, 43 psi), the fuel pushes the valve in the regulator open and excess fuel returns to the fuel tank . 90 Spring 02 Valve FUEL INJECTOR The fuel injector consists of the solenoid coil, plunger, needle valve and filter . It is an electromagnetic type injection nozzle which injects fuel in the throttle body according to the signal from the ECM. When the solenoid coil of the injector is energized by the ECM, it becomes an electromagnet and attracts the plunger. At the same time, the needle valve incorporated with the plunger opens and the injector which is under the fuel pressure injects fuel in conic dispersion . As the lift stroke of the needle valve of the injector is set constant, the volume of the fuel injected at one time is determined by the length of time during which the solenoid coil is energized (injection time)

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2007 Softail HARLEY DAVIDSON FUEL PUMP/ FUEL GAUGE SENDING UNIT REMOVAL AND INSTALLATION

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Filed Under (Harley Davidson) by admin on 30-03-2012

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1. Remove seat. 1 WARNING 1 WARNING To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00275a) 2. Purge the fuel supply line of high pressure gasoline. a. See Figure 4-36. Disconnect the fuel pump fuse from the main wiring harness. b. Start the engine and allow the vehicle to run. c. When the engine stalls, operate the starter for 3 seconds to remove any remaining fuel from the fuel lines. 1 WARNING 1 WARNING To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 3. Disconnect negative battery cable. 4. Remove instrument console. a. All but FXSTD, see Figure 4-37. Remove acorn nut and washer on instrument console to separate console from fuel tank. b. For FXSTD, see 8.26 INSTRUMENT CONSOLE: FXSTD. 5. Disconnect console wiring. Figure 4-36. Fuel Pump Fuse: View From Top Figure 4-37. Acorn Nut And Washer: All But FXSTD s0660x8xx 7526
4-28 2007 Softail: Fuel System HOME 1 WARNING 1 WARNING Gasoline can drain from the crossover line when disconnected from fuel tank. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. Wipe up spilled fuel immediately and dispose of rags in a suitable manner. (00259a) 6. Drain fuel tank. a. Obtain a short section of hose (5/16 inch I.D.). Insert bolt in one end of hose and install hose clamp to ensure that end is securely plugged. b. See Figure 4-38. Cut clamp (1) from one end of crossover hose (2). Quickly replace crossover hose on fuel tank fitting with open end of short hose while directing flow of gasoline from free end of crossover hose into suitable container. 7. See Figure 4-39. Unplug fuel pump module connector (3) [86]. 8. Remove top plate screws (2) and discard. 9. See Figure 4-40. Pull top plate (2) out of fuel tank enough to expose fuel hose and clamp (1). CAUTION Carefully inspect end of hose for cuts, tears, holes or other damage. Replace hose if any damage is found. Even the smallest hole can cause a reduction in fuel pressure. 10. Cut clamp and remove hose from regulator housing fit- ting.

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HARLEY DAVIDSON FUEL LEVEL SENDER ADAPTER BRACKET KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 28-02-2011

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INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Refer to the Service Manual and follow the instructions given to remove the main fuse. When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 2. Remove the currently installed fuel tank from the vehicle. Follow the instructions for the correct model vehicle under FUEL TANK: EFI, REMOVAL in the Service Manual. 3. See FUEL PUMP/FUEL GAUGE SENDING UNIT, REMOVAL in the Service Manual for instructions to: a. Unplug the fuel pump module connector. b. Remove and discard the top plate screws. c. Remove the top plate, fuel pump and fuel level sender (fuel gauge sending unit) from the tank. NOTE Take care to avoid bending the fuel level sender float rod. A bent float rod will lead to erroneous gauge readings. 2 6 1 3 4 7 9 8 5 is05284 1. Fuel level sender 2. Electrical grounding tab 3. Fuel level sender lock tab 4. Adapter bracket 5. Slot (2) 6. Terminal strip insert 7. Sender to adapter lock tab 8. Slider 9. Adapter to tank lock tab Figure 1. Fuel Level Sender Assembly to Adapter – 4. See Figure 1. Clean the electrical grounding tab (2) on the back of the fuel level sender if necessary. The tab must make firm contact with the terminal strip insert (6) in the adapter bracket. Slide the original equipment (O.E.) fuel level sender (1) into the slots (5) in the new adapter bracket (4) as shown until the lock tabs (3 and 7) snap into place. Make sure the wire is not pinched between the adapter and sender. 5. See FUEL SUPPLY CHECK VALVE/TUBE in the Service Manual. Remove the check valve/quick-connect fitting assembly from the old fuel tank, and assemble to the new tank, using a new O-ring (purchased separately). 6. Fit the slider (8) on the adapter bracket into the fuel level sender mounting channel inside the tank, and push down until the lock tab (9) snaps into place. Make sure the sender and adapter wires are not pinched between the adapter and the fuel tank tunnel, and remain accessible through the fuel tank top opening. 7. See Figure 2. Obtain the assembly of the top plate (1), regulator (2) and fuel filter (3) removed from the old fuel tank, and the stainless steel screw (8) and nut (9) provided in this kit.

