It doesn't seem to effect performance if you go over or under, both work well if you do the rest right.

Going over concerned me also because of the possibility of kinking the line at the bottom, but personal choice. I would go that way if I had some pre-bent line to do it with!

If you use an inline fuel filter, try to align it vertically so you avoid getting an air bubble in it. Usually not an issue, but it might cause a break in the fuel flow.

These steps are vital:
A larger carb float valve (grizzly is cheaper).
Venting of the tank (either the cap or removing the rollover valve).
Re-set the float level.
Remove the carb fuel inlet filter.

Optional:
Cut down the length of the main petcock tube so that switching to reserve comes after the 'low fuel light' comes on instead of before.

Anything else is just extra money and time.

Oh boy... new things to do... so, a few questions to get me in the right place:

1) Grizzly?
2) Carb filter?
3) No fuel filter? I just replaced mine and the one that came out was the original and pretty dirty.

went pumpless over the winter following all of the tried and true instructions thanks to the helpful members here on the clinic. no problems what-so-ever, maybe a carb cough here or there but i feel with anything carbeurated you'll have that here and there. thanks again to all who answered my questions and all the "guinea pigs" out there for helping to get this mod right.

Callred wrote:
Oh boy... new things to do... so, a few questions to get me in the right place:

1) Grizzly?
2) Carb filter?
3) No fuel filter? I just replaced mine and the one that came out was the original and pretty dirty.

A lot of the junk in your filter is the paper from the filter breaking down not the fuel. I haven't used a fuel filter in thousands of miles. Yes take the inlet screen filter out of the carb also. Some use the grizzly valve and some don't, that is up to you. I would use it. Also get a 5/16 high temp fuel injected fuel line from Auto parts store around $7 to $9.

Better yet just get one of these like myself and many of us have and you won't need the Grizzly valve hahaha.
My HSR42! LOVE IT!!!! Pumpless Beast!!!!

Callred wrote:
Oh boy... new things to do... so, a few questions to get me in the right place:

1) Grizzly?
2) Carb filter?
3) No fuel filter? I just replaced mine and the one that came out was the original and pretty dirty.

There's a part # for the grizzly valve from Yamaha, in one of the links here.. and some catch up
http://roadstarclinic.com/component/option,com_fireboard/Itemid,187/func,view/id,591648/catid,58/limit,10/limitstart,0/

Theres a small screen filter right at the carb inlet(elbow) where the rubber fuel line attaches.

You get rid of the fuel pump and the stock gas filter. Some don't use a filter, and some do.

Not that it is mandatory by any means, but I ended up with a credit at my local Powersports Store - they did me a favor and returned something they really didn't have to for store credit so I had them order me a Pingel Power Flow. Again, not needed, but they sure are purdy!!!!! It should be in Tuesday.
I had another reason though. When I first got the bike back together there was some slight seepage around the petcock lever. I took it apart, cleaned everything real good, and put it back together and it stopped leaking BUT it is on my mind while riding so now it will definitely be fixed AND look better.

My thought is that I was already going to replace my 35 with a 37.5 and adjust the carb float level while in there. If another $18 float valve and a couple of extra hours of work will get that much more off my bike and less to go wrong. I may as well go pumpless.

Grizzly part numbers

5km-14190-30-00

2C6-14190-30-00

Either one, but I believe the 2C6 is the newest number.

Thanks JD, it's also on it's way. This is very much turning into a good learning experience.

Callred wrote:
Thanks JD, it's also on it's way. This is very much turning into a good learning experience.

When you have time, go to the "Jetting", or "Technical Discussions" forums, and go back to the very first post, and then start working your way forward. Almost everything we discuss here, has been kicked around for years.