1986 Suzuki Intruder make-shift fuel pump toggle help.

[halloweentown122]

I purchased a 1986 Suzuki Intruder VS700 over the summer. I noticed that there is an unnatural toggle switch on the fuse box that is cutting out my fuel pump and making it whine/grind. How do I get rid of it?

Also, there seems to be some sort of leak that I can't locate the source of. It ends up leaking down towards the fuse box and hitting the exhaust, it's clear and has no smell... I think it's water, but it showed up even when there wasn't rain, what do I do?

This shows where the whining/grinding is coming from, the fuel pump, but if you look to the right, there is a toggle switch and a lot of wires that don't belong there. I feel like these may be the reason it's acting so weird and why it's cutting out.
http://farm7.static.flickr.com/6061/...6f64c925_b.jpg

Here is the back side of the fuse box place where the toggle switch is and all those damn wires. You can also see the liquid on the bottom of the fuse box where the leaking substance hits.
http://farm7.static.flickr.com/6192/...f1f8fef0_b.jpg


Help?

[Motorcycle Forum]

[DrBob]

If the switch is spliced into the brown/black wire or the black/white ground wire, then my guess is that someone put the switch in there to bypass a bad fuel pump relay, the idea being that you would switch on to run the bike and turn it off when you shut off the bike. If this is the case, then the fuel pump relay is bad, and running the power directly to the pump has most likely fried it. You should hear a little noise from the fuel pump, as it is electro-mechanical, but it should not make any funny or loud noises. Alternately, someone may have thought splicing that switch in there was a good anti-theft measure, the idea being you would switch it off and no theft would know to turn it back on. This would not be particularly effective on an Intruder, as gravity feed will keep at least one cylinder running even with the fuel pump disabled.

I'd remove the switch and replace the relay, and you probably need a fuel pump also.

If the switch is spliced into something other than the brown/black power wire or the black/white ground wire, I have no earthly idea what the person was trying to accomplish. But if you let me know what wire it is spliced into I can probably figure it out.

[halloweentown122]

Thoughts on how to remove the switch? Just take out all of the wiring or...?

[DrBob]

Yeah, remove the switch and the two wires connected to it, then put the wire the switch is spliced into back together. The rest of the wires are supposed to be there. If the switch connects to two different wires (rather than both going to the same color wire) let me know what colors the wires are and I'll tell you what the switch is supposed to do. You might want to get a little plug to cover the hole where the switch is, or water will get in the fuse box. The water in there now might just be condensation or water dripping into it that was trapped someplace from the last time the bike was washed or in the rain. Smell it though, and make sure it is not coolant.

[halloweentown122]

I was hoping I didn't have to replace the pump or the pump relay, I removed the toggle switch hoping it would run. Nope, nothing, it's firing but it sounds like it's not getting any gas.

[DrBob]

Like I said, a previous owner put that there for a reason, probably to bypass a dead relay. Constantly applying power directly to the pump was a bad idea, so it may be shot also. But before you spend a dime, make sure you are indeed not getting any fuel flow to the cylinders. Gravity alone should let one cylinder run, as the rear carb is below the petcock.