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BUELL ACCESSORY GAS CAP KIT INSTALLATION MANUAL

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Filed Under (Buell) by admin on 29-03-2011

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Installation NOTE When performing the following Steps, use the Fuel Tank Vent Valve Installation Kit (Part Number 91432-96Y). This kit consists of: * Fuel Tank Vent Valve Installation Aid * Fuel Tank Vent Valve Fitting Socket To protect against shock and accidental start-up of vehicle, disconnect the battery cables, negative cable first, before proceeding. Inadequate safety precautions could result in death or serious injury. Always disconnect the negative battery cable first. If the positive battery cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion which could result in death or serious injury. 1. Disconnect battery cables, negative cable first. An open flame or spark may cause a fuel tank explosion if all traces of fuel are not purged from the tank. Use extreme caution when servicing fuel tanks. Gasoline is extremely flammable and highly explosive. Do not smoke or allow open flame or sparks anywhere in the area when working on fuel system components. Inadequate safety precautions could result in death or serious injury. 2. Remove gas cap. 3. Carbureted Models: Drain fuel tank. Disconnect hose clamp and fuel supply hose from fuel supply valve and drain fuel into suitable, clean container. See applicable Service Manual, Section 4 for complete, detailed procedure. Fuel Injected Models: Relieve pressure from fuel system. See applicable Service Manual, Section 4 for complete, detailed procedure. Drain fuel tank. a. Using suitable external fuel pump, such as a Gas Caddy, pump fuel from tank and into a suitable, clean container. b. See instructions for external fuel pump for correct use. 4. See Figure 1. Cut cable tie securing vent hose to fitting and remove vent hose from fuel tank. Even with the fuel tank completely drained, a small amount of gasoline may leak from the bore when the fuel supply valve is loosened or removed. Thoroughly wipe up any fuel immediately and dispose of rags in a suitable manner. Gasoline is extremely flammable and highly explosive. Inadequate safety precautions could result in death or serious injury. 5. If the fuel supply valve requires cleaning or repair, refer to applicable Service Manual, Section 4, for complete, detailed procedures. 6. See Figure 1. Remove the fuel filler cap and O-ring. 7. Remove the eight self-tapping screws from fuel clamp flange and remove fuel cap flange

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2005 Honda CRF450X OWNER'S MANUAL AND COMPETITION HANDBOOK

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Filed Under (Honda) by admin on 04-12-2010

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Starting & Stopping the Engine Always follow the proper starting procedure described below. Your CRF can be started with the transmission in gear by pulling in the clutch lever before operating the kickstarter or start button. Preparation Make sure that the transmission is in neutral. Turn the fuel valve ON. Fuel Valve Starting Procedure Always follow the proper starting procedure described as follow. 5. Warm up the engine; don’t operate the throttle. 6. About 15 seconds after the engine starts, push the choke knob back all the way to fully OFF. If idling is unstable, open the throttle slightly. Extended use of the choke may impair piston and cylinder wall lubrication and damage the engine. HighAirTemperature 35°C (95°F) or above 1. Turn the fuel valve (1) ON. 2. Do not use the choke. 3. Keep the throttle fully closed. 4. Start the engine following step 4 under “Normal Air Temperature.” LowAirTemperature 10°C (50°) or below 1. If the temperature is below 32°F (0°C), open the throttle two or three times. (The engine requires a richer mixture for starting in cold weather. When the throttle is so opened, the accelerator pump will feed extra fuel to the cylinder, thereby facilitating starting in cold weather.) 2. Follow steps 1-5 under “Normal Air Temperature.” 3. Continue warming up the engine until it runs smoothly and responds to the throttle when the choke knob is pushed back all the way to fully OFF. Extended use of the choke may impair piston and cylinder wall lubrication and damage the engine. (cont’d) NOTICE NOTICE Basic Operating Instructions 15 (1) fuel valve The three-way fuel valve is used to control the flow of fuel from the fuel tank to the carburetor. ON -Turning the fuel valve ON before attempting to start the engine allows fuel to flow from the fuel tank to the carburetor. OFF -Turning the fuel valve OFF prevents the flow of fuel from the fuel tank to the carburetor. RES -Turning the fuel valve to RES allows fuel to flow from the reserve fuel supply to the carburetor. (1) fuel valve (2) choke knob Check the engine oil, transmission oil and coolant levels before starting the engine (pages 44,47,48). To restart a warm engine, follow the procedure for”High Air Temperature.” NormalAirTemperature 10°C-35°C (50°F-95°F) 1. Turn the fuel valve (1) ON. 2. Pull the choke knob (2) fully ON, if the engine is cold. 3. Keep the throttle fully closed. 4. Pull the clutch lever all the way in, and depress the start button. Or operate the kickstarter to start the engine. Starting from the top of the stroke, kick through to the bottom with a rapid, continuous motion. Do not operate the throttle. Allowing the kickstarter to snap back freely against the pedal stop can damage the engine

