XCiting 500i fuelpump repair/change

[Ruffus]

A fuel pump in a 500i quitted its service after 20.000 kms, though 18 years old and one owner.

Not a big deal to change this small motorpump within this plastic body.
There will be no TDC code to show up on your screen. Your scoot quitts accelerating and will stop whenever it is inconvenient to you.
Since Kymco wants to sell the whole piece....


-order an aftermarket pump body €55,-
-take the fuel unit out
-prepare small spoonshaped tools to hold this tongues to pry the plastic apart (red circle)
-take the whole plastic body apart, otherwise you cannot replug the small wires
-be very careful not to bend/brake this white prongs  (green arrows)
Whole fuelunit, if available, is €276,-.

Put it together and change all three relais in front from 8 to 20 Amps, because of age and larger switch areas.
Pls see pics.

[Ruffus]

When you clean, repair or do otherwise within you motor compartement, be careful NOT to switch on ignition as long any connectors are off.
Talking about fuelinjected motors.

As soon ECU recognizes this anomalty, it creates  failure codes and you will need a DiagTool to delete
them.

Happened to me during a repair of said fuelpump.
Pls see pics.

[Iahawk]

Ruffus, you are a wealth of knowledge!  Smart, money saving repair.

[wymple]

A fuel pump in a 500i quitted its service after 20.000 kms, though 18 years old and one owner.

Not a big deal to change this small motorpump within this plastic body.
There will be no TDC code to show up on your screen. Your scoot quitts accelerating and will stop whenever it is inconvenient to you.
Since Kymco wants to sell the whole piece....


-order an aftermarket pump body €55,-
-take the fuel unit out
-prepare small spoonshaped tools to hold this tongues to pry the plastic apart (red circle)
-take the whole plastic body apart, otherwise you cannot replug the small wires
-be very careful not to bend/brake this white prongs  (green arrows)
Whole fuelunit, if available, is €276,-.

Put it together and change all three relais in front from 8 to 20 Amps, because of age and larger switch areas.
Pls see pics.

How much is that in dollars?  When mine kept stopping, it turned out it needed 45 lbs pressure minimum to run, and I was dropping to 44. 1 pound is all it took. I bought an aftermarket pump advertised for the 500 and all it would do was 43 lbs.  Wasted 40 bucks. Ordered a factory pump from Kymco dealer &  it was North of 5 weeks to get it with no communication. About 160 bucks if I remember right.  It was plenty.

[Iahawk]

conversion this morning is 1.09 USD to 1 Euro.

[Ruffus]

...........  When mine kept stopping, it turned out it needed 45 lbs pressure minimum to run, and I was dropping to 44. 1 pound is all it took. I bought an aftermarket pump advertised for the 500 and all it would do was 43 lbs.  Wasted 40 bucks. Ordered a factory pump from Kymco dealer &  it was North of 5 weeks to get it with no communication. About 160 bucks if I remember right.  It was plenty.

@wymple: as said, fuelpumps are a tricky bred. This one lost performance only after 20 kilometers of riding and when heated up.
Our fuel injected Kymcos need a pressure between 2.8 - 3.2 bar (40 - 46 psi) to deliver fuel enough into our injectors.
Everything below causes starving, bucking and a unhappy rider.

Overheating of this little motor by constantely low fuel level MIGHT enhance this (fuel cools the pump).
Additionally the fuel pump relais gets pretty hot and fires up its contacts (therefore my recommandation to change them to 20 A).

There is NO way to test the pump in situ whether its faulty or not. Checking voltage and resistamce in the middle of nowhere is simply not possible, especially when the scoot behaves normal after a few minutes
of cooling down.

(pls see some more pics of this action)
New pump comes with different filters. You chose which one to take according to available space.

[wymple]

When I sent mine to the Iowa City dealer it checked out OK for them. I told them to have the mechanic take it to lunch, see if he got back with it OK. That got their attention.