fuel pump service

8/3/2019 Fuel Pump Service

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FUEL SUPPLY SYSTEM

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Pegaso 650 I.E.

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The filler cap is to be found on the top of the tank, whilstthe bottom part houses:

– the fuel supply pump unit;– a pipe for draining water from the filler cap in the event

of rain or during washing;– a pipe for draining off petrol in the event the tank is

overfilled.

Carefully read 0.5.1 (PRECAUTIONS AND GENERALINFORMATIONS) and 1.2.1 (FUEL).

aWARNINGFuel vapours are noxious for your health.Before proceeding, make sure that the room in whichyou are working is properly ventilated.Do not inhale fuel vapours.

Avoid any contact of the fuel with the skin.Do not smoke and do not use naked flames.Do not dispose of fuel in the environment.

Key

1) Fuel tank

2) Filler cap

3) Fuel supply pump unit

4) Filler cap water drainage pipe

5) Fuel “overflow” drainage pipe

6) Fuel level sensor

7) Fuel delivery filter

8) Fuel supply pump

9) Fuel delivery pipe

10) Fuel return pipe

Release 00/2002-02 - 00



FUEL SUPPLY SYSTEM

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Pegaso 650 I.E.

4.1.1 MAINTENANCE

N When the fuel supply pump is to be removed, see 4.3(REMOVING THE WHOLE FUEL SUPPLY PUMPUNIT), it is advisable to make sure the pipes (1) (2) areintact and that the following are working properly:

– fuel level sensor (3), see 6.12.2 (FUEL LEVEL INDI-CATOR);

– fuel supply pump (4), see 6.6.1 (CHECKING THE

FUEL PUMP).N Change the delivery filter (5), see 4.5 (REMOVING

THE DELIVERY FILTER).

NOTE During this procedure, it is also advisable towash the tank completely.

4.1.2 CHECKING THE FUEL SUPPLY

For the maintenance intervals, see 2.1.1 (REGULARSERVICE INTERVALS CHART) under:

– Fuel pipes.

aWARNINGCheck the delivery pipe (6), return pipe (7) and rele-vant rapid couplings extremely carefully; the operat-ing maximum pressure of the delivery pipe (6) is ap-prox. 650 kPa (6.5 bar).

Any fuel pipes featuring cracks or cuts must be replaced,without exception.

Fuel leaking from the flange (8) might be due to a dam-aged O-ring (9), consequently:

N Remove the whole fuel supply pump unit, see 4.3 (RE-MOVING THE WHOLE FUEL SUPPLY PUMP UNIT),check its state of repair and, where necessary, replaceit.

N Open the filler cap and make sure the vent on the tankis not clogged. Where necessary, unclog it using acompressed air jet.

NOTE For further details see 6.6.1 (CHECKING THEFUEL PUMP).

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See 2.7 (DRAINING THE FUEL TANK) for the fuel tank draining procedure.

Release 00/2002-02 - 00



FUEL SUPPLY SYSTEM

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Carefully read 0.5.1 (PRECAUTIONS AND GENERALINFORMATIONS), 1.2.1 (FUEL) and 4.1.1 (MAINTE-NANCE).

N Remove the fuel tank, see 7.1.1 (REMOVAL OF THEFUEL TANK).

aCAUTIONHandle the fuel tank with care and avoid scraping ordamaging them.

NOTE Set the tank on a clean surface with the pumpunit facing up.

N Unscrew and remove the screws (1).

NOTE When reassembling, screw all the screws onmanually and tighten them in a crisscross pattern in thefollowing order: A- B- C- D- E- F- G- H- I-L.

Petrol pump flange screw driving torque: 5 Nm (0.5kgm).

aCAUTIONWhen removing the pump unit (2), take care not todamage the pipes and the fuel level sensor (3), andthe filtering mesh (4).

N Raise the rear part of the pump unit (2), extracting thefiltering screen (4) from the tank.

NWithdraw the pump unit (2) completely.

aWARNINGThe delivery pipe (5) and the return pipe (6) remainconnected to the pump unit (2).

Do not invert the position of the pipes (5) (6).If it is necessary to remove the two pipes, before re-moval mark them with IN and OUT, as indicated bythe writing stamped on the pump flange (8).

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FUEL SUPPLY SYSTEM

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N Remove the whole fuel supply pump unit, see 4.3 (RE-MOVING THE WHOLE FUEL SUPPLY PUMP UNIT).

NOTE Before removing the screw (1), observe the po-sition of the components, in order to be able to reassem-ble them correctly.

N Unscrew and remove the screw (1).

N Disconnect the electric connector (2).N Remove the fuel level sensor (3).

NOTE Upon reassembly, position the fuel level sensor(3) and the electric terminal (4) correctly in their seats.

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NOTE Have the appropriate special toolm to hand:– aprilia part# 0277295 (hose clamp installation pliers).

aCAUTIONUpon installation, replace the hose clamp that hasbeen removed with a new one having the same di-mensions, see 0.4.2 (SPARE PARTS CATALOGUES).

Do not attempt to reinstall the removed hose clamp,since it is unusable.

Do not replace the removed hose clamp with a screwclamp or with other types of clamp.

N Release the hose clamp (5).N Slip the pipe (6) off the filter (7).N Release the hose clamp (8).N

Slip the filter (7) off the pipe (9).

aCAUTIONDo not use filters that have already been used.

N Replace the filter (7) with a new one of the same type.

NOTE The arrow (10) stamped on the filter (7) indi-cates the direction of flow of the fuel.Upon reassembly, take care to position the filter correctly:the arrow (10) must be directed towards the pipe (6), (seefigure).

Release 00/2002-02 - 00



FUEL SUPPLY SYSTEM

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NOTE Have the appropriate special toolm to hand:– aprilia part# 0277295 (hose clamp installation pliers).

aCAUTIONUpon installation, replace the hose clamp that hasbeen removed with a new one having the same di-mensions, see 0.4.2 (SPARE PARTS CATALOGUES).

Do not attempt to reinstall the removed hose clamp,since it is unusable.

Do not replace the removed hose clamp with a screwclamp or with other types of clamp.

N Release the hose clamp (1).N Pull the fuel pipe (3) off the pump (2).N Disconnect the electric connector (4).

aCAUTIONWhen reassembling, make sure the electric connec-tor (4) is plugged in properly.

N Unscrew and remove the screw (5).

Fuel pump screw driving torque: 10 Nm (1.0 kgm).

aCAUTIONWhen performing the operations below, take care notto entangle the electric cables.

N Remove the fuel pump (6), taking the clamp (7).

aCAUTIONIf the filtering mesh (8) features traces of sediments,clean it using a compressed air jet directed so thatthe impurities do not get inside.

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FUEL SUPPLY SYSTEM

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Carefully read 0.5.1 (PRECAUTIONS AND GENERALINFORMATIONS).

N Remove the fuel tank, see 7.1.1 (REMOVAL OF THEFUEL TANK).

N Unscrew and remove the two screws (1), taking the

washers.

Pressure regulator screw driving torque: 3 Nm (0.3kgm).

aCAUTIONThe seals (2) (3) offer resistance to the removal of thepetrol pressure regulator (4).Proceed with care.

N Remove the fuel pressure regulator (4) from the sliderby alternately levering on more points with a cut-tippedscrewdriver.

NOTE Upon reassembly, replace the seals (2) (3) withnew ones.

aCAUTIONDo not try to remove the petrol pressure regulator (4)by forcing on the pin (5).

Release 00/2002-02 - 00

fuel pump service

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