Newbie with Suzuki ALT 125 fuel issues!

[thinkfaster]

Hi everyone! A couple days ago my uncle gave me a 1983 suzuki alt 125. It had been sitting in a garage for about 2 years. I got it out today and checked/ looked it over. *note* It was parked due to a fuel issue so thats where i started:

First i cleaned the fuel pump...the diaphrams felt a little stiff, but no leaks(dont know if this could be the problem?)

The gas tank was empty and debris free.

I took the carb completely apart and blew out all the passages(they were all clean for the most part) the only thing i had a question about was the primer on the side of the carb?i put fuel in the tank and pulled the knob out a couple times and it went back in like i thought it should but about the third time it stayed out...is this operating right?

i checked all the fuel lines and vaccuum lines...all were clear and in good shape...

The ONLY way i could get fuel to the carb is to completely cover the inlet side of the carb with my hand and pull the rope...with the excess fuel in the carb, it would run for a few seconds and die...

Is there anyone who has any idea what the problem is with the fuel system??
Thanks- Alex

[SYKO]

the little primer on the side of the carb is one problem area and even if the fuel pump looks good its probably shot, I had to start my alt all the time with engine start then it would run the rest of the day... but after it sat... no go.

[CRAZY70MAN]

primer knob will stay out, do not force it in....... that means it is has fuel. Have you checked the vent tube under seat from tank and made sure it is clear?? Got some alt parts if ya' need some......no engine parts though..... good luck.

[thinkfaster]

sykolincoln - where is the best place to order a rebuild kit for the fuel pump?

CRAZY70MAN - vent tube is clear...if it has fuel in the carb, what is keeping it from starting and running till the float level gets low enough to cut off the fuel? if the primer knob stays out, does that mean the carb bowl is full?

[SYKO]

best bet is just get a new mikuni universal pump from denis kirk out of there snowmobile catalog or just look one up on ebay.. I dont think there is any rebuilds for those ALT's any more

my primer was shot so I just made a cover for it and got rid of it all together.

[MonroeMike]

You could try for a fuel pump here in the classifieds also.

Welcome to the board.

[thinkfaster]

my primer is still in good shape and seems to do its job...ill keep an eye out for a new pump...another question: what are the screws on the carb supposed to be set to...i believe they are around 2 1/2 turns out?

[MonroeMike]

Initial setting is 1 3/4 turns out.

[thinkfaster]

Ok cool...do you have any idea how much the stock fuel pump flows? i'm seeing alot of mikuni pumps on ebay but they flow different amounts of fuel...does it really matter what they flow? This is the cheapest OEM one i can find:
http://www.bikebandit.com/suzuki-atv...d-1983/o/m5790

[MonroeMike]

No clue on the psi or gpm, however it's rated.

If you're not going for a restore, it would be cheaper going with Syko's suggestion. A few KLT owners have used universal pumps with success.

http://www.3wheelerworldforums.com/s...ad.php?t=95823

http://www.3wheelerworldforums.com/s...ad.php?t=86784

[thinkfaster]

i dunno if i can run an electric fuel pump because i have no electrical system...im seriously considering this one:

http://cgi.ebay.com/ebaymotors/NEW-M...Q5fAccessories

It says "THIS IS A STANDARD VACUUM FUEL PUMP FOR ANY ATV OR MOTORCYCLE USING A SINGLE CARB" ...what do you all think?

[MonroeMike]

Duh, I didn't even think about the electrical system.

Nice find on that pump.

Maybe someone else will chime in with their thoughts.

[thinkfaster]

cool...i think it will work...i mean its relatively the same size and it will only pump as fast and as the engine is running since its a simple vaccuum pump...right?

[thinkfaster]

Heres a pic of my ALT and my 93 cobra in the background...

[thinkfaster]

Well i got her runnin like a champ today!!! Much thanks to monroemike for the manual with all the necessay specs, as I was able to adjust the float correctly! It turns out the float was set so low that it wouldnt allow but a drop of fuel into the bowl. And thanks to sykolincoln for the primer block off plate idea! It solved what i thought was a fuel pump issue...somehow when the primer would stick out, the one way valve (aka ball bearings) in the carb bowl sealed off the fuel line inlet...i removed the top ball bearing and the retaining clip and she runs awesome!