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Good luck, sorry I couldn't be of more help.

If it runs with the cover off, then that's as far as I can offer without you springing me a ticket to Chicago.

Make sure the cover is installed correctly, as Doghead mentioned, because the only other thing it could be then is the solenoid not moving the shutoff lever.

Take some carb cleaner and make sure the check valve in that fitting is not stuck. make sure it moves easily. Take a VOM and make sure the -tab- for the CO solenoid is not grounding to the cover in any way. Make sure you have proper voltage to the lead. Don't just hit it with a test light...

Again, just because the CO solenoid moves does not mean it's good. It has to hold that lever back as long as the engine is running, and it may not be strong enough now.

Alcohol was killer to the material as well. Some rebuilders were shooting themselves in the foot using it as a solvent.

Here's one partially mounted, and a crappy diagram pointing it out in the pump.

/\ This. Try the solenoid first. If it duplicates with a new/known good solenoid, then you've confirmed you have a dying IP.

I'd double check the cutoff solenoid, off the truck. I bet it's weak or bad.

Depends on how it's failing. the coil could be shorting in a way that still generates a field that allowed operation, but as it broke down, would reach a point where it clicks, but lacks the force to move the lever. Starter solenoids sometimes will do the same thing, where thy move enough to...

No, I've had some where it clicks, but is not moving far enough to allow operation.

You're removing what the pink wire operates, and the pump now has only the throttle as control. You'd have to shut it off by using a screwdriver to move the cutoff lever normally actuated by the solenoid. And yes it make a bit of a mess, like I said earlier. But if it starts with the cover...

Did you try starting with the cover removed?

This is a last ditch method - Act accordingly. Clean the outside of the IP, then pull the top cover. make sure there's fuel in it's sump and that it's clean in there. Try starting. If it starts, it will make a bit of a mess, but you then know that the IP is doing it's job. I'm going to bet...