Carbureted vs. Fuel Injected Systems

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Filed Under (Tips and Review) by admin on 25-10-2010

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fuel injection (FI) systems have been around since the 1950′s and became widely used in cars during the 80′s. By the 1990′s all cars sold in the United States were equipped with FI systems, and though motorcycle manufacturers have included FI systems with some models as early as 1982, it isn’t until recently that the industry has seen wide spread use of FI. Since a lot of people come into my shop with questions about FI, I thought I would point out some of the differences between FI and carbureted systems as well as the benefits and disadvantages of both. A carbureted system is a mechanical system using air pressure to control the flow of fuel through the system. There are three basic parts in a carburetor, the throttle valve, the venturi and the float bowl. The throttle valve controls the amount of air that flows into the throat of the carburetor also known as the venturi which is simply a tapered hole through the carburetor body. As the venturi narrows, air moving through it is forced to speed up creating low pressure inside the carburetor. In a siphoning effect as the air tries to equalize the pressure, fuel is drawn in from the float bowl mixing with the air before entering the engine. The wider open the throttle valve, the more air will flow, drawing more fuel. A number of circuits are built into the carburetor in order to control the amount of air/fuel being drawn into the engine. In this context a circuit refers to a fuel passageway as opposed to an electrical circuit. In fact, nothing electrical controls fuel delivery in a carbureted system, it is all based on fluid flow, vacuum and hydraulics. The different circuits represent various throttle positions such as idle, partially open and fully open, and each of these circuits can be tuned to modify the efficiency of fuel delivery to the system. Fuel injection (FI) systems, on the other hand, rely on an electronic fuel pump to deliver fuel. The fuel pump delivers fuel at around 50psi as opposed to carbureted systems at normal atmospheric pressure of about 15psi. When the fuel reaches the injectors, the higher pressure allows much finer atomization (creating mist) of the fuel. The injectors then spray the atomized fuel into the intake manifold in a uniform conical pattern. The uniform pattern and fine atomization of the fuel spray increase the efficiency in which it is burned

HONDA CR250R Owner’s Manual

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Filed Under (Honda) by admin on 24-04-2011

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l. CONTROLS( 1 ) Frontbralte tever (2) Throttle grip ( 3 ) Engine stop switch When shutting off engine, press in the  engine stop switch button. (4 ) Rear brake pedal ( 5 I Kickstarter pedal ( 6 } Clutch lever (1′) Fuel tank filler cap ( 8) Gear change pedal The transmission has S speeds. Depress the pedal to Shift into [st gear. Raise the pedal to shift into 2nd, 3rd, 4th and 5th. Neutral is located between 1st and 2nd.  9 ) Fuel mixture enrichment l-mob When starting a cold engne, raise the fuel mixture knob and fully depress the kickstarter pedal. (10) Fuel valve When the fuel valve is turned to "OFF", fuel cannot Flow from the fuel tank to the carburetor. When the fuel valve is turned to “ON”, fuel will flow from the tank to the carburetor. (1 1] Rear shock absorber adjuster The rear shock absorber springs have three settings for precise adjustment of the rear suspension to suit riding conditions and differences in rider weight. Page 6 2 l. OPERATING – Fig. l—2 (1) Fuel tank -  2. FUEL The Honda CRZSUR ELSINORE has a two-stroke engine that requires a gasoline-oil mixture. The capacity of the “fuel tank is 8.59 (2.2 US gal. 1.9 Imp. gal). I Any automotive gasoline with :1 pump octane number of 86 or higher. or research octane number of9i or higher‘ may he used. If “l ofgasoline or a higher octane grade. USE HONDA 2-STROKE INJECTOR OIL OR EQUIVALENT. I Premix gasoline and oil in a ratio of   20:1 Prepare the fuel mixture in a clean container, and shake until thoroughly mixed before Flling the fuel tank. i Too much oil will muse excessive smoking and spark plug fouling. Too little oil will cause engine damage or premature wear. Mix fuel in a ratio of 20 parts gasoline to 1 part oil. I Vegetable oils separate from gasoline more easily than mineral oils, especially in cold weather. It is advisable to use mineral oil when ambient temperatures of below 0°C (32°F) are expected. I If the gasoline-oil mixture is left standing in a container for a long period of time, lubricity will deteriorate. Use the mixture within 24 hours. I Once an oil container is opened, the oil must be used within one month, since oxidation may occur. Do not mix vegetable and mineral oils. Gasoline is flammable and explosive under certain conditions. Always stop the engine and do not smoke or allow open flames or sparks near the motorcycle when refueling

