Katerina Swanson
If you're looking to change the fuel pump on a 2001 Yamaha 200, you're in for a straightforward task. It's a simple swap of the old pump for a new one, and you can easily find compatible replacement pumps online. The process involves disconnecting the battery cables, removing the fuel hoses, and unscrewing the bolts holding the pump in place. You'll also need to clean the engine block and install a new gasket before securing the new pump. It's important to take safety precautions when working with fuel systems, so be sure to disconnect the battery and avoid creating sparks.
| Characteristics | Values |
|---|---|
| Year | 2001 |
| Manufacturer | Yamaha |
| Model | 200 |
| Engine Type | EFI |
| Number of Fuel Pumps | 3 |
| Pump Type | Low Pressure |
| Pump Price | $37.46 |
| Gasket Price | $1.00 |
| Zip Tie Price | $0.34 |
| Total Cost | $140.02 |
| Fuel Filter Element Price | $23.92 |
| Time Taken | 2 hours |
What You'll Learn
Disconnecting the battery and fuel lines
Disconnecting the Battery:
- Locate the battery in your Yamaha 200. It is usually placed in an accessible area, such as under the seat or near the steering column.
- Identify the battery cables, which are the large red and black wires connected to the battery terminals.
- Before disconnecting the cables, make sure to turn off the engine and all electrical components to avoid any accidental sparks.
- Using an appropriate wrench or socket, loosen the nut or bolt securing the negative cable (black) to the battery terminal. Do not allow the cable to touch any metal parts of the engine or vehicle.
- Repeat the process for the positive cable (red). You may need an assistant to hold the cables away from the battery during this process.
Disconnecting the Fuel Lines:
- Identify the three hoses connected to the fuel pump: the two fuel hoses and the vacuum hose.
- Wrap a piece of duct tape around each line on the three hoses. This will help you identify their correct connections later. Label the tape with an indelible pen: top, bottom, and cover plate.
- Carefully disconnect the fuel hoses from the pump. Use duct tape to cap the ends of the fuel hoses to prevent fuel leakage and minimize the risk of sparks.
- Remove the vacuum hose from the pump cover. Unlike the fuel hoses, the vacuum hose does not need to be capped.
By following these steps, you will have successfully disconnected the battery and fuel lines, making it safe to proceed with removing and replacing the fuel pump on your 2001 Yamaha 200. Remember always to work in a well-ventilated area when handling fuel, and have a fire extinguisher nearby as a safety precaution.
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Ordering the right parts
When ordering the right parts to change the fuel pump on a 2001 Yamaha 200, it is important to be aware of the specific model of your Yamaha 200. In the sources found, the model number "VX200TLRZ" is mentioned in relation to the 2001 Yamaha 200. This model number can be used as a reference to ensure you are ordering the correct parts.
It is also important to identify the specific components that need to be replaced. In addition to the fuel pump itself, you may need to replace associated gaskets, fuel filters, bulbs, and clamps. These additional parts ensure a proper seal and secure connection for the fuel pump.
When ordering a new fuel pump, it is crucial to match the pump to your Yamaha's engine specifications. The fuel pump should be compatible with the year, model, and horsepower of your Yamaha 200. For example, some fuel pumps are designed for Yamaha 200 models from 1999 to 2005, while others are specific to models from 2006 onwards.
Additionally, pay attention to the type of engine your Yamaha 200 has. Some fuel pumps are designed for four-stroke engines, while others are meant for two-stroke engines.
It is also worth noting that some fuel pumps come as part of a kit, which may include items such as strainers or regulators. If you are ordering individual components, ensure that they are compatible with the fuel pump you have selected.
When in doubt, cross-reference the part numbers provided by the manufacturer or retailer with those found in online forums or Yamaha service manuals. This ensures that you are ordering the correct parts for your specific Yamaha 200 model.
Lastly, consider the reputation of the seller or retailer. Opt for reputable sources that provide clear and detailed product descriptions, and check customer reviews to gauge the quality and performance of the fuel pump and associated parts.
