Fuel Lines - Pioneer 1200 Maintenance Service Manual

14
FUEL SYSTEM
Fuel Tank Installation, Continued:
5. Connect the black wire from the fuel gauge to one of the fuel level sending unit screws. Connect the
orange wire to the center stud and install the flat washer, lock washer and nut and tighten to 18 in-lb (2.0
N·m) (Figure 14-17, Page 14-25).
6. Slide the rubber boot over the stud.
7. Check the park brake and differential lock lever for proper adjustment and operation.
8. Add gasoline to the fuel tank.
9. Connect the battery cables, positive (+) post first, and tighten terminals to 20 ft-lb (27.1 N·m). Coat ter-
minals with Battery Terminal Protector Spray (CCI P/N 1014305).
10. Check to be sure the fuel shut-off valve on top of the fuel tank is in the open (ON) position (Figure 14-21,
Page 14-27 and Figure 14-22, Page 14-28).
11. With the Forward/Reverse handle in NEUTRAL, turn the key switch to the ON position, and start the
engine and allow it to idle. See following DANGER.
∆
DANGER
• The engine produces carbon monoxide, which is an odorless, deadly poison. Do not operate
the engine in an enclosed area without proper ventilation.
• After installing the fuel tank and adding gasoline, carefully check all fuel lines and
connections for leaks. Repair any leaks before using the vehicle.
12. Allow the engine to run for a few minutes to ensure that the fuel lines are full of fuel.
13. Inspect each fuel line connection for leaks.
13.1. Check all clamps at the carburetor, fuel filters, fuel pump, and fuel tank for leaks.
13.2. Inspect each fuel line to ensure that the lines are not cracked, cut, or worn.

FUEL LINES

See General Warning, Section 1, Page 1-1.
The fuel lines must be properly routed, and all hose clamps must be tight. The fuel lines should be kept clean.
See following WARNING.
∆
WARNING
• Make sure fuel lines are the right length and are properly routed. Failure to heed this warning
could result in damage to fuel lines and fire.
Fuel line no. 1 runs directly from the fuel tank to the primary fuel filter (17). Arrow indicates flow (Figure 14-15,
Page 14-23 or Figure 14-16, Page 14-24).
Fuel line no. 2 runs directly from the primary fuel filter (17) to the fuel inlet of the fuel pump (18).
Fuel line no. 3 runs directly from the fuel outlet of the fuel pump (18) to the secondary fuel filter (22). Arrow
indicates flow.
Fuel line no. 4 runs from the outlet of the secondary fuel filter (22) to the carburetor. Arrow indicates flow.
A screw band clamp should be used at the carburetor.
Page 14-26 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
Fuel Lines