About 2 months of here and there work on my project and it's almost finished. Got all the body panels fixed up and painted, just gotta throw the chain on, new brake pads and change out the fork seals then I can hit the road.
But in all of this I hit another snag. One day I had the bike running, then shut it down, took off the tank & air box to check the carbs. Didn't do anything to them, just looked them over. Then, when I put it all back together she didn't want to start. Eventually I noticed that the fuel pump wasn't engaging when I turned the key on. I by passed the pump and ran the fuel line straight from the tank to the carbs, and bam, fired right up. Figuring it was a bad pump I took it out just to test it just tohave it work. After checking all the systems I figure it's the Fuel Cut Relay that's gone bad, but when I took it off the thing looks brand new. I'm wondering if there's any way to test it before spending another $60 on a new one? I bridged the connector with it out and the fuel pump works fine, just doesn't stop pumping. Anyone run their bike without the cut relay? Could it be something else that I'm missing? Please help, I wanna get riding!!!!!

Thanks,
Mike

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dont quote me on this unless ya wana but....... i dont think you really need a fuel pump some years came with them and some didnt the 93-95 model had them 96-99 didnt now the new fuelinjected bike have them.. I say leave it off run new fuel lines and run a vacume line from the tank to the motor .. i think the 93-95 models have a different petcok<---- so you might have to get one from a 96-97 and thats it your done

 

That's pretty much how I have it hooked up now, just straight from the tank to the carbs. Seems as long as there is over a gallon of gas in it she runs fine. Don't have a vacume line hooked up, where should I run that to?

 

i remember on my 96 i had taken the tank off and when i put everything back together she wouldnt start. so after another tear down and i put it back together i found i didnt hook up one of the vacum hoses right and when i did she fired right up. i wasnt getting any gas going to the carbs but once the right vacum line was hooked up things flowed very nicely lol

 

the vacume line goes fom the motor to the tank/petcock its a smaller line.. but if you bike is running without it my guess is your bike doesnt have a diafram in the petcock so if you dont turn your fuel off at night your going to flood the bike....

 

ive got a 95 and was having problems with the fuel pump. took the pump out and just ran it gravity feed. havent had any problems since just have to make sure you shut off the gas when you are done riding.

 

I've gone through this one to many times. I have a 94 with a 96 wiring harnes that does'nt have the connection for a pump. what I found is that 96 and up carbs have a bigger orphus on the needle and seat to flow more fuel in order to be gravity fead and not starve out of fuel, but a fuel pump can not be installed on 96 and up carbs because they won't hold the pressure and they will flood. If your carbs are original 95 and down the needle and seat have a small orphus and will probably starve if gravity fead. Change the needle and seat and remove the pump, thats what I did and I finally solved my problem. I'm running a petcock valve that does'nt have a vacuum line and it works great. Johnny