Like this Manual?SAFETY FIRST: Protective gloves and eyewear are recommended at this point.
The 2006 and newer 650 models have a vacuum fuel pump instead of the electrical fuel pump. See the Vacuum Fuel Pump topic for information on the vacuum fuel pump.
Electric Fuel Pump Testing
To test the fuel pump supply voltage a digital multimeter is needed. Make sure the battery is fully charged.
Fuel Pump Voltage Supply
Remove the seat. See the Seat topic for more information.
Turn the ignition switch to the OFF position. Make sure the transmission is in neutral.
Disconnect the fuel pump connector.
Set the multimeter to read DC voltage (VDC).
Touch the positive meter lead to the brown wire terminal of the fuel pump connector and the negative meter lead to the black/red wire terminal.
Turn the ignition switch to the ON position and measure the voltage. The voltage should display close to the battery voltage.
If the measurement is out of specification there is a problem with the wiring harness or the igniter box.
Connect the fuel pump connector.
Operational Inspection
Fill a container with kerosene.
Install a pressure gauge to the output hose of the fuel pump. Direct the output hose back to the kerosene container.
Use a 12 volt battery to power the fuel pump. The positive battery lead should be touched to the brown wire terminal of the fuel pump. The negative lead should be touched to the black/red wire terminal. Take care not to create a spark.
Measure the fuel pressure with the pressure gauge. If the pump doesn’t work it must be replace. If the pressure reading is close to the specification but not quite there, close the output end of the output hose and wait for the pump to stop. Measure the fuel pressure again.
Replace the fuel pump if the measurement is out of specification.
Fuel pump pressure: 17.7 ~ 22.6 kPa (0.18 – 0.23 kgf/cm2, 2.6 – 3.3 psi)
Fuel Level Sensor
The fuel level sensor is its own separate component on the 2006 and newer model 650s. For these models remove the fuel tank. See the Fuel Tank topic for more information.
Remove the four fuel level sensor mounting bolts and the fuel level sensor.
The fuel level sensor is a float arm mated to a resistance plate. Clean the resistance plate with alcohol prior to testing the fuel level sensor.
Set the multimeter to read ohms of resistance (Ω).
Measure the resistance between the blue and black/yellow wire terminals of the fuel pump/ fuel level sensor connector with the float in the empty position.
Measure the resistance with the float in the full positions.
| Fuel level sensor | Model | Resistance |
| Full level position | 650, 2002 – 2003 | 120 Ω |
| 650, 2005 | 117 – 123 Ω | |
| 650, 2006 – 2011 | 3 Ω | |
| 700 | 3 Ω | |
| Empty level position | 650, 2002 – 2003 | 3 Ω |
| 650, 2005 | 2 – 4 Ω | |
| 650, 2006 – 2011 | 120 Ω | |
| 700 | 120 Ω |
If the measurement is out of specification replace the fuel pump on the 700s and 2005 and older model 650s. Replace the fuel level sensor on the 2006 and newer 650 models.
Electric Fuel Pump Removal
Note: Gasoline is extremely flammable. When working with the fuel system make sure your work area is free of any sources of spark or open flame. Only work on the fuel system components with the ignition switch in the OFF position, the engine is cold, and the negative battery lead has been disconnected from the battery terminal.
Remove the fuel tank. See the Fuel Tank topic for more information.
Remove the six fuel pump mounting bolts with an 8 mm socket.
Remove the fuel pump and gasket. Do not allow the float and fuel filter to contact the fuel tank.
Cleaning and Inspection
Clean the fuel filter in a well ventilated area that is free of sources of open flame and sparks. Clean the fuel filter by dipping it into a container of high flash point solvent and moving it around. Dry the filter with low pressure compressed air.
NOTE: Always wear safety glasses when using compressed air and never point it directly at yourself or anyone else.
Electric Fuel Pump Installation
Install a new gasket and insert the fuel pump into the fuel tank. Do not allow the float and fuel filter to contact the fuel tank.
Install the six fuel pump mounting bolts with an 8 mm socket.
Tighten the bolts securely.
Install the fuel tank. See the Fuel Tank topic for more information.