Fuel Pump Oddity

So, I've got my bike back in one piece after my wreck. Replaced foot pegs, right clip-on, right side upper cowl, wingrack and patched up and inspected pretty much everything else. While the bike was apart, the battery had run it's self down, and I left it on the charger for a few hours. Before I had everything back together, I'd briefly started the bike up to see where I stood with the engine. Everything started fine, but I was hearing a strange high frequency clicking noise coming from the rear of the engine. I was pretty concerned about some issue with the rear cylinder head (I'd just finished a valve check), and shut it down immediately. Upon inspection I found the green harrness clip that run to the fuel pump disconnected. Reconnected it, restarted the bike and all was well.

Flash forward two days with everything buttoned up. Pulled the bike out of the garage, and started it up in the driveway. It was pretty cold, so I was on heavy choke to get it started. Bike started right up, but the clicking was back. With the bike still running I pulled the seat and popped the left side rear fairing loose. Touching the fuel pump verified the clicking was in sync with a heavy vibration coming from the pump. I visually and physically inspected the green harness connector, and all was fine there. I checked the fuel tank stopcock, and it was in the off position (that valve is notorious for not actually stopping fuel flow on my bike, but rather just slowing it down). I flipped it to the on position, and the clicking from the fuel pump stopped. Unfortunately, the engine RPMs almost immediately began decreasing. I played with the choke and throttle to keep it running, but it's heart just wasn't in it any longer and it stalled out. I attempted to restart it, and got 4 or 5 cranks out of it before the battery went flat again.

Based on this, I'm left with a couple of possibilities that I can see:
1. Clicking from the pump is electrical in nature, and the harness connection caused it the first time, and a nearly flat battery caused it the second time.
2. Clicking from the pump is physical in nature, and I'm stressing the pump with the low fuel low from the tank, or crossed up electrical control.

From here I can see the following possible remedy's:
1. Replace the battery and hope for the best.
2. Trace the harness connections and check the fuel pump relay, connections and grounds.
3. Replace the fuel pump.

#1 is easiest and quickest. #2 is cheapest. #3 is my last resort.

Wiring seems likely (and may be causing battery problems) since I had the bike stripped down to frame, engine and sub-frame prior to putting it back together.

Anything else I'm forgetting to look at?
Anyone else have experience with a clicking fuel pump? (this one is new to me)

Thanks

Is it possiable that with the fuel valve half shut off, "leaking fuel through" that the fuel pump had to work double time to keep up. Then when you opened the valve, you flooded the engine? Maybe a thought.

solman244, Jan 24 2007, 04:52 PM<snip>
I checked the fuel tank stopcock, and it was in the off position (that valve is notorious for not actually stopping fuel flow on my bike, but rather just slowing it down). </snip>

Hey, I learned this about mine recently, too. pissed.gif My garage still reeks of fuel, 10 days later. Sorry, Mother Earth!

Sorry I can't help more, but I tend to agree with Chris's thought.

chris2992, Jan 24 2007, 10:00 PMIs it possiable that with the fuel valve half shut off, "leaking fuel through" that the fuel pump had to work double time to keep up. Then when you opened the valve, you flooded the engine? Maybe a thought.

You hit it on the head. After a nights worth of charging, the bike starts and runs with no problems. I still suspect the battery is on the way out, but it looks like the fuel pump is fine.

Thanks