FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION

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Except MZ-CD 1.6 (Y6), MZR-CD 2.2

Note

•  Fuel pump unit cannot disassemble.

MZ-CD 1.6 (Y6)

Warning

•  Fuel line spills and leakage are dangerous. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel gauge sender unit when removing or installing.

•  A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before draining fuel, make sure to discharge static electricity by touching the vehicle body.

1.  Level the vehicle.

2.  Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [MZ-CD 1.6 (Y6)].)

3.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

4.  Drain the fuel using the following procedure.

When the fuel tank is full

1.  Disconnect the breather hose from the fuel-filler pipe.

2.  Drain the fuel by tilting the breather hose.

3.  Siphon the fuel from the fuel tank using a fuel drawing pump.

Except when the fuel tank is full

1.  Disconnect the joint hose from the fuel-filler pipe.

2.  Drain the fuel by tilting the joint hose.

3.  Siphon the fuel from the fuel tank using a fuel drawing pump.

5.  Remove the rear seat cushion. (See REAR SEAT CUSHION REMOVAL/INSTALLATION.)

6.  Remove the service hole cover.

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7.  Disconnect the fuel gauge sender unit connector.

8.  Set the main silencer out of the way. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

9.  Remove the insulator (middle No.1). (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

10.  Remove in the order indicated in the table.

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1	Quick release connector
2	Fuel hose (See Fuel Hose Removal Note.)
3	Fuel gauge sender unit cap (See Fuel Pump Cap Removal Note.) (See Fuel Pump Cap Installation Note.)
4	Fuel gauge sender unit
5	O-ring

11.  Install in the reverse order of removal.

12.  Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [MZ-CD 1.6 (Y6)].)

Fuel Hose Removal Note

1.  Remove the fuel-filler pipe installation bolts. (See FUEL TANK REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

2.  Disconnect the joint hose of fuel tank side. (See FUEL TANK REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

3.  Disconnect the breather hose of fuel-filler pipe side. (See FUEL TANK REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

4.  Remove the fuel tank strap. (See FUEL TANK REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

5.  Remove the following parts as a single unit.

•  Fuel tank

•  Breather hose

•  Fuel gauge sender unit

•  Fuel hose

6.  Remove the fuel hose.

Fuel Pump Cap Removal Note

Caution

•  The fuel pump cap could be damaged if the SST is used with any gap between the cap and the SST. Securely attach the SST so that there is no gap between the SST tabs and the side of the cap.

1.  Remove the fuel pump cap using the SST.

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Fuel Pump Cap Installation Note

Note

•  The fuel pump unit will rotate and cannot be secured in the specified position if there in any gasoline on the gasket. Thoroughly wipe away all gasoline from the gasket.

1.  Align the fuel tank and fuel pump unit alignment marks.

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2.  Set the SST as shown in the figure.

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3.  Using the SST, tighten the fuel pump cap within the specified tightening torque without shifting the alignment marks.

•  If the specified tightening torque cannot be obtained, replace the fuel pump cap and gasket.

•  If the specified tightening torque cannot be obtained after replacement of the fuel pump cap and gasket, replace the fuel tank.

MZR-CD 2.2

Warning

•  Fuel line spills and leakage are dangerous. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel gauge sender unit when removing or installing.

•  A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before draining fuel, make sure to discharge static electricity by touching the vehicle body.

1.  Level the vehicle.

2.  Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [MZR-CD 2.2].)

3.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR-CD 2.2].)

4.  Drain the fuel using the following procedure.

When the fuel tank is full

1.  Disconnect the breather hose from the fuel-filler pipe.

2.  Drain the fuel by tilting the breather hose.

3.  Siphon the fuel from the fuel tank using a fuel drawing pump.

Except when the fuel tank is full

1.  Disconnect the joint hose from the fuel-filler pipe.

2.  Drain the fuel by tilting the joint hose.

3.  Siphon the fuel from the fuel tank using a fuel drawing pump.

5.  Remove the rear seat cushion. (See REAR SEAT CUSHION REMOVAL/INSTALLATION.)

6.  Remove the service hole cover.

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7.  Disconnect the fuel gauge sender unit connector.

8.  Set the presilencer out of the way. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

9.  Remove the insulator (middle No.1). (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

10.  Remove in the order indicated in the table.

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1	Quick release connector (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [MZR-CD 2.2].)
2	Fuel hose (See Fuel Hose Removal Note.)
3	Fuel gauge sender unit cap (See Fuel Pump Cap Removal Note.) (See Fuel Pump Cap Installation Note.)
4	Fuel gauge sender unit
5	O-ring

11.  Install in the reverse order of removal.

12.  Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [MZR-CD 2.2].)

Fuel Hose Removal Note

1.  Remove the fuel-filler pipe installation bolts. (See FUEL TANK REMOVAL/INSTALLATION [MZR-CD 2.2].)

2.  Disconnect the joint hose of fuel tank side. (See FUEL TANK REMOVAL/INSTALLATION [MZR-CD 2.2].)

3.  Disconnect the breather hose of fuel-filler pipe side. (See FUEL TANK REMOVAL/INSTALLATION [MZR-CD 2.2].)

4.  Remove the fuel tank strap. (See FUEL TANK REMOVAL/INSTALLATION [MZR-CD 2.2].)

5.  Remove the following parts as a single unit.

•  Fuel tank

•  Breather hose

•  Fuel gauge sender unit

•  Fuel hose

6.  Remove the fuel hose. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [MZR-CD 2.2].)

Fuel Pump Cap Removal Note

Caution

•  The fuel pump cap could be damaged if the SST is used with any gap between the cap and the SST. Securely attach the SST so that there is no gap between the SST tabs and the side of the cap.

1.  Remove the fuel pump cap using the SST.

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Fuel Pump Cap Installation Note

Note

•  The fuel pump unit will rotate and cannot be secured in the specified position if there in any gasoline on the gasket. Thoroughly wipe away all gasoline from the gasket.

1.  Align the fuel tank and fuel pump unit alignment marks.

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2.  Set the SST as shown in the figure.

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3.  Using the SST, tighten the fuel pump cap within the specified tightening torque without shifting the alignment marks.

•  If the specified tightening torque cannot be obtained, replace the fuel pump cap and gasket.

•  If the specified tightening torque cannot be obtained after replacement of the fuel pump cap and gasket, replace the fuel tank.