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May 17th, 2011, 06:42 PM   #41
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Re: Aftermarket fuel pump

After chasing this problem for the last 6 months or so, I am finally going to call it quits. I can take the bike apart when it runs bad, put it back together, and it will be fine. For awhile. Then, back to running like crap. It is for sure an electrical issue, causing the injector to not function properly. I have changed out the injector, pump, filters, disassembled, cleaned and greased all the connectors, and I am officially at a total loss. It is not a 'heat' issue, because once it starts running bad, it does even when cold.

So, anyone want a smokin deal on a 09 450? Never raced(by angry midgets) Runs great when it runs great. Otherwise, not so much. This really was my favorite 4 stroke of all time, but I need to get past this breaking down thing.
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May 17th, 2011, 11:46 PM   #42
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Re: Aftermarket fuel pump

Sounds like my bike, was a loose wire inside the loom near the shock never had a problem since, I think your dealer should send it back to husaberg or keep it tll he finds the problem
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May 18th, 2011, 08:52 AM   #43
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Re: Aftermarket fuel pump

Originally Posted by BRN2RDE
After chasing this problem for the last 6 months or so, I am finally going to call it quits. I can take the bike apart when it runs bad, put it back together, and it will be fine. For awhile. Then, back to running like crap. It is for sure an electrical issue, causing the injector to not function properly. I have changed out the injector, pump, filters, disassembled, cleaned and greased all the connectors, and I am officially at a total loss. It is not a 'heat' issue, because once it starts running bad, it does even when cold.

So, anyone want a smokin deal on a 09 450? Never raced(by angry midgets) Runs great when it runs great. Otherwise, not so much. This really was my favorite 4 stroke of all time, but I need to get past this breaking down thing.
I'm sorry to hear that. I can appreciate the frustration! I've only had one ride on mine, and it did two odd things: the tough restarting, and twice it bogged (at the base of the same hill while I was getting a run at it!). I've now got a CA-Cycle pump and Gates line at home, ready to be installed if it continues. I also wrapped the header and did the tank protection. We shall see if that helps. I also wrapped an old inner tube around the harness near the rear shock to prevent it chafing.

I wonder if there is something to investigate based on the very lean condition that you noted earlier? Mine has what I would describe as a normal amount of black soot in the pipe. It's not unheard of for a FI bike to be very lean and have a clean pipe, but it does seem a little odd.

I know you've checked all the connectors, but I would consider removing the whole harness to investigate. Or - when it has died, can you trace back the failure point? If there's no spark, is there power to the coil? If not, route back from there.

Best of luck with it. Let us know if there's anything you want me to try on my bike to see if the result is the same.
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May 18th, 2011, 09:43 AM   #44
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Re: Aftermarket fuel pump

Mine was so frustrating!!! Drove me mad, my fried who's an auto electrician Sussed it in no time, where as the dealers were very helpful especially simon at Midwest it was clearly very difficult to diagnose, it even gave a fault code of 5 long flashes, one minute my bike would run, then it would stop and nothing for hours without the bike moving!!!!! Listen there's that many of these bikes that run sweet, that it's fixable when you find it, this bike is awesome !! Don't give up!!!
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May 18th, 2011, 07:22 PM   #45
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Re: Aftermarket fuel pump

Spent some quality time with my Husaberg after work today. Stripped it right down to begin tracking down the problem. Once again, I beleive I have found the issue: A bad or faulty connector at the fuel injector.

What I did was remove the subframe and tank, then I jigged up the tank to be connected, fuel and power wise to the bike, but sitting on a cart next to the bike.
The bike still ran poorly, so without wiggling much of anything, I loosened up the throttle body and removed the injector. For kicks, I then re-installed the injector and the bike ran poorly again. Removed the injector, swapped in the same injector I had removed a few weeks ago because it was running bad. Started it up multiple times, and it ran perfectly. Go figure. Rather than just put it back together, I once again removed the injector, and swapped it with the one I had JUST removed, put it back together, runs perfectly.

With that, I believe I have the issue narrowed down to that one connector. I was very careful to not disturb anything else, so I think I got it. I then removed the connector, cleaned it really well, greased it up with dielectic grease, and put it back together. Runs perfectly.

Whether or not the problem returns, time will tell, but at least I am pretty confident I have the culprit. Anyone know where I could find that particular connector, to replace it outright should the problem return?

Pessimistally optimistic,

BRN2RDE
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May 19th, 2011, 12:12 AM   #46
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Re: Aftermarket fuel pump

Mine was a connection, deep inside the loom,3 wires to 1 it just seemed to point to so many different things that's what makes it so frustrating, because my friend was an auto electrician, right from the off he said there was a broken wire or poor connection somewhere, rather than get ripped off for a new loom which are so over priced he was going to make me one, but he found the culprit once we took out the loom and opened it all up, he then replaced that whole wire with new and some of his own connectors, now it's perfect again, and by far the best bike I've ever owned happy ))
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May 19th, 2011, 09:13 AM   #47
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Re: Aftermarket fuel pump

Originally Posted by BRN2RDE
Spent some quality time with my Husaberg after work today. Stripped it right down to begin tracking down the problem. Once again, I beleive I have found the issue: A bad or faulty connector at the fuel injector.

