thanks for the info and the manual link - i'll prob have to bite the bullet and take it to the garage then
kev
No need to take it to the garage, lad. The manual in the link RSD provided will provide you with dang near everything you need to know.
Now, that being said...do you know if your pump is internal or external? I read that you swapped the tank out (tanks after the 2000 went to an internal pump set-up) for an 02 or 03, yes? If it is still external, then you need to check your fuel lines underneath the tank (there will be two: feeder and return) for kinking, as the 99-00 model years did have issues with that particular problem. If the bike is warmed up and then starts cutting out, you may also want to check for a vacuum leak. If the little vacuum hoses underneath haven't been replaced, then now would be a good time to do so. You may also want to check the fuel petcock as well. Make sure it's set to the right position.
Don't worry...I know it sounds like a lot, but trust me on this one: the manual will help you
TONS.
Now, I believe you also said you hear the pump engaging right away, yes? That may or not mean anything useful...it could also be your fuel pump giving out. The way to check for that is also in the manual. Basically, you'd need to get a bucket (clean, preferrably), and then run the petrol line into it. I forget the exact measurements, but a healthy pump needs to push out XX amount of CC's of petrol upon turning the bike on. Don't
start the bike, simply put the ignition on "ON". You should hear the fuel pump doing it's business, and then you should notice a flow of petrol going into the bucket. Measure the amount of petrol that came out from the pump (use the hose that goes from the pump to the T-rail --- the T-rail is the located right next to your throttle bodies and is where the petrol flows through to your injectors).
Now, if the petrol that flowed out from the hose on the fuel pump measures up to the recommended CC's, then your pump is good.
If not, replace as necessary. If your pump is working fine but you still have delivery issues, then would need to follow the chain of delivery.
Take apart the fuel pump and take special care not to bugger up the o-rings in there. The housing assembly is going to be a two-piece deal, so make sure that you don't treat it rough. Be gentle and try and preserve the o-rings and seals.
Now that you have the fuel pump housing disassembled, you're going to see your pump on one side. Be gentle taking that one out...really try and be gentle. When you get out the pump, look inside and you'll see a plastic sleeve. Be
VERY gentle when removing that little bugger. They don't sell that piece by itself...you mess that up and you're gonna hafta buy a whole new fuel pump. Be gentle trying to remove it. Once you do, you're gonna see a screen on the bottom. Clean that out thoroughly. Also, on the housing assembly where you pulled the pump and the sleeve out of, look on the inside towards the bottom. There's a small hole...and in that hole is another screen. Make sure that one gets cleaned too.
If all that checks out, then we move on to the supply hose that goes from the pump to the T-Rail. After that, it's cleaning out the injectors. Don't worry...you'll be fine. You can do all this with some patience and determination.
Take your time and read the manual thoroughly. If you have any other questions, post 'em up and we'll try to help you out.