problem solved = bad fuel pump the diaphragm was bad

parts with numbers and pics if I can ever stop riding the thing
all purchased from napa auto parts just a walk in
I happened to get everything at sale price and saved 15. should run a person 115 w/ tax w/o sale price
fuel pump = napa brand # NFP P60504
fuel pump regulator = flowmaster BK 735-7298
tools = knife, philips screw driver, flathead screw driver, crimps for the connectors, wire stripper/cutters, zip ties
hose I used was the same size as the breather tube for the tank I had some extra laying around

How I did it.
snipped the old plug off the last pump. I suggest getting more wire and soldering it on and attaching it to the new plugs for the new pump. i attached the bracket and zipped tied the bracket to the old fuel pump bracket. I removed the fuel filter for the pump and used my own hose and connected the pump filter up higher. I then ran a line up to the petcock. make sure the hoses are going down. fluids don't go up hill is what i was thinking when i was putting this together. living in CO sometimes there is no gas stations way out in the twisties for 30-40 miles so I want all of my reserve. after I installed the regulator at 1.5psi. I read 2 psi is good but I don't want any sort of flooding in my carbs so i kept it at 1.5 psi. I snipped some line from the regulator to the carb to make it manageable. I suggest making the entire getup before install and then installing. I clamped all connections after the pump, i only used the clamps that were originally on the bike and that came with the new pump. After, start the bike up you have to get fuel up to pressure so you might have to crank for a second. Check for leaks!!!! let it idle for a second so it can pressurize, check for any sort of lag in higher rpm ranges so you can adjust pressure and what not do not exceed 2.5 as you are really pushing the float seals at this point. the pump is quiet so put your hand on it to check if it is pumping. This was difficult due to the size of the pump, so be patient and keep the swear jar handy.

here is my setup windows paint style
http://s1303.photobucket.com/user/Jo...tml?sort=3&o=0

I have taken the bike up to 115mph(on a track) and all the way up to 13k in other gears with no lag. No shorts/fuses blown for at least 120 miles now. I also rode for nearly 2 hours non stop with no problems.

I have a 95 cbr 25k on it.

might be a little long but that's only because I am at my wits end with tearing this bike apart.

I have had this problem with starting and running the bike. The problem started in august the bike started right up and died on choke after a minute or two. I started the bike and let it idle i go to take off choke and the bike dies. i start it up again no problem then i go to ride away. i start to take the choke off and the bike begins to idle real rough then dies. After the second death the bike would crank but no start. I check the typical. the plugs were carbon fouled so i replaced them still cranked but didn't start. I then checked the grounds on the ignition i checked the ignition pulse generator, ICM, and coils all are within tolerances specified in the manual for both voltages and resistance. fuel pump works battery is charged fuel in the carbs. After about a week of trying to start on starter fluid and carb fluid i sent the bike in to the mechanic. mechanic started the bike on carb cleaner and charged me a hefty 140 for about a half hour of work(the bike only had the gas tank on it with a seat).

the bike ran really good for about a month and then the problems came back but not as bad. In that month I ran the bike i rode a lot for my riding habits 250-300 miles a week in a spirited manner in the canyons of colorado. Now about a week ago I ran low on fuel and switched to reserve. ran fine home I then didn't ride for about 4 days and went to start up my bike started fine then about a mile down the road the bike dies. i start it up then the bike dies again immediately. i get the bike down the road to the gas station fill the bike up and then the bike refused to start. crank no start. after numerous attempts nothing so i pushed it home. i get home i hit the start bike fires up like nothing happen. i get on and go for a literally a house the bike dies again no rough idling just dies. I then check battery , fuel everything is good. I pull plugs carbon fouled again so i ripped the carbs thinking it needs a good tuning. Now while i was in there i noticed a OEM jet kit with needles. carbon foul = weak spark/too rich air fuel mix. I have 5 slots on my needle so i pushed the washer one up towards the flat part of the needle. I then clean the carbs they were sparkling clean surprisingly. I adjusted the floats to the manual specs. i reassemble carbs put them back fuel the bike up, bam bike fires up nice. I try to go for a ride and rough idle pursues with the bike barely taking off. i get down the block and the bike dies but it will start up if i wait for a minute but if i touch the throttle the bike dies. also idling doesn't last long maybe two minutes before the bike kicks off. the bike seems laggy/heavy when i rode it down the block. I am almost a 100% certain that the problem is involved with this jet kit. Living in colorado the kit is necessary due to the above 6500' riding i do so i am wondering what i do now? I can't get the bike warm enough to do a accurate carb sync because the bike dies. i am wondering if there is somewhere else i should be tuning to make the bike works properly.

 

I have had the bike for almost 3 months. the only history is that the last guy dumped the bike doing what seemed to be about 15mph. The last owner had the bike for about 1k miles and rode it around the neighborhood to keep the bike running. When I bought the bike i repainted the bike and did a general tune up chain, oil, and i put cleaner in the tank. At some point in this bikes history someone wanted it to go fast(er) and put this jet kit in. The bike ran fine for a little over a month and then carbon fouled the plugs.

I just recently went after the fuel pump and I cleaned the contacts and made sure the pump is working. the pump is electrically working and pumps fuel maybe not good enough? Every time i take the bike out after reassembly it idles fine maybe a tad bit hard to start( Maybe because i keep draining the line of gas to work on the carbs). When i go to ride around to test the bike rides all the way up to about 5k and seems to either run out of fuel or air not really sure. between 5k-6k the bike was laggy and then boom power. As I hit the end of the road(100 yards) the bike just lost all power(not electrical) the bike then died and was real hard to start like it was out of fuel/flooded. I pushed it back to my house and then it fires up again i checked the smell of the exhaust smelled a tad rich I was thinking it was from the choke just being on.

With the tank off it runs fine. i fed it through a funnel while i synced the carbs which were synced perfectly from the get go. To me it sounds like a fuel delivery system but I can feel the the pump working when i crank the bike over and while i was riding i reached down and i felt the pump still working. I don't see any kinks. I am going to grab another set of spark plugs in about an hour, second set the bike carbon fouled. The air filter is pretty clean a tad bit dirty but nothing that will cause this problem i can post a picture/video a little later on.

 

ya i am pretty sure the fuel pump is shot the r/r seems to work. i tested to see if the charging system was ok above 5k the battery reads out 14 volts and doesn't exceed 15 volts. i think the fuel pump has a bad diaphragm which sometimes seals and sometimes doesn't i feel and hear the electrical side going though. gas spews out in a trickle and the carb bowls are almost bone dry after a small 100 yard ride and push back.

the plugs are a tad rich like a very small amount it could be that the plugs are still a little dark from before though.

 

I was going to go to napa/autozone and buy a 2 psi in-line pump. the only thing is I don't see anywhere in the manual about the psi pressure the carb can take and the rating in gallons per hour(GPH) of the pump i should get. would you happen to know? about the GPH and PSI?

 

new fuel pump and fuel regulator and now no more problems. the old pump had a corroded diaphragm. i bought a inline fuel pump 2-4psi and put a regulator after the pump which is set at 1.5 psi.

 

ok I attached my parts and setup to the top