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Old 06-09-2011, 02:00 PM   Thread Starter #1
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Default Repair: Yamaha Zuma 125cc Fuel Pump

One of my clients owns a scooter rental business called NJRentAScooter, and has been recently having trouble with his Yamaha Zuma 125cc. After riding for some time, the bike would simply stop working and fail to start.

It turns out the fuel pumps are a common component to fail, and all signs pointed to that being the culprit after an adequate diagnosis (checked fuel level, quality, spark, and cleaned the throttle body)

Here's the Zuma:

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In order to get to the in-tank pump, I first removed the seat, tank lid, and accompanying plastics:

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I disconnected a 10mm bolt that held the fuel line in place, took off the one quick disconnect line, disconnected the 4 pin harness, turned the gas tank upside down, and undid the 6 hex key bolts and lifted the fuel pump out of the way. I made sure to mark the orientation of the pump with a sharpie, so there won't be any alignment problems in reassembly:

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The old pump with dirty filter element:

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The new pump ready to go in:

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I made sure to seat the gasket properly, then tightened down all bolts, and reassembled the bike:

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After this, I checked if the fuel pump was priming (it was), checked for leaks (none), and cleaned the spark plug.

It started up and ran like new, and now my client's customers can enjoy thousands more miles worry free!


Thanks,
-Freddy
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Old 06-09-2011, 02:17 PM   #2
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Default Re: Repair: Yamaha Zuma 125cc Fuel Pump

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jk, nice write up bro
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Old 06-09-2011, 04:10 PM   #3
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Default Re: Repair: Yamaha Zuma 125cc Fuel Pump

Lol @chulo ...good job freddy.
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