Motorcycle Repair: Fuel pump or relay location and testing, fuel pump relay, pressure response

Question
Chris,
I own a 1988 Hurc1000 with 5700 original miles and love it. Wish they had made hard touring bags for it. I actually gave up a Ducati for it.

Problem... ran fine last fall (2005).
Spring 2006... Fuel pump seems to be acting up... If I by pass the relay, (disconnecting the 2-pin connector and running directly to the battery)the pump responds and gives good pressure response...you can actually see the fuel hose jump... but the bike won't run very long before out of fuel. Repeat procedure again and we are running again. Fuel tank is 1/2 full.

All fuses are good. I took them out and cleaned the blades. I do have the battery on a charger at the time of writing for almost 24 hours now.

An area dealer alluded to me that the ignition switches were a potential "problem" for this year?  He said that the bottom contact plate would not be making full contact.

The fuel pump is on the left side. That was easy enough to figure out. However, where is the fuel pump relay generally located and how does one go about trouble shooting one before $$$ is spent on a new one or even a new ignition switch? I found what appears to be the little "black box" with a 4 pin connector inboard, next to the pump. Would this be my problem child?

Your advice will be greatly appreciated.

Thank you for your time. You can post this question on the message board.

Regards,
Capt Dave Cleland

Answer
Hi Captain Dave.

The black box is not the problem.  The relay is a small part connected to the fuel pump and, guess what:  You have already tested it and it failed.  Replace the fuel pump relay.  It will be connected to the fuel pump.  It is a small, wafer-like part with 2 wires coming from it.  Other than that, I am not certain of the location of it in your bike, but it will be near the fuel pump.

Good luck and ride safe.
FALCON

P.S. Too bad about the lack of touring accessories for that bike.