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 Electric Fuel Pump topic for information on the electrical fuel pump.
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 rear fender. See the Rear Fender topic.
Vacuum Fuel Pump Removal
Squeeze the clamps with pliers and slide them back to free the hoses from the fuel pump. Remove the two mounting nuts and take off the fuel pump.
Vacuum Fuel Pump Inspection
Wipe off the fuel pump fuel pipes. Blow in the fuel output pipe (to the carburetors) the air should not escape from the fuel input pipe (from the fuel valve). Repeat the test in reverse. The air should not pass through the fuel pump. Replace the fuel pump if it fails this test.
Vacuum Fuel Pump Installation
Install the fuel pump mounting bracket to the fuel tank if it was removed. Tighten the two bolts to specification.
Fuel pump bracket mounting bolts [2006 – 2011]: 8.0 N-m, 0.80 kgf-m, 71 in-lb
Install the fuel pump to its mounting bracket on the fuel tank. Thread on the two nuts and tighten them to specification.
Fuel pump mounting nuts [2006 – 2011]: 8.0 N-m, 0.80 kgf-m, 71 in-lb
Connect the hoses to the fuel pump above. The carburetor fuel hose will be marked with a red stripe and the vacuum hose to the intake boot will be marked with a blue stripe. Secure the hoses with the clamps.
Fuel Level Sensor
See the Electric Fuel Pump topic for more information.