Ok! I tested the fuel pump connecting positive to positive and negative to negative to my battery and it worked. I then tested the lead to the pump with the key on and had no power. Does anyone have a wiring diagram or know where the power to the pump comes from?

Check your fuses. I'm at work right now, so don't have access to my books, but I'm sure that there's a fuse for the fuel pump.

When you turn the key on, you should hear the pump 'click' a few times to build up the pressure.

There's a fuse for the pump circuit .... check it first.

Next you need to check the fuel pump relay unit. Take the relay out. The terminal to which the red/black wire connects goes to the battery positive, the blue/red terminal goes to the battery negative, the red/black terminal goes the postive probe of your tester and the blue/black terminal goes to the negative probe. If there is no continuity between the red/black and blue/black, then buy another relay.

To test the pump measure the resistance between the pump connectors; it should be 1.6 - 2.2 ohms.

If both are OK then you need to replace the ignitor.

I recommend that you get a manual or download one from http://www.ras123.com/roadstar/docs.htm

Personally ..... I like to kill trees.

Doc

I will try testing everything you said. I spoke with my local dealers machanic and he blamed it on the ingnition. This bike has a hopped up Speedstar ignition. The machanic said he had this same problem on another Roadstar with the same ignition and swapped it with a stock ignition and then it worked. Let me know what you think.

I extracted 5 pages about the fuel pump electrics from a manual on the 2004/2005 Road Star. I'll try to upload it but if it doesn't work, send me your email and I'll mail it direct.

Tried to upload a pdf file. Wouldn't work. Converted page with circuit diagram to a jpeg. I'll see if it will upload.

Still no luck. Jpeg is 190k and system limit is 50k. Send me your email address to pday@bellsouth.net and I'll send you the five pages in an Adobe Acrobat document (pdf).

I kind of doubt that it's the ignition but you easily can swap it out for your old one.

It's not uncommon to have fuel pump problems. I've certainly had them (don't have a fuel pump now )

Doc

Good news, the Roadstar is back on the road. it turned out to be the ignition. Once I swapped the old one for the new one it started right up.
I want to thank everyone for thier advice.

One for the dealer!



Doc