Apparently, fuel pump covers are rare.

I snapped the tab off yesterday getting at the fuel filter. I thought I would just go online and buy one today and have it in a few. Not so much.

Why are these things so hard to find and does anyone know where I can get one? Maybe I take the epoxy route but, not much cross-section there to hold it together. Poor design.

Go pumpless! It's pretty simple to do, and 1 less thing to leave you stranded! Engine looks so much better without that ugly cover there too.

Sorry sold mine a few months ago to another member on here. + 1 on the pumpless, been that way 4 1/2 years now never a problem. Bike loses 10 pounds, better wind getting to the left side of the cylinders, looks better without it and don't have to worry about it quitting on you. Cheap to do also.

I'm something of a packrat, and when I broke off the tab on the fuel pump cover, I located a small 1/2" piece of sheet metal that had a hole in it. It was apparently part of something I had disassembled in the past. Clamping the piece in a pair of vise grips, I bent it 90 degrees, and drilled a small hole in the top center of the cover (about where the tab broke off). I then located a small panhead sheet metal screw and one of those little sheet metal 'nuts' used for trim. This has worked for several years. One thing to consider is the length of the part of the bracket you have made that goes into the slot the plastic tab on the cover did.

I went the pumpless route... on all 3 of my R*s, without issue!

I should have added... I don't have any remaining covers, but one... with the same broken tab!

I have a cover in good condition I am not using.
I sent you a pm.

Thanks to all. I finally found the cover online. It's actually called "cover, control rack" and it's shown on the intake parts diagram on the Yamaha parts site. Wow. Who woulda thunk it? I ordered it from Partzilla for $27 plush shipping. Problem solved. I'll be more careful taking things apart next time.

But, now that I've spent money on the cover, I'm interested in going pumpless. Is there a tech document on this site explaining the steps, etc.? What are the downsides, if any?

I wasn't sure about the pumpless thing and didn't have a cover, so I moved the fuel pump up under the fuel tank. And yes, there was a tech article on here about pumpless as well as moving it under the fuel tank.

dodadnules wrote:
Thanks to all. I finally found the cover online. It's actually called "cover, control rack" and it's shown on the intake parts diagram on the Yamaha parts site. Wow. Who woulda thunk it? I ordered it from Partzilla for $27 plush shipping. Problem solved. I'll be more careful taking things apart next time.

But, now that I've spent money on the cover, I'm interested in going pumpless. Is there a tech document on this site explaining the steps, etc.? What are the downsides, if any?

There are no real down sides to doing it. You will need to spend money; Is that ever a down side when "modding" our bikes? I think not! You will switch to reserve earlier, but you can go longer on reserve, just dont push it and find out the hard way just how far A few have cut about 1/4 inch off of the main petcock tube and found that it brought the reserve back in line with the fuel light coming on. I quit changing out the cheap ass fuel sending units and just ride til I hit reserve and know that I have about 50 miles more I can go.

Basically you will need to change the needle and seat in the carb, adjust the float level up a bit, pull a little screen filter out of the fuel inlet of the carb, run a new fuel line & filter and thats it really.

Parts to buy are a Yamaha Grizzly needle & seat assembly about 2 feet of 5/16" fuel line, a 5/16" inline fuel filter and maybe some hose clamps (I just re-used the factory ones).

The down side to NOT doing it is the possibility of the fuel pump crapping out on you when you least expect it. Can be bypassed out on the road, but a pain in the ass if not really prepared for it.

Glad you found your new cover and thank you for sharing the info for others to find it as well.

Rod

EDIT: I FORGOT one thing You will need to vent the gas cap. Take it apart and remove a couple of rubber plugs, then put it back together.