My incredible wonderful dear friend Pat from 2RideTheGlobe shared these tips with me. The instructions are for a Yamaha XT250. As of writing this blog post (March 10, 2016) the bike has only 200 miles. Everything should be clean. This procedure will be performed at the end of the summer once I complete the Labrador Highway ride. Until then, I will keep it posted here as a training reminder and/or help anyone else that can benefit from his work.
Tips on fuel pump removal and filter cleaning (Be sure the tank has less than a gallon of gas left in it).
A. Fuel line removal: push the orange clip away from the fuel line to open it. Then squeeze the two black tabs on the connector and slide the fuel hose off the barb.
B. Squeeze the tab on the electrical connector (faces outward toward the right side of tank) and pull it off.
C. Remove the vent hose from under the tank (if your bike has one).
D. Pull the tank off and stand it on the front edge (mounting bolt area) with the rear of the tank high.
Note the position of the fuel hose barb on the fuel pump. It should point to around 2 o'clock (I think) when you have the tank standing up and you're looking at it from the bottom. Also notice that there is a small notch in the metal mounting ring that aligns with the white plastic of the fuel pump and is at the 12 o'clock position.
E. Use a 3mm allen wrench and remove the six screws holding the fuel pump in.
F. Remove the metal mounting ring and then pull the fuel pump out.
G. Look at the filter. Use a clean cloth and squeeze the filter several times to get as much gas and dirt as possible out of it.
H. I sprayed mine with Simple Green, but clean gas would work also. Then continue to squeeze it out with a clean cloth (I used a bandana on the road).
I. Use Q-tips and rub the filter screen, especially down near the intake to the fuel pump. Keep doing this until the Q-tips no longer turn black.
Reassembly is easy: the black rubber o-ring has three tabs that fit in three notches in the fuel pump, and will only fit one way. Likewise, the metal mounting ring only fits one way with the little notch aligning with the tab on the fuel pump. That little notch and tab point straight up (towards the rear of the tank).
Tighten the six screws in a cross-wise pattern (top, bottom, upper left, lower right, lower left, upper right).
Plug everything back in. When you slide the fuel hose onto the barb you'll feel and hear it "click" into place. Then slide the orange plastic lock into place.
If necessary, you may have to clean the fuel injector as well (well, kind of clean it....I had to a couple of times). Again, easy: look down at where the other end of the fuel hose connects. That black plastic piece is the injector. Push down on the blue plastic electrical connector tab and slide the connector rearward off the injector. Use a 10mm wrench and remove the one bolt holding the fuel injector in place. Wiggle it and pull and it will come out. I also sprayed a little Simple Green into the end of the injector, then used a Q-tip to swab it out. Push the injector back in. It will have some resistance because of the o-ring. (I carry a couple of extra o-rings but I haven't had to use one yet; still on the original).
Ok, that's it for this installment of "This Old XT". Time for a commercial break....
PS: Don't be afraid to get your hands dirty. I know you can do this stuff.
Thank you Pat for all your help!!!! Be safe and a big hug to you.