After putting the 900 back together it will not start. It sounds like it is not getting gas. I was wondering if I hooked the fuel/vacumm hoses up incorrectly.?. The items in picture #1 are COMPLETELY out of the bike/not connected. They were not hooked up when I tore down the bike, so I figured it would be ok to leave them out. Are these hoses important or needed for the bike to run?

The small thin hose labeled by #2 is connected directly to thin tab underneath the tank next to the large one that is used for the overflow. I have the thin hose connected to the carburetors currently. From the picture at RonAyers it looks like it should be connected to the small tab on the petcock for air pressure of some sort instead of how I have it.?.

Also, where is the fuel pump located on the 97' 900....is there one?

Anybody know for sure where these hoses connects to please reply. Thanks! I will post up some pics of how I have it connected currently in a bit.

 

pretty sure the 97 RR's run on petcock and vacuum, no fuel pump. From the looks of it you need to connect those hoses to get the proper vacuum assistance.

but then again, what do I know I ride a suzuki

 

No fuel pump on a 97.....the #5 hose (your fuel hose) is the the hose running off the petcock to the hose that splits off to the carbs, the thin #25 hose is your vaccume hose and it runs off the side of your petcock to the motor....then just make sure you overfill hose is hooked up...if you still need help let me know....

 

Yeah, I have the #12 hose connected where it looks like the #25 hose should be. I am going to swap them around and see what happens. The other 2 hoses connected to the third one look like they just hang out the bottom of the bike for overflow or something . It makes sence now the more I look at it. The #25 should definitely be connected to the petcock for vacumm pressure I would imagine inorder for it to suck up the fuel.

 

Your 5 and 25 hose are the most important, make sure you have them hooked up correctly first off, the vaccume that come out of the motor (#25 hose)pushes the gas out of the tank (through the #5 hose)

 

is there gas in the tank? c'mon now jimmy jk

 

My bad luck continues. I fixed the gas problem and the bike runs fine, HOWEVER I have a few problems with the Cylinder head cover. See the below pic. I take it I will probably need to drill out the broken bolt, or if I am lucky it can get to the broken screw with a pair of vice grips. The leak I am hoping can be fixed by fixing the bolt and resealing it. Either way I now have to drop the damn engine again .

 

ya, if you take that valve cover off, hopefully there will be enough of that bolt sticking out that you can get it with vise clamps. might take a file to 2 sides of it so it has flat sides, then hook a vise clamp to it and try taking it out. that shoudl work. just make sure you cover the valves up so you don't get the metal dust into it when you are filing.

 

Jimmy,

Go to your local harware store and get a reverse drill bit and an easy out smaller then that bolt, drill a small hole through the center of the bolt and if the drill bit doesnt pull it out while your drilling use the easy out.

 

just did that myself man. it sucked i was just done a rebuild.
As it turns out i messed up the cranck and the valve's so i have to go back in anyway. Reverse drill bit will do the trick. it just sucks having to get a new gasket.

 

shoulda got a 98-99