What I did was remove the subframe and tank, then I jigged up the tank to be connected, fuel and power wise to the bike, but sitting on a cart next to the bike.
The bike still ran poorly, so without wiggling much of anything, I loosened up the throttle body and removed the injector. For kicks, I then re-installed the injector and the bike ran poorly again. Removed the injector, swapped in the same injector I had removed a few weeks ago because it was running bad. Started it up multiple times, and it ran perfectly. Go figure. Rather than just put it back together, I once again removed the injector, and swapped it with the one I had JUST removed, put it back together, runs perfectly.

With that, I believe I have the issue narrowed down to that one connector. I was very careful to not disturb anything else, so I think I got it. I then removed the connector, cleaned it really well, greased it up with dielectic grease, and put it back together. Runs perfectly.

Whether or not the problem returns, time will tell, but at least I am pretty confident I have the culprit. Anyone know where I could find that particular connector, to replace it outright should the problem return?

Pessimistally optimistic,

BRN2RDE
I hope you're onto it this time. Like so many have said, they are great bikes but the electrical gremlins can be frustrating to say the least.
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May 22nd, 2011, 05:14 PM   #48
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Re: Aftermarket fuel pump

Subscribing. Seems like some good info here that hopefully i'll never need to make use of...
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May 23rd, 2011, 10:45 AM   #49
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Re: Aftermarket fuel pump

Update on my fuel pump change out to the ca-cycleworks pump. I switched back to the OEM pump even though it has heat issues. I was prepping Friday night for my Saturday race. I had just finished hosing off my bike and was going to start it up to help dry it off. It wouldn't start. My first thought was that I got water in somewhere that it shouldn't be since I rode it the previous Sunday and it was fine. I fiddled with the spark plug cap thinking that may be the issue and it started but wouldn't idle and would die if I tried to give it any throttle. Then it wouldn't start at all. Every time I would hit the starter I could hear the pump running so I knew I didn't have an electrical problem related to the pump.

As I started my investigation my first approach was looking at it like a spark issue. I removed the plug and verified that I had spark. I poured some gas into the cylinder and put the plug back in. It started and ran for a short time and then died again. Now I was thinking fuel problem. My first thought was that one of the connections to the fuel pump that I had redone had come loose so I pulled the tank off and pulled the pump out. I only pulled the pump out far enough to see that the connections that I had made were still intact. I put the pump back in thinking it was fine and then turned my attention to the fuel injector. My thoughts were that it was possibly plugged, although I wasn't to solid on that thinking becasuse it wouldn't run at all. Most of the injector related issues that I have read about are poor running or bogging type issues. I pulled the injector out and did my best to clean it. I put it all back together and it still wouldn't start. At this point I didn't know where to look and was thinking my race the next day was out of the question. While sitting down at dinner I was thinking about the situation and decided that maybe I was having problems with the new pump. I made a decision that I was going to put my OEM pump back in. I went and pulled my tank back off and pulled the pump out. This time though as I looked at things more carefully in prep for changing the pump I saw my problems. Yes, multiple issues became obvious to me. Number one, since the ca-cycleworks pump does not have a barbed fitting of any kind (it is just a smooth outlet fitting) I was concerned about the fuel pump pushing the line off of that fitting when under pressure so I tightened the clamp very tight. The clamp ended up cutting through the fuel line so there was a big hole in the line causing an obvous pressure loss. Problem two was a kinked line right above the fuel filter from when I put the whole thing back in the tank. So on top of low pressure I had a flow restriction to boot. I put the OEM pump back on and with the barbed fitting on its outlet I felt better about having a lightly clamped connection. I also zip tied the fuel outlet line and the fuel return line toghether about an inch above the fuel filter to provide more rigidity in that area to help with the kinking problem. Instead of jamming the whole thing in from the bottom like I did last time, I remove the fuel regulator from the top of the tank and pulled the fuel pump into position by pulling from the top. The whole thing went together much easier from the top with the pump end already secured. I put everything back together and it fired up and ran perfectly with the OEM pump back in there. I learned some more stuff about my bike while going through this. That kinked line is something to be aware of as possibly causing bog or hesitation issues when making large throttle movements. Right after I installed the ca pump, I noticed an off idle hesitation that wasnt there before the pump change. I am pretty sure it was due to the kinked line as I don't think the hole in the fuel line had progressed to the failure point yet.

Anyway, I raced 80 miles Saturday and the berg ran perfect. I'll have to pay attention to the over heating fuel pump until I can find a better replacement or KTM/Husaberg drops the price on an OEM replacement.
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May 23rd, 2011, 11:45 AM   #50
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Re: Aftermarket fuel pump

Go to the submersable fuel line and you will not have the cutting problem with the clamps. The submersable stuff is expensive, but clearly better suited for in tank applications.
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