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June 2nd, 2011, 01:28 PM   #61
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Re: Aftermarket fuel pump

Well yesterday my 450 left me stranded twice with the same hot bike no restart problem. No fuel pump engagement until after cooling down 20 minutes prox. Then it restarts as if nothing happened and I can hear the pump spin up.

I getting so that I can tell when the fuel pump is going to stop working soon when I restart and it hesitates and stumbles trying to get started. I've called my dealer and he acknowledged the problem but said that the magic replacement pump isn't available for 5 weeks!!!!!!!!!!!!!! He gave me the KTM customer relations number and said to file a claim but the number is continually busy. I'm not happy, I don't feel comfortable riding this bike anymore when I ride by myself.
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June 4th, 2011, 04:59 PM   #62
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Re: Aftermarket fuel pump

Originally Posted by LadyBerg
Well yesterday my 450 left me stranded twice with the same hot bike no restart problem. No fuel pump engagement until after cooling down 20 minutes prox. Then it restarts as if nothing happened and I can hear the pump spin up.

I getting so that I can tell when the fuel pump is going to stop working soon when I restart and it hesitates and stumbles trying to get started. I've called my dealer and he acknowledged the problem but said that the magic replacement pump isn't available for 5 weeks!!!!!!!!!!!!!! He gave me the KTM customer relations number and said to file a claim but the number is continually busy. I'm not happy, I don't feel comfortable riding this bike anymore when I ride by myself.
I also am waiting for a new fuel pump for one that failed after 2.5 hours on a 2011 FE450. I was told these were available in the US on June 8/11, but maybe they have slipped. How are these new "magic pumps" identified? Different color? Different part number?

Cheers,

Blaine
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June 5th, 2011, 04:01 AM   #63
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Re: Aftermarket fuel pump

This ones brown..
http://ktmtalk.com/index.php?showtopic=423944&st=15
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June 5th, 2011, 05:18 PM   #64
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Re: Aftermarket fuel pump

I'm a bit reluctant to post my status after there's still others experiencing problems with their fuel pump systems but here goes...

I finally got a hold of KTM east coast on Fri. After explaining my situation, the fact that my dealer was 8 hours away and I didn't think that another closer dealer would support me, plus my experience as a BMW mc tech (ages ago folks) the KTM service rep sent a fuel pump assy directly to me and I got it on Sat. Mind you it's the original FP assy but a newer build date. Couldn't believe it!

The rep commented that this unit may fail as well but I was willing to do the work. I pulled the bike apart Fri night, and when the assembly came I installed it fairly quickly but it does take some careful work with the QR fuel line connectors. (I'll write what I did in another post if others are interested).

I nervously refilled the tank and radiators and hit the button, a start, ohhhhh good! I've ridden the bike 2.1 hrs/55 miles on the street trying to duplicate the situation where the FP would fail on a hot REstart. This means hot hot hot, fan running, fuel percolating, heavy clutching, accel, as much as I legally could run it up. No problem, NONE Smoother accel, no popping on decel. I'm now ready to head back into the woods and maybe a local HS. I did order the CA cycle works FP and am going to see if I can fabricate a nipple or mechanical method to retain the fuel hose on the straight barb as a back up.
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June 6th, 2011, 06:46 AM   #65
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Re: Aftermarket fuel pump

That's great news LB. Glad it's working out.

I dug into mine to swap out filters last night. Despite flushing the tank with zero miles on the bike, the screen on the pump was maybe 50-60% blocked with tank goo.

We'll see what that does for me. Hopefully that will cure the bogging issues. I'll have to wait and see on the restarting.
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June 6th, 2011, 08:46 AM   #66
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Re: Aftermarket fuel pump

Good News LB! I've got my CA cycleworks pump in the tank, wraped my header and put some heat shield on the tank bottom. I'm going to seal the header wrap with silicone spray tonight and try to put it all back together. I'll post with an update when I get a chance to ride it and get it good & hot. I'm definetely looking forward to the days when I can spend all day on the bike and not be stranded or flaming out evey couple hundred yards.
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June 7th, 2011, 05:12 AM   #67
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Re: Aftermarket fuel pump

Originally Posted by aaronc70
Good News LB! I've got my CA cycleworks pump in the tank, wraped my header and put some heat shield on the tank bottom. I'm going to seal the header wrap with silicone spray tonight and try to put it all back together. I'll post with an update when I get a chance to ride it and get it good & hot. I'm definetely looking forward to the days when I can spend all day on the bike and not be stranded or flaming out evey couple hundred yards.

Well I got my bike put back together last night with the new pump and everything mentioned above. Its starts really quick and the fuel metering seems spot on. I let it idle till the fan came on and rode it up and down the street a little. Seems just about perfect finally. I won't know for sure until I'm able to get it on the trail, but that may be a week or two. Hopefully this has it fixed!
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June 7th, 2011, 09:41 PM   #68
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Re: Aftermarket fuel pump

Wow! I am suprised with all the fuel pump issues. I bought a new leftover 2010 FE 450 and now have 300 hard miles with no issues. From day one I have added:

* No white crap in tank from day one
* Header Wrap
* Removed the Gas cap ball and valve check
* Installed Can-Am Filter
* CV4 Tank wrap plus a ton of tinfoil tape around all other areas
* Removed Screen in Exhaust

I have had fuel boiling and radiator anti-freeze boil over in super slow rocky sand washes in Colorado, but never any starting issues. Always starts first press of the button, hot or cold.

Cross fingers that I have continued luck!
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June 8th, 2011, 04:49 AM   #69
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Re: Aftermarket fuel pump

Originally Posted by aaronc70
Originally Posted by aaronc70
Good News LB! I've got my CA cycleworks pump in the tank, wraped my header and put some heat shield on the tank bottom. I'm going to seal the header wrap with silicone spray tonight and try to put it all back together. I'll post with an update when I get a chance to ride it and get it good & hot. I'm definetely looking forward to the days when I can spend all day on the bike and not be stranded or flaming out evey couple hundred yards.

Well I got my bike put back together last night with the new pump and everything mentioned above. Its starts really quick and the fuel metering seems spot on. I let it idle till the fan came on and rode it up and down the street a little. Seems just about perfect finally. I won't know for sure until I'm able to get it on the trail, but that may be a week or two. Hopefully this has it fixed!
Well, I was able to sneak of to a friend's house last night and rode the 570 in some super tight, two-stroke enduro style single track. It was 92deg F out and the fan was running almost constantly for 45 minutes or so. The bike did great and it looks like I may have this thing lined out finally! I'm not goign to trust it to take me deep in the mountains alone, but hopefully after a few trail rides with buddies to back me up I'll be able to go solo.
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June 26th, 2011, 09:46 AM   #70
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Re: Aftermarket fuel pump

I've ridden the bike the last two weekends with no problems. I also took it on one really tough ride for 45 minutes on super tight, slow singletrack that is really only suitable for a 2-stroke- the 570 did great. I'm 95% sure I had a bad fuel pump, possibly due to being clogged up by white goo from the fuel tank, as everything got better once I replaced it. I used the CA Cycleworks pump. See you on the trails!
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