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HARLEY DAVIDSON LED FUEL GAUGE KIT REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 29-01-2011

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Removing the Analog Fuel Gauge NOTE The fuel gauge wires are routed through a tube in the fuel tank, and are secured by a clip at the bottom of the tank and, on some models, a clamp on the frame. Open the clip and clamp as needed, and be sure there is enough slack in the wires to be able to lift out the gauge. 1. At the bottom left side of the fuel tank, bend back the flexible clip slightly to free the fuel gauge conduit. Open the harness clamp on the frame if necessary to free the conduit. Gently pull on the conduit to draw the Multilock connector [117] out of the tunnel. 2. See Figure 2. Depress the pin on the socket terminal side of the connector, and pull apart the pin and socket halves. 3. See Appendix B in an appropriate Service Manual. Use a pick (Snap-On TT600-3 or equivalent) to remove the terminals or clip off the wires. Remove and discard the fuel gauge. 4. For Carbureted Models: See Figure 2. Remove the fuel gauge by firmly grasping and carefully pulling up (do NOT twist) on the gauge just far enough to free it from the fuel tank. Disconnect the two sending unit connectors. Feed the conduit and two wires up through the tube while removing the gauge. Remove and discard the fuel gauge. For Fuel-Injected Models: See Figure 2. Remove the fuel gauge by firmly grasping and carefully pulling up (do NOT twist) on the gauge to free it from the fuel tank. Feed the conduit and three wires up through the tube while removing the gauge. Remove and discard the fuel gauge. 5. Remove and discard the rubber gasket. INSTALLATION For Kit Numbers 75084-04B or 75237-03B 1. See Figure 2. Assemble the new gasket (3) to the LED fuel gauge (1) from the kit. Install the gasket so the flat side contacts the edge of the gauge. 2. See Figure 1. Use three of the Phillips-head screws and washers from the kit to connect the wires as follows: Fasten the Orange wire (1) ring terminal to the gauge connection marked “12V and “O” with a screw and washer. Fasten the Black wire (2) ring terminal to the connection marked “GND” and “BK” with a screw and washer. Fasten the Yellow/White wire (3) ring terminal to the connection marked “Y/W” with a screw and washer. 3. See Figure 2. While carefully lowering the fuel gauge, feed the wire harness (2) down into the drain tube until the three short (Orange, Black, Yellow/White) wires exit the hole at the bottom of the fuel tank. Gently pull the wires to remove slack while installing the gauge to the fuel tank. Do not twist the gauge during installation. Hold the gauge firmly and press down until it snaps into place

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Honda Shadow VT750C Fuel Valve Diaphragm Replacement

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Filed Under (Honda) by admin on 25-11-2010

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1. Drain the fuel into an approved container. 2. Remove the fuel tank using the procedure in the Service Manual. However, do not remove the fuel valve from the fuel tank. 3. Remove the four screws, and diaphragm cover. NOTE: The diaphragm cover is under spring pressure. The countermeasure part has a paint mark near the air vent hole. 4. Replace the diaphragm, spring, cover, and screws with new parts included in the kit. Install the new diaphragm with the plastic retainer facing the diaphragm cover. NOTE: Make sure the air vent hole is facing downward towards the ground. 5. Reinstall the fuel tank using the procedures in the Service Manual. 6. Refill the fuel tank

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