Replacing A Yamaha 1760 Fuel Pump: Step-By-Step Guide

If you're looking to replace the fuel pump on a 2004 Yamaha 1760, you'll need to identify the specific model of your Yamaha vehicle to ensure you source the correct replacement part. The process for replacing the fuel pump will vary depending on the engine configuration, but it typically involves disconnecting the battery cables, fuel lines, and hoses, before removing the old pump and installing the new one, ensuring all components are securely connected and aligned.

Disconnect the battery cables

Disconnecting the battery cables is an important step when replacing a fuel pump, as it helps prevent any accidental sparks that could ignite fuel vapours. Here is a detailed guide on how to do this safely and effectively:

Step 1: Before you begin, gather the necessary tools and safety equipment. You will need a basic tool kit, including a socket wrench and a standard or Phillips-head screwdriver. It is also recommended to wear safety goggles and gloves to protect your eyes and hands.

Step 2: Locate the battery. The battery in a 2004 Yamaha 1760 is typically located near the engine block. It is usually held in place by a mounting bracket or clamp.

Step 3: Identify the positive and negative battery terminals. The positive terminal is usually marked with a "+" sign and red colour, while the negative terminal is marked with a "-" sign and black colour.

Step 4: Loosen the nut or bolt securing the negative battery cable to the negative terminal using your socket wrench. Do not allow the wrench to touch both the positive and negative terminals at the same time, as this could cause a short circuit.

Step 5: Once the nut or bolt is loose, carefully remove the cable from the terminal. You may need to wiggle it gently to detach it completely. Place the cable away from the battery to avoid accidental contact.

Step 6: Repeat the process for the positive battery cable, ensuring you do not allow the wrench or cable to touch the negative terminal.

Step 7: With both cables disconnected, you can now safely work on other components of the engine, such as the fuel pump, without worrying about electrical sparks.

Step 8: When you have finished your repairs and are ready to reconnect the battery, start by attaching the positive cable first. Ensure the connection is secure and tight.

Step 9: Reconnect the negative cable in the same way, ensuring a secure connection.

Step 10: Check that the battery cables are not touching any other engine components that could cause a short circuit.

Remember, always exercise caution when working with electrical systems and flammable liquids. Ensure you have the necessary skills and knowledge before attempting any repairs, and always refer to a qualified mechanic if you are unsure.

Label and cap the fuel lines

To label and cap the fuel lines, start by wrapping a piece of duct tape around each line on the three hoses connected to the fuel pump. Write on the tape with an indelible pen where the hoses are connected: top, bottom, and cover plate. This will help you identify and distinguish the different fuel lines during the fuel pump replacement process.

Next, carefully disconnect the fuel hoses from the pump. As you disconnect them, cap the two open ends of the fuel hoses with duct tape to prevent any fuel leakage. Make sure the duct tape is securely wrapped around the openings to avoid any accidental spills or exposure to the fuel.

It is important to note that the vacuum hose, which runs to the pump, does not need to be capped with duct tape. Simply remove it from the pump cover.

By properly labelling and capping the fuel lines, you can ensure a safer and more organized process when replacing the fuel pump on your 2004 Yamaha 1760.

Remove the bolts and the pump

To remove the bolts and the pump, start by disconnecting the cables from the battery. This is an important safety precaution as it prevents sparks from igniting any fuel vapours that may be present while you work on the fuel system.

Next, use duct tape to wrap each line on the three hoses connected to the fuel pump. This will help you keep track of where each hose is connected. Label the tape with an indelible pen: top, bottom, cover plate. Now, you can disconnect the fuel hoses from the pump. Cap the two fuel hoses with duct tape as you disconnect them.

Then, remove the vacuum hose that runs to the pump from the pump cover. This doesn't need to be capped with duct tape.

Now, you can remove the bolts. First, remove the bolt next to the pump cover nipple, and then the bolt diagonally across from it. Use a 1/4-inch socket for this.

With the bolts removed, you can take out the pump. Use a razor blade, putty knife, or scraper to remove any remaining bits of the mounting gasket from the engine block.

Clean the engine block

To clean the engine block of your 2004 Yamaha 1700 Road Star, you will need to follow these steps:

Prepare the Work Area:

Choose a well-ventilated area with proper drainage for the cleaning process. Place a suitable container or tarp beneath the engine block to collect any cleaning solutions or debris.

Safety Precautions:

Before starting, ensure you are wearing appropriate safety gear, including gloves and safety glasses, to protect yourself from chemicals and debris. Remove the battery cables, starting with the negative cable to avoid short-circuiting.

Removing Grease and Oil:

You can use a degreaser or steam cleaning to remove grease and oil from the engine block. Apply the degreaser to the entire block and allow it to penetrate, then use a brush to agitate the surface and rinse with water. Alternatively, direct steam to the affected areas and use a brush to scrub away contaminants.

Cleaning the Block:

Use a rigid spiked brush or a wire-bristled brush to scrub away any remaining dirt, grime, oil, or grease from the engine block. Be careful not to damage any delicate electrical parts. Rinse the engine block with water, being careful not to pierce the plastic or detach any loose wires.

Final Steps:

Check for any leaks from the engine, including oil and coolant leaks. Run the engine idle for 10-15 minutes to return it to its normal temperature. Finally, dry the engine block completely using compressed air or a clean, lint-free cloth before proceeding with any further maintenance or reassembly.

Install the new pump

Now that you have removed the old fuel pump, it is time to install the new one.

First, slip the two mounting bolts through the new pump. This will allow you to fit the new gasket onto the bottom of the pump. The mounting bolts will hold the gasket in its proper alignment while you mount the new pump. Grab the pump and the gasket and set the pump in place on the engine block.

Next, thread the mounting bolts into the block and tighten them to 55 inch-pounds with a torque wrench. Now, reconnect the two fuel lines, using the tags as your guide. Then, reconnect the vacuum hose to the pump's cover. Wrap plastic wire ties around the lines to hold them in place on the pump.

Finally, reinstall any parts you had to remove to gain access to the fuel pump, in the order in which you removed them. Reconnect the cables to the battery.

And that's it! You have successfully replaced the fuel pump in your 2004 Yamaha 1700.

Frequently asked questions