Removing the fuel pump / fuel filter assembly - 2005 Monster 620

[annguye1]

Hey guys, girls,

I'm trying to replace my fuel filter but I'm having trouble getting to it.  Would appreciate the help.  I found the tutorial for the S2R but that looks like a different animal.

I can't budge the cap at the top of the tank and unscrewing the plastic nut at the bottom of the tank doesn't get me anywhere.  Any tips?

[Howie]

Did you unscrew the grub screws that hold the flange in the tank?   

[annguye1]

Where are the grub screws?

[Privateer]

Where are the grub screws?

grub screws are small allen head set screws that hold the filler neck to the tank. 

If you're looking down at the tank, and picture a clock face on it, the screws are where the hour/minute/second hands would point.  They go through the filler and press into the tank metal.  They're very small and easy to lose/drop so use caution when loosening them.

[annguye1]

Aaaahhh I see em.  Whew, glad I didn't try to pry the thing off with a hammer.  Much appreciated!

[JoeB]

once you have the grub screws out, you probably WILL need to pry the cap out with a hammer, as the o-ring is really f-t in there and seals up nice. make sure you grease it up with zinc grease before putting it back too. and the black o-ring on the edge needs to be in place on the cap before you push it down into the tank again. it's a bit fiddly, but you'll see what I mean by that if you try and put it back without them both in place.

Insofar as removing the fuel filter, thats a doddle, once you have the tank cap out. If the clamps are the crimp type, a small flat screwdriver will allow you to unclip, then you simply replace the (mahle kl145?) 425.4.004.1B  fuel filter  and use pliers to recrimp the clamp. they are simple and effective.

If you have to remove the pump, thats a whole different story. it's a PITA.

1. Drain ALL the fuel.
2. Remove Tank cap holder. Be careful of the o-ring. do not damage.
3. Unclip breather hoses with small flat blade screwdriver. remove clips and set aside with cap holder
4.mark hoses on tank (because, believe it or not, the factory manual showed me a different layout to the orange sticker, and reversing the pump and return lines will net you a bike that will not start)
5. remove rear tank pin. do not lose the washer, circlip or spacers. Clean thoroughly and apply zinc grease liberally to all these components. set aside.
6.remove fuel filter.
7. reach down into tank and pry the rubber insulated housing of the pump up towards the tank upper half. it will take some time, and if you have larger than average forearms it takes a long time. (use a torch to check progress)
8. CAREFULLY remove the pump, as you do not want to lose the gauze filter or circlip. Disconnect the sender /pump electrics on the top of the pump.
Clean the tank thoroughly NOW, before you put anything back in.   Use some thinners or methylated spirits , slosh it around good and drain it out (mityvac works well to pull fuel dregs through while you move the tank around.

9. remove circlip from pump with tiny flat blade screwdriver. set aside.
10. remove gauze.  clean with thinners and low pressure compressed air.  REPLACE, if it is dirty around the pickup tube, or it will clog again. 425.4.008.1A fuel filter gauze

Instalation is essentially a reverse of the removal process. be aware, that the orientation of the fuel pump is critical. gauze horizontal on the bottom, and the rubber insulator on the pump needs to have the 'flat' sides on the top, so it fits into the c clamp properly in the tank.

take your time putting it all back. it is not easy due to limited space.

[annguye1]

The cap actually came off pretty easily once the grubs screws were out.  Once I got in the tank it took some patience getting the pump out of the clip.  Not too bad, though.  Replaced the mesh fuel filter ... hopefully I put everything back the way I found it and it starts right up.  I'll have to remember the zinc grease for next time.