So the teardown on my bike this spring was a result of a problem last year. Many hours and dollars later (not to mention ~4000Km) I thought I had the problem solved. Guess not&nbsp; :wallbash:. Last Friday myself and 2 friends thought it would be a good day to head up to Saskatoon for supper. We made it as far as Lumsden :censoredsmilie:. As we are going down the hill my bike just dies. This is the same thing that happened last year, and nothing common about any of the times. Go through and do some basic testing. Electrical is all good, and there is good spark at all of the plugs. There is fuel in the filter before the pump, but nothing getting to the carbs. This is where it gets a little odd. Last year it did the same thing, but with a full tank of gas it wasn&#039;t a problem as it would gravity feed the carbs. One thing that we did note this time was that the fuel pump was very hot (seams odd for a demand pump). I am guessing that the problem is the fuel pump, but haven&#039;t pulled it out yet to bench test it. I am jjust wondering if anyone has seen/heard of a pump failing like this. <br /><br />After last years problems I cleaned and rebuilt the carbs with new o-rings. All new fuel lines. Replaced the shutoff valve on the secondary tank. New glass fuel filter. And I also replaced the fuel pump relay. After all of this, I went out for a ride, and found that the gas cap was not venting, so I also replaced that.<br /><br />After all of that, I guess I am looking for reasurance that I am heading down the right road with the fuel pump, or should I maybe be looking for another cause of this problem?

If you are confident that fuel is not making it to the carbs, then you are going down the right path.&nbsp; There are only so many things to check and it sounds like you have gone through most of them.&nbsp; I&#039;d take a crack at the fuel pump if it was me.<br /><br />Another thing you could check for is rust in the tank, assuming you have a steel tank.&nbsp; If you store a bike over winter and the tank isn&#039;t full, the condensation build up will tend to put rust in the tank.&nbsp; Over time some of this flakes off and lies loose in the tank.&nbsp; You might have a flake or two blocking the inlet side and this would cause your fuel pump to work hard.&nbsp; Should be pretty easy to check and the radiator shops in town can help with repairs.

JGC stole my words...albeit more elegently put than I would have said them...hehe