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**abhi7013** · 12-24-2013, 06:40 PM

Re: Hero Honda Karizma ZMR

Originally posted by rreneav1987 View Post

If I was in such situation, I will definitely play around with it. besides. the Fuel Pump is not inside the tank, it is below the tank. when you remove the tube to the inlet of fuel pump from the tank, ensure either you don't have fuel or you have something to hold the tube tightly so that the fuel doesn't come off spilling. I would suggest remove the fuel from the tank and then proceed..

I don't think the Mechanics have common sense. just give it a try. you are not gonna lose anything by trying, are you? if you succeed, you have learnt a DIY and you can post it here on xBhp to help others

Well, I could do it provided I was independent. But rite now, am dependant on my folks for all the cash and if something unfortunate happens then it would be them who'll have to pay not me. I know where the pump is bro! Lol!
Lets see what kinda options present themselves in front of me in future

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**Divya Sharan** · 12-24-2013, 06:50 PM

Re: Hero Honda Karizma ZMR

Originally posted by abhi7013 View Post

What say divya bhai?

Come to Royal motors this Saturday. My bike also needs to undergo operation for the leaking O ring.

**abhi7013** · 12-24-2013, 06:59 PM

Re: Hero Honda Karizma ZMR

Originally posted by Divya Sharan View Post

Come to Royal motors this Saturday. My bike also needs to undergo operation for the leaking O ring.

Ill be leaving the bike there for adjusting tappets nd injector cleaning. Hope we can split open the pump though. Saturday at 11am?

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**Divya Sharan** · 12-24-2013, 07:58 PM

Re: Hero Honda Karizma ZMR

Originally posted by abhi7013 View Post

Ill be leaving the bike there for adjusting tappets nd injector cleaning. Hope we can split open the pump though. Saturday at 11am?

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I'll be there by 11.

**psr** · 12-24-2013, 08:29 PM

Re: Hero Honda Karizma ZMR

@abhi , the fuel pump inner is made of high tensile plastic while the outer is hard Aluminum. The Aluminum is crimped on to the top of the pump on the plastic to form good seal. Opening needs careful levering of the crimped edges without damaging it...so do it carefully..If you successfully open and replace the brushes, then you have to re-seal it...you can use Araldite for entire edges to seal it off ....
Here are some pictures of ZMR fuel pump outside...

**rreneav1987** · 12-24-2013, 09:05 PM

Re: Hero Honda Karizma ZMR

Originally posted by psr View Post

@abhi , the fuel pump inner is made of high tensile plastic while the outer is hard Aluminum. The Aluminum is crimped on to the top of the pump on the plastic to form good seal. Opening needs careful levering of the crimped edges without damaging it...so do it carefully..If you successfully open and replace the brushes, then you have to re-seal it...you can use Araldite for entire edges to seal it off ....

This is where experience comes into picture. Not only experience but also the love to learn more. Respect to Psr sir

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**Raja Saiyan** · 12-24-2013, 10:08 PM

Re: Hero Honda Karizma ZMR

Originally posted by Divya Sharan View Post

Agree. But I don't face difficulty anymore an my bike maneuvering around even at 20 clicks. Maybe it's about getting used to the size and weight. In fact, I'm so used to it that when I rode my dad's Splendor back home, I felt very uneasy for the first 10 odd min.

I think am gonna get rid of the center stand.. coz I love riding at long curves at very crazy speeds and each time I bend the bike @ 90 in a particular SH road the stand get scratched.. will there be any probs if i removed it??

**psr** · 12-24-2013, 10:13 PM

Re: Hero Honda Karizma ZMR

@abhi.... the fuel pump seems to be similar to Honda CBF 125 one....and known for failure...some more pictures...

