So I got rid of the pump today. Will vent the cap tomorrow. Rode it a bit and only starved after hitting the rev limit in 1st and 2nd gear, but it certainly ran well under normal conditions. My main question is about the fuel line. I replaced the hard line with 5/16 fuel line with an in line filter. I put the spring cover over the line. Right before it connects to the carb it is up against the fins, otherwise there is good clearance. How dangerous is this??? I don't really see any way around this at that spot.

If you are say the spring is over the line that is how mine is been 3 yrs no problem. I would suggest a pingle fuel filter it is high flow and quality is high also. The pingle petcock is nice but with stock carb it is just eye candy, that flows more fuel.

Yes, the spring is over the line where it touches the fins. I put a NAPA filter on for now. Might have to look into Pingle. I zipped it to where the pump bracket bolted in.

Looking at making the same mod, either that or replace a non-functioning fuel pump. Was making this change difficult?

No just read the tech article and I do highly suggest the pingle high flow filter.

Very simple. Although I'm not done. Most of it comes from experience of working on bikes, none of which ever had a pump! Lot of god help here helps out A LOT....

Have you changed out the fuel inlet valve in the carb? I'm guessing you have the OEM Mikuni carb. If that is the case, then you will find it doesn't let enough fuel into the carb bowl without the pressure a fuel pump provides. At highway speeds, climbing a hill or against a head wind is when I would hit the fuel starvation issue. Most times around town, no problem, but when on the highway it would die out. Not a very comfortable situtation.

I don't have the part number right now, but quite a few of us switched ours out for a larger Suzuki inlet valve that fits our carb. It is in some of the threads on this issue.

Also, quite a few have cut down the main petcock tube so as to get the main fuel setting to run down closer to the 'low fuel light' coming on. Otherwise there isn't enough gravity pressure to feed it until then.

Hope it helps.

Ratl.

The new Pingle is a real good thing to do with the High Flow fuel filter. I ran mine without them for around 10K miles no real problems but it did starve out in a drag race and it would run out of gas early. Pingle solves both and it's much easier to turn on and off! You do have to file a little of the fuel tank hole out, but that is the hardest part, easy with the right tools. The hi Flow filter from Max Air is serviceable, so you just clean it. Whoooooo I like serviceable stuff! Fix it on the fly!

Today I vented the cap. VERY simple. Also mounted the choke on the left tank bolt. Took it for a nice ride. Runs XLNT!!
Does starve when I push it hard(high revs), takes a lot though to starve it. I'm going to order the valve and needle assembly tomorrow. For now it runs great. The left side definitely looks better. Lovin' it!!

Do the pingle Valve, because when you starve it at high RPM, that's running lean at high RPM. Not a good idea.