GV250 fuel pump replacement

[Terrence Fleming]

hello my fuel pump went dead in the cold and now I am trying to hunt one down for my 2002 Hyosung GV250, the fuel pump is an electric fuel pump and that’s where the problems comes it seems this is the only year for a few years that used electric and not vacuum.

[♠️ M77]

Hey
Sorry that happend , what you saying is true, you can see also why Hyosung saw fit to contract Mikuni Japan to make them a custom version of their DF series vacuum pipe that uses vacuum feed.

This in turn caused later carb models of the hyosung bikes to have their rubber intake pipes to finally be re-moulded / re-made with an injection nipple for the vacuum hose to slot in to.     Only the front or rear pipe with 1 nipple is all it takes.

Would you be open to be using a vacuum pump going forward ?  – You might save “electric energy” so the stator & regulator is less overloaded too  (less electrics the better on a carby bike as its stator is only 12-poles)  (Full EFi bikes have 16-20+ poles depending if its Hyosung,Suzuki , Honda or etc)

[♠️ M77]

The chinese have also cloned these pumps  (both electric and vacuum) and they fail a lot.  Since Hyosung isn’t making new carby electric pumps anymore,  be sure that if using a Vacuum version , it must be a genuine “Mikuni Japan” and it will say it on its sides.  Also it will have different screws than the chinese clones.

[Terrence Fleming]

This is the fuel pump I have and that is the mounts for it.

 

[Terrence Fleming]

♠️ M77 wrote:

Hey Sorry that happend , what you saying is true, you can see also why Hyosung saw fit to contract Mikuni Japan to make them a custom version of their DF series vacuum pipe that uses vacuum feed. This in turn caused later carb models of the hyosung bikes to have their rubber intake pipes to finally be re-moulded / re-made with an injection nipple for the vacuum hose to slot in to. Only the front or rear pipe with 1 nipple is all it takes. Would you be open to be using a vacuum pump going forward ? – You might save “electric energy” so the stator & regulator is less overloaded too (less electrics the better on a carby bike as its stator is only 12-poles) (Full EFi bikes have 16-20+ poles depending if its Hyosung,Suzuki , Honda or etc)

Quote

 

it would need the fit the bolts above and hopefully be a simple process

[DannyG76]

Hey I just acquired and old 2002 gv250 and there is no power to the electric fuel pump, which looks to be swapped for a non genuine pump. Testing the plug where the plump plugs in, it has no power. Should this be constant 12v or does that plug go back to a fuse somewhere? Thanks.

[DannyG76]

Does the electric fuel pump pug into constant 12v, and where does the plug get power from, is there a fuse? I don’t have any power at the plug.

 

If I was to change to vacuum pump your instructions don’t show how to connect vacuum lines? Does it connect to tank? Is there another component where vacuum line goes off from the intake manifold to a T peice, as I’ve seen on other diagrams?

 

Thanks.

[♠️ M77]

Do your rubber intake pipes on the engine heads have an injection nipple intact or is it broken or blanked off ?

Also,  the vacuum pump is easier to fit as it mounts to the battery box ,  as you can drill a hole and zip tie it or do a nut and bolt trick but…,. zip tie method is easier if the battery tray doesn’t already have threaded mounts for it.

This is the pump Hyosung uses for later carb modes but.,… Mikuni made a special version of the DF series pump to have 2 gold fuel ports and a single silver vacuum hole

See our tutorial below for routing diagram too

How to change / upgrade fuel lines & fuel filter on CARBY GV125 & GV250 Diagram

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