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FUEL SUPPLY SYSTEM

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Pegaso 650 I.E.
4.1 FUEL TANK
The filler cap is to be found on the top of the tank, whilst
the 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 GENERAL
INFORMATIONS) and 1.2.1 (FUEL).
aWARNING
Fuel vapours are noxious for your health.
Before proceeding, make sure that the room in which
you 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
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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 PUMP
UNIT), it is advisable to make sure the pipes (1) (2) are
intact 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 to
wash the tank completely.
4.1.2 CHECKING THE FUEL SUPPLY
For the maintenance intervals, see 2.1.1 (REGULAR
SERVICE INTERVALS CHART) under:
Fuel pipes.
aWARNING
Check 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, replace
it.
N Open the filler cap and make sure the vent on the tank
is not clogged. Where necessary, unclog it using a
compressed air jet.
NOTE For further details see 6.6.1 (CHECKING THE
FUEL PUMP).
4.2 DRANNG THE FUEL TANK
See 2.7 (DRAINING THE FUEL TANK) for the fuel tank
draining procedure.
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FUEL SUPPLY SYSTEM
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Pegaso 650 I.E.
4.S REMOVNG THE WHOLE FUEL SUPPLY
PUMP UNT
Carefully read 0.5.1 (PRECAUTIONS AND GENERAL
INFORMATIONS), 1.2.1 (FUEL) and 4.1.1 (MAINTE-
NANCE).
N Remove the fuel tank, see 7.1.1 (REMOVAL OF THE
FUEL TANK).
aCAUTION
Handle the fuel tank with care and avoid scraping or
damaging them.
NOTE Set the tank on a clean surface with the pump
unit facing up.
N Unscrew and remove the screws (1).
NOTE When reassembling, screw all the screws on
manually and tighten them in a crisscross pattern in the
following order: A B C D E F G H I
L.
Petrol pump flange screw driving torque: 5 Nm (0.5
kgm).
aCAUTION
When removing the pump unit (2), take care not to
damage the pipes and the fuel level sensor (3), and
the filtering mesh (4).
N Raise the rear part of the pump unit (2), extracting the
filtering screen (4) from the tank.
N Withdraw the pump unit (2) completely.
aWARNING
The delivery pipe (5) and the return pipe (6) remain
connected 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 by
the writing stamped on the pump flange (8).
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Pegaso 650 I.E.
4.4 REMOVNG THE FUEL LEVEL SENSOR
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.
4.5 REMOVNG THE DELVERY FLTER
N Remove the whole fuel supply pump unit, see 4.3 (RE-
MOVING THE WHOLE FUEL SUPPLY PUMP UNIT).
NOTE Have the appropriate special tool m to hand:
aprilia part# 0277295 (hose clamp installation pliers).
aCAUTION
Upon installation, replace the hose clamp that has
been 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 screw
clamp 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).
aCAUTION
Do 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), (see
figure).
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Pegaso 650 I.E.
4.6 REMOVNG THE FUEL SUPPLY PUMP
N Remove the whole fuel supply pump unit, see 4.3 (RE-
MOVING THE WHOLE FUEL SUPPLY PUMP UNIT).
NOTE Have the appropriate special tool m to hand:
aprilia part# 0277295 (hose clamp installation pliers).
aCAUTION
Upon installation, replace the hose clamp that has
been 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 screw
clamp 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).
aCAUTION
When 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).
aCAUTION
When performing the operations below, take care not
to entangle the electric cables.
N Remove the fuel pump (6), taking the clamp (7).
aCAUTION
If the filtering mesh (8) features traces of sediments,
clean it using a compressed air jet directed so that
the impurities do not get inside.
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4.7 REMOVNG THE PETROL PRESSURE
REGULATOR
Carefully read 0.5.1 (PRECAUTIONS AND GENERAL
INFORMATIONS).
N Remove the fuel tank, see 7.1.1 (REMOVAL OF THE
FUEL TANK).
N Unscrew and remove the two screws (1), taking the
washers.
Pressure regulator screw driving torque: 3 Nm (0.3
kgm).
aCAUTION
The seals (2) (3) offer resistance to the removal of the
petrol pressure regulator (4).
Proceed with care.
N Remove the fuel pressure regulator (4) from the slider
by alternately levering on more points with a cut-tipped
screwdriver.
NOTE Upon reassembly, replace the seals (2) (3) with
new ones.
aCAUTION
Do not try to remove the petrol pressure regulator (4)
by forcing on the pin (5).
Release 00/2002-02 - 00