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Removing the old pump
To remove the old pump from your 2001 Yamaha 200, you'll need to begin by disconnecting the cables from the battery. This is an important safety precaution, as it will prevent sparks from igniting any fuel vapours while you work on the fuel system.
Next, take some duct tape and wrap a piece around each line on the three hoses connected to the fuel pump. This will help you keep track of where each hose is connected. Label the tape with an indelible pen: top, bottom, cover plate. Now, carefully disconnect the fuel hoses from the pump. As you do this, cap the two fuel hoses with more duct tape.
Then, remove the vacuum hose that runs to the pump. Unlike the fuel hoses, you don't need to cap this with duct tape. Now, using a 1/4-inch socket, remove the bolt next to the pump cover nipple, and the bolt diagonally across from it. With these bolts removed, you should be able to take the pump out of the engine block.
Finally, use a razor blade, putty knife, or other scraper to remove any remaining bits of the mounting gasket from the engine block.
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Installing the new pump
To install the new fuel pump in your 2001 Yamaha 200, you'll need to follow these steps:
Firstly, slip the two mounting bolts through the new pump, allowing you to fit the new gasket onto the bottom of the pump. This will hold the gasket in place while you mount the pump. Next, grab the pump and gasket and set the pump in place on the engine block. Thread the mounting bolts into the block and tighten them to 55 inch-pounds with a torque wrench.
Now, reconnect the two fuel lines, using the tags as your guide. If you labelled them earlier, you should know exactly where to reconnect them. You should also reconnect the vacuum hose to the pump's cover. Wrap plastic wire ties around the lines to hold them in place on the pump.
Finally, reinstall any parts you had to remove to access the fuel pump, in the reverse order that you removed them. Reconnect the cables to the battery.
And that's it! You've now installed a new fuel pump in your 2001 Yamaha 200.
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Reattaching the fuel lines and battery
When reattaching the fuel lines and battery, it is important to follow the correct steps to ensure a safe and proper installation. Here is a detailed guide on how to complete this process:
Before beginning, ensure you have the necessary tools and materials, including duct tape, an indelible pen, a 1/4-inch socket, a scraper or razor blade, and the new fuel pump with its gasket and mounting bolts.
To reattach the fuel lines, follow these steps:
- Wrap duct tape around each of the three hoses connected to the fuel pump. This will help prevent any fuel leaks during the process.
- Label the duct tape with an indelible pen to indicate the location of each hose: top, bottom, and cover plate.
- Disconnect the fuel hoses from the pump, capping them with duct tape to prevent any fuel spillage.
- Reconnect the fuel lines to the new pump, using the labels as a guide to ensure they are attached to the correct locations.
- Secure the fuel lines in place on the pump using plastic wire ties.
Now, to reattach the battery:
- Reconnect the cables to the battery. Ensure that the positive and negative terminals are correctly identified and attached.
- Check that all tools and loose parts are removed from the work area.
By following these steps, you can safely and effectively reattach the fuel lines and battery when changing the fuel pump on a 2001 Yamaha 200. It is important to work carefully and methodically to avoid any fuel leaks or electrical issues.
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Frequently asked questions
The process is relatively straightforward, but it is important to disconnect the cables from the battery before beginning work to avoid sparks igniting fuel vapours. You will need to remove the fuel hoses and the vacuum hose from the pump, as well as the bolts holding the pump in place, before installing the new pump with a new gasket and reconnecting the hoses.
You may need to change your fuel pump if you experience symptoms such as excess smoke, reduced power, poor running, rough idle, or reduced WOT. You can also test your fuel pump by checking for fuel leaks and observing whether the primer bulb becomes hard when pumped.
You will need to order a new fuel pump, a new gasket, and possibly new fuel hoses and zip ties, depending on the condition of your existing parts.
Replacement fuel pumps for the Yamaha 200 are available from a variety of online retailers, including Amazon, Fuel Pump Factory, and BBC Boards.
Changing the fuel pump on a Yamaha 200 is generally considered to be a straightforward process that can be completed in a few hours. However, it is important to follow the correct procedure to avoid damage or injury.
