Follow the different things on the Tech Articles page. There is an article on going pumpless, and it recommends the Suzuki 2.5 needle and seat in the carb, and pulling the small screen in the carb inlet.

http://roadstarclinic.com/content/view/163/96/

You will want to vent the tank. I vented the cap per the article on the same page....

http://roadstarclinic.com/content/view/136/96/

An inline fuel filter is a good idea as well. I used some of the pre formed fuel line(90 degree bend) on the pump to do my setup, as well as the spring that protects the fuel line. Some use all rubber fuel line(5/16 fuel injection line), and ditch the metal line between the jugs. I saved enough of the metal line to make the quick jog off the carb, and cut it after it straightens out between the jugs. The 5/16 fuel line fits snug on the metal line, and I use a screw clamp to secure it instead of a spring clamp.



You will need to find a new place to mount the enricher knob. You can cut just inside of the two points where the chrome cover was screwed on, and save the enricher part of the pump bracket, then drill a hole in the flat of the bracket, and use a bolt and nylock nut, to mount it right up under the tank where the old pump bracket mounted.
I finally finished my setup in the pic, so that the bracket is shorter, and the knob is right under the crankcase breather. Now that its done, it looks cleaner. That part of the bracket between the breather and the enricher in the pic, is gone now. I need to get a new pic taken.

Thanks, SKWEARpeg!

I'll be doing some reading tomorrow after tracking down a new temp battery.

Ricohoc wrote:
Picked up a new temp battery. Charged on trickle for 6 hours.

Nothing. All I get is a 'click' when I hit the starter.

Well, it's after dark over here. Thursday is coming to a close. Something tells me that I need to take a look in the headlight bucket tomorrow and do some jiggling and wiggling.

Also might take the starter off and see if it is locked up.

Other than that, I can't think of anything else to do to get the bike to start again.

Have you tried jumping the relay. If you jump across the two post, and the starter spins you'll have that much figured out.

SKWEARpeg wrote:
Have you tried jumping the relay. If you jump across the two post, and the starter spins you'll have that much figured out.

SKpg, explain to this novice what I need to do to execute that move.

Ricohoc wrote:
SKWEARpeg wrote:
Have you tried jumping the relay. If you jump across the two post, and the starter spins you'll have that much figured out.

SKpg, explain to this novice what I need to do to execute that move.

Sorry, I got side tracked...

You remember the new starter relay you put in awhile back(I think you did????)? It's inside the left side cover. The battery lead connects to one side. The other side goes to the starter. Simply use a big screwdriver or something metal....it'll spark...., and make a connection between those two post. The screwdriver or whatever becomes the switch and closes the circuit. This bypasses all the rest, and if the relay is bad, the starter will spin, because you just bypassed it. Leave the ignition off, and it will still spin the starter.

Yes, I installed the Warrior relay. I was repositioning things inside the left side cover today while waiting for the battery to charge.

So leave the cables connected to the relay and use something metal to make contact with both posts. It the starter spins (with the ignition off), then the relay is bad.

I'll add that to my list of checks in the morning. Thanks!

Ricohoc wrote:
Yes, I installed the Warrior relay. I was repositioning things inside the left side cover today while waiting for the battery to charge.

So leave the cables connected to the relay and use something metal to make contact with both posts. It the starter spins (with the ignition off), then the relay is bad.

I'll add that to my list of checks in the morning. Thanks!




Having not performed this bit of magic myself on the bike.....cars yes, I'm pretty sure the jump trick would work with the ignition switch on or off...by the way, make sure the bike is in neutral, because there isn't anything stopping it from jumping forward, if its in gear.

Just dug out the old stock starter -- replaced, but always worked. I may just take the time to put it back on the bike and see if it does the trick rather than watch the sparks fly.