Google Search

https://www.google.co.in/search?q=cbf+125+fuel+pump+image&tbm=isch&tbo=u&source=univ&sa=X&ei=36q5UrTUO82prAfe34HADQ&ved=0CCgQsAQ&biw=1007&bih=599

**rreneav1987** · 12-24-2013, 10:17 PM

Re: Hero Honda Karizma ZMR

Originally posted by psr View Post

[MENTION=64074]abhi.[/MENTION]... the fuel pump seems to be similar to Honda CBF 125 one....and known for failure...some more pictures...

https://www.google.co.in/search?q=cb...w=1007&bih=599

Sir, if they are known for failure. Why is it installed on the zmr and why havent they rectified it. Something doesnt sound right..

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**psr** · 12-24-2013, 10:22 PM

Re: Hero Honda Karizma ZMR

Originally posted by rreneav1987 View Post

Sir, if they are known for failure. Why is it installed on the zmr and why havent they rectified it. Something doesnt sound right..

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Abroad free replacement is given by Honda, while here no such things is possible...again they say it is a specific batch of pump ,and not all of them...

**Divya Sharan** · 12-24-2013, 10:44 PM

Re: Hero Honda Karizma ZMR

Originally posted by psr View Post

[ATTACH=CONFIG]129203[/ATTACH]

So sir, we need to separate the black plastic from the aluminium bottom, right?

**abhi7013** · 12-24-2013, 11:11 PM

Re: Hero Honda Karizma ZMR

[MENTION=32286]psr[/MENTION] sir- thanks a million for the pics and the procedure that you have mentioned. It will surely help us to remove the pump and replace the brushes. Just hope we get them easily. If any doubt occurs we'll call you

And once the aluminum metal is removed, we can get access to the brushes? Else is there a certain process for that too?

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**psr** · 12-24-2013, 11:14 PM

Re: Hero Honda Karizma ZMR

Originally posted by Divya Sharan View Post

So sir, we need to separate the black plastic from the aluminium bottom, right?

Yes it is there to give grip to the clamp, and to prevent the clamp damaging the pump...sort of a buffer.

----consecutive posts auto-merged-----

Originally posted by abhi7013 View Post

@psr sir- thanks a million for the pics and the procedure that you have mentioned. It will surely help us to remove the pump and replace the brushes. Just hope we get them easily. If any doubt occurs we'll call you

And once the aluminum metal is removed, we can get access to the brushes? Else is there a certain process for that too?

Sent from my MT27i using xBhp Connect mobile app

Once you remove the outer can crimping, the inner will slide out, and you will see the Fuel pump Motor inside.

You may still have to take it to a Car fuel pump repair guy to get the brushes changed, and also to get the commutator of motor(contact area) cleaned .

First of ALL make Sure It Is NOT Blocked Injector...and no Electrical Issue..

**sibun** · 12-24-2013, 11:29 PM

Re: Hero Honda Karizma ZMR

A lot of things has been discussed here about fuel pump and i was a silent spectator. [MENTION=32286]psr[/MENTION] sir has given a nice explanation and also a good photo representation about how to go about doing the change.One thing i want to ask :- Is company God or what? If they have build it then it must have some way to open it.The pump is centrifugal type where the rotating vanes push the fuel to the outlet. So there is no chances of fuel going to motor.Moreover those mechanics are speaking like idiots because there are no fuel pumps in the world that has the motor and carbon submerged in petrol as when a motor rotates then the carbon will create spark which will ignite. Even those that have submerged pump will have the outer casing submerged in fuel to cool it and the pump will be sealed with a sealant.By removing the pump from the aluminum casing you can get access to the brush side of the pump and you can change the carbon. If carbons are not available get drill machine carbon and grind those to fit the carbon.Casing can be removed by slowly prying the lip of casing and pulling out the pump and resealed by using gasket sealant or water pump sealant, and then by lightly tapping the edges of lip back to position by a small ball peen hammer.If you have been near me then i could have helped you to change the carbon.

**vijaycool** · 12-24-2013, 11:31 PM

Re: Hero Honda Karizma ZMR

I was telling in general for the bike which got more weight up front and their behaviour.
Rreneav: be careful with the pump. Check the wear of the carbon brush if its not worn much use IPA solution and clean the brush and contact. If its still giving trouble then think about replacement brush. The reason is carbon brush have hard, medium, soft type depends upon requirement

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Hero Honda Karizma ZMR

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