I took a couple of weeks off work and decided to set out from Adelaide to Alice Springs. With all the surrounding sites, the trip totaled a bit over 4000km. My 99 Roadstar has 30k on it so it's not too worn. Anyhow, Somewhere mid trip I noticed fuel leaking rather badly from the area the petcock seals to the tank. In the frosty mornings I'd notice a puddle of fuel on my floorboard. I tightened the screws as much as I could but they were pretty tight as is. Putting a container under the bike I measured roughly 100ml of fuel being lost overnight. The next morning when I started it up I found considerably more leakage, this time from the pump. Somewhere midway on the pump it was pissing out - looked like the membrane had gone. Being in a caravan park, 200km from the nearest major town, I decided to rip the pump/filter assembly out and try and use the existing hose to connect the tank to the carb. I had read on these forums that this was possible. Success was the result. I ended up riding some 2000km back to Adelaide. Travelling at around 130km/h at approx 2500rpm with no issues at all. Possibly a little surging whilst the cruise control was active, but this could have been wind related, not sure. Looks a lot tidier without the pump as well.

The pump assembly with mount weighs 10 pounds. I know I just shipped one. It also blocks a lot of wind from getting to the cylinders. Plus, it's unsightly. I could't lose mine fast enough once I found out (on here) I didn't need it. Almost 4 years without it now, and zero problems.

Gravity is good.
Pull the carb, and put in the Grizzly gravity style needle and seat, and a few other things, and you'll be there.
I'll post up a link.

http://roadstarclinic.com/component/option,com_fireboard/Itemid,187/func,view/id,680787/catid,13/limit,10/limitstart,0/


and.....

There are more ideas and part numbers in this one.

http://roadstarclinic.com/component/option,com_fireboard/Itemid,187/func,view/id,591648/catid,58/limit,10/limitstart,10/


JMHO, but don't use the fuel filter the guy in the second link opted for. The clear sided one. Keep it simple.
The ff1203 style filter is little more then a flat screen inside a hollow body, and it works fine. Some members have had issues, and although a couple have had serious tank venting issues that required them to actually drill out the vent elbow at the front corner of the tank, several have resulted from going with a filter that may be fine when used with a fuel pump, but seem to add problems with gravity flow.

Almost all the guys who have gone with the HSR carbs, are running pumpless.

If the bike has been lowered in the rear, you may notice some early starvation issues, that can be cured by trimming the tall(main)petcock tube about a half inch. With the petcock tube at the front of the tank, and the bike lowered, you'll notice problems under acceleration or some cornering, if/when it forces the fuel away from the front left corner of the tank. Just remember, if you trim the main tube, you'll have just a little less reserve.

Dump the pump, dump the carb and put on a HSR42. End of pump and carb problems period.

Wonder if the pump failed due to the leak?? Maybe just of old age too

Do like SKWEARpeg said and you will be very happy. I had a lot of trouble with my pump so I went pumpless years ago.

going pump less is like a hot chick going braless

Got a great deal on a pump from Po. 10 pounds of glory to be removed next winter after I install some goodies acquired over the years. HSR, Curts manifold, etc. My fuel pump gave out after getting some repairs at the bike shop. Went to start the bike, no joy. The Tec came out, and wisely guessed it was the fuel pump. Asked me if I wanted to leave the bike there and order a pump. Naw, just lend me your players for 5 minutes and by passed the pump. My only complaint pumpless is fuel,starvation as I tend to mash the throttle a lot on the highway. I am too lazy to install grizzley valve, thus pump easy fix. I broke the plastic pump cover but Po included it so I am good to go. My thoughts, if you have the time and energy, (I lack both at present heh), dump da pump. Or, carry a few tools and a spare one. Or replace it every 250000 km. If I was on the road without tools, I would have been stuck. Worst still, at night away from home without a cell on a back country road in the middle of no where. Dump the pump, or carry a cell phone and a Roadside assistance membership.

I'm glad to hear it worked OK. Got to admit I was a little worried about that as it had been sitting 3+ years in my garage. Of course I would have made it right had it not worked. Easy to say that after the fact, I know. I may be a lot of things, but I'm not in the business of fuing people. How did you like my business card?

HEH! The business card is a collectible, a keep sake. A one of a kind item. I carry it in my wallet and when I show off the fuel pump with the shiny cover, whip out the card and tell the story of how it was attained and Road Star clinic adventures. Many parts on the bike came from this forum. Stuff like that is why my bike is more than a bike, it encapsulates a lot of memories from my adventures on this forum in getting parts, advice and help in making the bike my own. It's not just the pump, but who and where it came from. Stuff like that makes the bike impossible to sell, my first heavy duty cruiser, the magic carpet I sit on that blows the stress off me after being kicked around all day. Took the bike out of storage and rode it for an hour. Surprisingly, I rode it very civil, did the speed limit (except at the end of the ride). I have a first ride of the season ritual. Ride to the Otter Lake back road and do several full lock turns from stop. Several figure 8's then ride to Hubbard's gas stop. Park the bike and drink a cold Coke and watch the cars and bikes ride past the sleepy rural gas station. Hit the highway and ride until the sun goes down. I do that every season. Before going home, do a few more slow turns in some parking lot and try to get the head and eyes turning. This is season #4 and going to take a refresher advanced safety riding course next month. Almost crashed three times last year being a throttle jockey trying to cash cheques I couldn't afford. This year's theme will be, smell the roses and think of intersections as kill zones heh. Last year riding too fast and getting too lax and a bit confident for my experience level. I just realized I accidentally high jacked the thread and went off topic. I must say, dump da pump, of get a membership that offers free towing 24/7.