Dave:
It appears that if there is fuel in the pump body, there is just enough more
resistance that the diaphram doesn't move quite far enough to throw over the
points. You could have a weak pressure spring or the diaphram is not stretching
enough. If you're sure you've followed the manuals directions correctly, I
would unscrew the diaphram one more hole counter clockwise to make sure that the
points throw over.
There is also the possibility that you have one of the valves in backwards. The
valves don't hold air well so enough leaks past the valves with no fuel. When
the valves are wetted with fuel they seal and the pump thinks its full. A quick
test is to remove and empty the pump of fuel and try sucking from the outlet.
You should be able to easily such air, and hear the valves chatter, but blowing
will be difficult. If you can't suck any air out of the outlet, then the outlet
valve is in backwards.
Blake
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