Replacing The Fuel Screen On A 1996 Fourtra: Step-By-Step Guide

If you need to replace the in-tank fuel screen on your 1996 Fourtra, you'll first need to drain the fuel tank. The easiest way to do this is to run your vehicle until the fuel tank is empty. You can also use a siphon to remove the fuel. Once the tank is empty, disconnect the battery at the positive terminal post by turning it counterclockwise and pulling it from the post. This will shut off any electrical current that could cause injury during the fuel screen replacement process.

Removing the fuel tank

To remove the fuel tank from a 1996 Fourtrax, you'll need to first remove the four black tabs that are holding down the gas tank cover. Once those are removed, take off the gas tank cover. You'll then need to remove the two bolts at the front of the gas tank, which are located directly beneath the bars. After that, remove the hose that's attached to the petcock (the on, off, reserve switch).

It's also recommended to remove the black side plastics to make the process easier. You can do this by using an Allen wrench to take off the two black tabs.

Now, to fully remove the tank, you need to address the two bolts holding it in place at the front, and the rubber straps on either side. Finally, you can disconnect the fuel hose at the petcock—just remember to turn the fuel to "off" first.

Disconnecting the battery

Step 1: Locate the Battery

The battery in your 1996 Fourtrax is typically located under the seat. Remove the seat by lifting it up and pulling it towards the rear of the ATV. This will expose the battery and other electrical components.

Step 2: Identify the Cables

Before disconnecting any cables, it's important to identify them correctly. The positive cable is usually red, while the negative cable is typically black. Make sure you know which cable goes to which terminal.

Step 3: Disconnect the Cables

Start by loosening the nut that secures the negative cable to the negative terminal of the battery using an appropriate-sized wrench. Do not allow the wrench to touch any other parts of the ATV to avoid short circuits. Once loose, carefully remove the cable from the terminal.

Next, repeat the process for the positive cable. Again, ensure that the wrench only touches the nut and not any other parts of the ATV.

Step 4: Secure the Cables

After both cables are disconnected, secure them away from the battery to prevent accidental contact. You can use cable ties or tape to keep them in place.

Step 5: Work Safely

It is important to work safely when the battery is disconnected. Do not attempt to start the ATV or reconnect the battery until you have completed the fuel screen replacement.

Additionally, always wear appropriate safety gear, such as gloves and eye protection, when working on your 1996 Fourtrax.

By following these steps, you can safely disconnect the battery in your 1996 Fourtrax, ensuring a safe and efficient replacement of the in-tank fuel screen. Remember to reconnect the battery correctly once you have finished your maintenance or repairs.

Lifting the truck

Lifting a truck requires a certain set of tools and a good deal of preparation. Before starting, ensure you have a clean workspace and that all the tools you need are located and working correctly.

First, disconnect the negative battery terminal to prevent damage to sensors and electrical components during disassembly. Next, elevate the vehicle. Park on solid, level ground, and use a lift or floor jack to raise the vehicle and install jack stands beneath the frame, distributing weight evenly. If you don't have access to a lift, you can use a bottle jack, which is cheaper and can lift higher than a floor jack. If using a floor jack, loosen the lug nuts half a turn while the tires are still on the ground.

Now, remove the wheels and tires. For a levelling kit, you only need to remove the front wheels and tires; for a suspension lift, remove all four. Follow the instructions provided with your lift kit to disassemble and then modify your vehicle's suspension, taking your time and using caution to prevent injury or damage. Some modifications may include cutting, trimming, welding, and drilling holes, so use proper eye and skin protection.

Then, follow the instructions to assemble your suspension, using a combination of new and old components as specified. Ensure you torque bolts to their specified values. Once assembled, bolt the wheels and tires back on, torque the lug nuts, lower the vehicle, and reconnect the negative battery terminal.

Finally, get your vehicle aligned to prevent undesirable driving characteristics and uneven tire wear. It's also important to retorque all mechanical components after around 3,000 to 5,000 miles, as nuts and bolts may loosen as components settle.

Disconnecting the gas tank and fuel pump's connections

Disconnecting the gas tank and fuel pump connections is a delicate procedure that requires careful attention to safety precautions. Here is a detailed guide on how to perform this task:

Prepare the Vehicle:

Start by draining the fuel tank. You can do this by using a siphon or simply running the vehicle until the fuel tank is empty. A lighter tank will make the removal process much easier. Ensure you have a suitable drain pan to catch any fuel that may spill during the disconnection process.

Disconnect the Battery:

Disconnect the battery at the positive terminal post. Turn it counterclockwise and pull it away from the post. This crucial step ensures that any possible electrical current is shut off, preventing potential injuries.

Lift the Vehicle and Remove Rear Wheels:

Use a floor jack to lift the truck and place the rear frame rails onto jack stands. For easier access to the fuel system and tank, you may also choose to remove the rear wheels by turning the lug nuts counterclockwise and pulling the wheels off the hubs.

Disconnect the Gas Tank and Fuel Pump Connections:

Now, we get to the core of the procedure. You will need to disconnect the electrical and hose connections of the gas tank and fuel pump. Typically, there are two or three hoses and an adapter plug located in the upper-front area of the tank. Using a pair of pliers, pinch the hose clamps and then pull the hoses off the plastic nipples. These hoses are sized, so there is no need to mark them. For the adapter plug, disengage the small catch clip on top and then firmly pull it out of its socket. Be cautious, as some fuel may spill during this step.

Unbolt the Fuel Tank Shield Plate:

Turn all the mount bolts on the edges of the fuel tank shield plate counterclockwise and then set the plate and bolts aside.

By following these steps, you will have successfully disconnected the gas tank and fuel pump connections. Remember to exercise extreme caution when working with electricity and gasoline, and always refer to a qualified mechanic if you are unsure about any part of the process.

Unbolting the fuel tank shield plate

To unbolt the fuel tank shield plate of your 1996 Chevy Truck, you will first need to lift the truck with a floor jack and place the rear frame rails on jack stands. If you haven't already, make sure the fuel tank is drained. Next, disconnect the battery at the positive terminal post by turning it counterclockwise and pulling it from the post. This will prevent any possible electrical current that could cause injury.

Now, you can begin to unbolt the fuel tank shield plate by turning all the mount bolts around the edges counterclockwise and setting the plate and bolts aside. Place the floor jack head underneath the fuel tank for support, then turn all of the tank's mount bolts counterclockwise. As the bolts come out, the tank will drop. To remove the last of the bolts, pump the floor jack to keep the tank positioned. Finally, lower the tank out of the truck with the floor jack and move it to a work area.

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