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August 26th, 2011, 10:32 AM   #91
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Re: Aftermarket fuel pump

I finally installed a CA cycleworks pump, filter before the injector and cleaned the injector. The bike runs better than ever and i feel confident that I will not be left behind anymore . Be careful when you flare the outlet of the pump if you use the stock fuel line because it is a tight fit. With a very slight flare and the correct clamp I think it should hold together fine. BTW.. my stock pump was made in China...thanks KTM for finding the worst pump and then not standing behind it. I love my bike now that it appears to be sorted but I will not buy another KTM.
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August 26th, 2011, 12:25 PM   #92
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Re: Aftermarket fuel pump

lets just imagine there's some people who ride husabergs, that have no idea about,how to start to do what youve done, and are talking about and would love pictures lol lol
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August 26th, 2011, 12:36 PM   #93
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Re: Aftermarket fuel pump

Originally Posted by johny
lets just imagine there's some people who ride husabergs, that have no idea about,how to start to do what youve done, and are talking about and would love pictures lol lol
I just followed the pics and advise of DeeG on the previous page when installing the fuel pump. There is a posting somewhere on the forum about how to install the filter just before the injector and to clean the injector I just soaked the tip in cleaner and back blew compressed air thru it.
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August 26th, 2011, 12:45 PM   #94
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Re: Aftermarket fuel pump

My replacement OE pump looks VERY similar to the old unit but does not have the part No. on it. Also the pump sounds different when running, much quieter. The old pump always made a distinct whirring sound even from new. This may or may not be significant but as for longevity/reliability only time will tell. I just hope it's not going to be a regular replacement every 65hrs or so!
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August 26th, 2011, 03:48 PM   #95
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Re: Aftermarket fuel pump

I finally finished installing the CA Cycleworks fuel pump.

Here are the two types of hose clamps that are approved for fuel injection pressurized lines; Oetiker (and crimp tool) on the left, and screw type on the right.



Flaring out the pump outlet port made it more difficult to get the hose on. If I were doing it again, I wouldn't do that. In fact a standard barbed outlet would be almost impossible to install with these stock fuel lines. Perhaps that is why CA Cycleworks did not include barbs.



It was a real pain to install the CA Cycleworks filter - DO NOT USE THIS FILTER. It does not fit inside the housing, so I had to remove it - also a pain.



I switched back to the Profill filter.



The hose now has a different twist on it than the stock pump, so it puts a lot of pressure on the housing and the top kept popping off. Others have used screws to secure the housing. I opted to use some bailing wire on each side. I routed it through the inlet hole in the bottom and out the larger holes on the top. It did not require any drilling, but it does make it harder to install the pump housing in the tank.



Be sure to secure the wires to the pump. They can pop off really easily.



I have not yet tested this. I hope it works!
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August 26th, 2011, 05:23 PM   #96
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Re: Aftermarket fuel pump

Originally Posted by DeeG
I finally finished installing the CA Cycleworks fuel pump. ...........

I switched back to the Profill filter.


................
I have not yet tested this. I hope it works!
Great solutions, DeeG ... and thanks for the pics!

I still have an un-used ProFill pre-filter sitting on my shelf and it is snowy white. I notice that the one in the pic has a brownish tint to it. Is that coloration due to dust/dirt/munge in the fuel tank?

Thanks! E-Ticket
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August 26th, 2011, 08:00 PM   #97
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Re: Aftermarket fuel pump

Originally Posted by E-Ticket
Originally Posted by DeeG
I finally finished installing the CA Cycleworks fuel pump. ...........

I switched back to the Profill filter.


................
I have not yet tested this. I hope it works!
Great solutions, DeeG ... and thanks for the pics!

I still have an un-used ProFill pre-filter sitting on my shelf and it is snowy white. I notice that the one in the pic has a brownish tint to it. Is that coloration due to dust/dirt/munge in the fuel tank?

Thanks! E-Ticket
I am not sure. The filter was white when I installed back in the spring. It doesn't look dirty. I think it just changed color from being in the fuel.
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August 26th, 2011, 08:19 PM   #98
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Re: Aftermarket fuel pump

Originally Posted by DeeG
Originally Posted by E-Ticket
Originally Posted by DeeG
I finally finished installing the CA Cycleworks fuel pump. ...........

I switched back to the Profill filter.


................
I have not yet tested this. I hope it works!
Great solutions, DeeG ... and thanks for the pics!

I still have an un-used ProFill pre-filter sitting on my shelf and it is snowy white. I notice that the one in the pic has a brownish tint to it. Is that coloration due to dust/dirt/munge in the fuel tank?

Thanks! E-Ticket
I am not sure. The filter was white when I installed back in the spring. It doesn't look dirty. I think it just changed color from being in the fuel.
Coolio ... thanks for the quick response.

BTW, how is your Pro-FILL filter sock held on to the fuel pump. Did you remove, and re-install, the circlip over the mounting stud?
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August 26th, 2011, 11:27 PM   #99
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Re: Aftermarket fuel pump

Thank you so much that, was invaluable now if my pump goes down I think I'll have more if an idea about how to go about replacing it.
There is one thing that's been on my mind, I'm in the uk and so far I've not heard about any pumps going down in the uk, and mostly seem to be failing in the states! Opinions please
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August 27th, 2011, 12:38 AM   #100
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Re: Aftermarket fuel pump

Originally Posted by johny
Thank you so much that, was invaluable now if my pump goes down I think I'll have more if an idea about how to go about replacing it.
There is one thing that's been on my mind, I'm in the uk and so far I've not heard about any pumps going down in the uk, and mostly seem to be failing in the states! Opinions please
I'm in the UK. AFAIK I was the first claim my dealer had handled but the first one in the UK? Only KTM will know that.

One other difference on the new pump versus the old which I forgot to mention is the OE filter on the pump base is more substantial and a better fit.
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