Installation Instructions for Fuel Pump Replacement on S LTR450 and LTR450Z

Tools Required:

1. Wrench Set (including metric sizes)
2. Screwdriver Set (both Phillips and flathead)
3. Pliers
4. Fuel Line Disconnect Tool
5. Socket Set (for more accessibility)
6. Torque Wrench
7. Shop Towels or Rags
8. Container for Fuel Drainage
9. Safety Goggles
10. Gloves

Installation Steps:

1. Preparation:

   • Ensure the quad is parked on a stable surface and secured with wheel chocks.
   • Gather all the necessary tools and materials before starting the installation.

2. Remove the Fuel Tank:

   • Disconnect the fuel line using the fuel line disconnect tool.
   • Unscrew the bolts securing the fuel tank and carefully lift it off. Ensure to keep any seals or grommets as they may be reused.

3. Remove the Old Fuel Pump:

   • Locate the old fuel pump assembly.
   • Disconnect any wiring harnesses connected to the pump.
   • Unscrew the pump from its mount and carefully take it out of the tank.

4. Install the New Fuel Pump:

   • Position the new fuel pump in the tank, ensuring alignment with the mounting points.
   • Secure the fuel pump with screws, tightening them to the manufacturer's specified torque using a torque wrench.

5. Reconnect Wiring:

   • Attach the wiring harness to the new fuel pump, ensuring a secure connection.

6. Reinstall the Fuel Tank:

   • Position the fuel tank back in place.
   • Reattach the fuel line and ensure all connections are secure and leak-free.
   • Bolt the tank down, making sure it's secure.

7. Final Checks:

   • Double-check all connections and fittings.
   • Turn the ignition to the "ON" position without starting the engine to prime the fuel system and check for any leaks.
   • If all is well, start the engine and monitor its performance.

8. Clean Up:

   • Dispose of any spilled fuel properly and clean your work area.
   • Store tools safely.

Note:

Always refer to the vehicle's service manual for specific instructions and torque specifications. If unsure at any point, consult a professional mechanic.

Enjoy your enhanced performance with the new fuel pump! Safe riding!