So here's the backstory... Someone listed the scooter for sale locally and was transparent with the fuel pump problem. According the the owner, he said the scooter didn't start so he started tearing it down to see if he could fix it. He stripped most of the bodywork off to gain access to the fuel pump assembly. At some point, he decided to just haul it to his local Yamaha dealership to have to diagnose it. Dealer tore more stuff apart like unbolting the fuel tank and removing the six bolts that fastens the fuel pump assembly to the fuel tank. Unbolting the fuel tank leads me to believe they weren't 100% sure what they were doing and was trying to figure out how to remove the fuel pump assembly from the fuel tank. According to the owner, the dealer told him they were able to get the scooter running with starting fluid and diagnosed it with a bad fuel pump. After getting a quote for the fuel pump assembly at $300+ for parts only, he decided that getting rid of it was his best option. After some back and forth, we strike a deal and I tow the scooter home.
After some research and digging through this forum, I message minimac and he jumps in to the rescue. After a few message exchanges, I felt that I was armed with enough info to tackle the fuel pump repair. With the help of a neighbor, I was able to lower the subframe and get enough space to wiggle out the fuel pump assembly. I opted to replace just the pump with a Kemso pump off eBay and a new fuel pump seal from my local dealer. Pump replacement was pretty straight forward and getting the assembly back in resulted in some head scratching but got it back in w/o bending or breaking anything. I connect the battery, turn the key on and my neighbor alerts me that fuel is leaking everywhere. I immediately turn the key to the "Off" position and check around the fuel pump assembly and it's dry. I switch the key back on and discover fuel is spraying out of the injector area. I check the bolt that fastens down the fuel injector and it is completely loose (I'm guessing more dealer "exploration?"). I tighten it down, turn the key and fuel still sprays out from where the injector seats against the motor (or throttle body?). So I loosen the bolt and tried to pull the injector out. I get it unseated but there is a bracket that keeps the fuel line in place preventing me from completely removing the injector. There is a small fastener holding the bracket in place (I think it's an Allen head) but it's on there pretty tight and I'm scared to death about stripping it. I decided to push the injector back in but had a tough time getting it back in. At this point, I started losing daylight and decided to call it a day. Good news is that I was able to remove and replace the fuel pump. Bad news is that I can't figure out how to properly reinstall the fuel injector. Gonna spray some WD40 on the Allen head fastener and let it sit overnight and give it another go tomorrow. Plan is to hopefully remove the bracket that's holding the fuel line and pull the injector all the way out to inspect the condition of the o-rings. Reinstall injector and torque the fastener to spec and hope there are no fuel leaks. If anyone has been down this path and has any advice, it would be greatly appreciate it!
Sorry for the lengthy post, but I wanted to provide as much info as possible in hopes of getting the right help in getting the scooter back on the road. BTW, the scooter seemed to be well taken care of and kept in a garage most of its life with just under 12K miles on the odometer.
Thanks!
After some research and digging through this forum, I message minimac and he jumps in to the rescue. After a few message exchanges, I felt that I was armed with enough info to tackle the fuel pump repair. With the help of a neighbor, I was able to lower the subframe and get enough space to wiggle out the fuel pump assembly. I opted to replace just the pump with a Kemso pump off eBay and a new fuel pump seal from my local dealer. Pump replacement was pretty straight forward and getting the assembly back in resulted in some head scratching but got it back in w/o bending or breaking anything. I connect the battery, turn the key on and my neighbor alerts me that fuel is leaking everywhere. I immediately turn the key to the "Off" position and check around the fuel pump assembly and it's dry. I switch the key back on and discover fuel is spraying out of the injector area. I check the bolt that fastens down the fuel injector and it is completely loose (I'm guessing more dealer "exploration?"). I tighten it down, turn the key and fuel still sprays out from where the injector seats against the motor (or throttle body?). So I loosen the bolt and tried to pull the injector out. I get it unseated but there is a bracket that keeps the fuel line in place preventing me from completely removing the injector. There is a small fastener holding the bracket in place (I think it's an Allen head) but it's on there pretty tight and I'm scared to death about stripping it. I decided to push the injector back in but had a tough time getting it back in. At this point, I started losing daylight and decided to call it a day. Good news is that I was able to remove and replace the fuel pump. Bad news is that I can't figure out how to properly reinstall the fuel injector. Gonna spray some WD40 on the Allen head fastener and let it sit overnight and give it another go tomorrow. Plan is to hopefully remove the bracket that's holding the fuel line and pull the injector all the way out to inspect the condition of the o-rings. Reinstall injector and torque the fastener to spec and hope there are no fuel leaks. If anyone has been down this path and has any advice, it would be greatly appreciate it!
Sorry for the lengthy post, but I wanted to provide as much info as possible in hopes of getting the right help in getting the scooter back on the road. BTW, the scooter seemed to be well taken care of and kept in a garage most of its life with just under 12K miles on the odometer.
Thanks!
