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August 1st, 2011, 01:02 PM   #81
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Re: Aftermarket fuel pump

Mine just started failing as well. 35 hours with no problems. Then it hit.

My tank was about 1/2 full when it started acting up. It got worse as my fuel got lower - which makes sense since there is less volume of fuel to keep the pump cool.

So far mine has not cut out while riding. It just won't start when hot. I think when the pump expands in the heat something must get too tight and the pump can't overcome the friction to start it spinning. Once it is spinning, it will keep going.

I am trying to contact KTM Customer Service and see if they will replace it with a newer pump. So far I haven't gotten through.

If that doesn't work I will either get the CA Cycleworks pump or the Aprilia pump assembly. Has anyone actually installed the Aprilia assembly in the Berg? That looks like a good solution if it really works.
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August 2nd, 2011, 10:53 AM   #82
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Re: Aftermarket fuel pump

Originally Posted by aaronc70
Originally Posted by Davo
It's just pure bloody odd that a High Pressure pump has no barb. Just my opinion not saying it is correct.

I agree they should have designed it with a barb BUT: to-date, has anyone besides BRN2RDE had the fuel line blow off the CA Cycleworks pump end?
I installed the CA Cycleworks pump on a 2010 FE 570 with 8.8 hours owned by my friend which was failing to restart when hot and finally, not at all. With the help of this thread and Dale E O, we ordered the aftermarket since no dealers had pumps and we were headed to Colorado to ride. Now, having completed about thirty hours of tough riding in Crested Butte, CO, (including two nasty high-speed falls-ouch!) the installation worked and has held. The fuel line has remained connected and the bike ran great for him.

Here is what we did. First, we roughed up the nipple on the CA Cycleworks pump with a Dremel tool rasp ever so slightly to increase purchase once we put back together; cleaning it thoroughly of any plastic when done. Then, we followed the directions for removing the tank in the service manual. Then emptied fuel from the tank into a clean container for reuse. After unscrewing the fuel pump assembly from the bottom of the tank, removing the fuel pump assembly from the tank by a few inches only so I would not have to deal with the nest of wires and lines in the tank, and then removing the pump from the plastic housing, we simply cut the stock plastic fuel line lengthwise on one side of the barbed nipple on the stock pump to allow the stock fuel line to be removed, cutting as little as possible. There was a section of the stock fuel line that was smoother without the accordian finish that the fuel line has further up the line toward the fuel filter; we wanted to preserve as much as possible to use that smooth section to re-attach to the CA pump nipple. Then, we trimmed the fuel line square above the previous cut we made, again preserving as much of the fuel line as possible. Then, we slipped an Oetiker Stepless Clamp, 9.5 mm, STD, stainless steel, part number 48548846, purchased for $0.53 from MSC Industrial Supply (Grainger may have as well) onto the fuel line. Then, carefully slipped the stock fuel line over the nipple on the CA pump. Slid the clamp down midway onto the pump nipple over the fuel line and clamp so that the clamp would not interfere with the plastic holder or wires later. We attached the wires and then adjusted the plastic ties so that it all hung in line and even with no pressure on wires. Reassembled and slipped into the tank. Followed reassembly exactly as per manual, including torques, and then started the bike. Rode and smiled. Total time was 1.5 hours not including time to remove the tank the first time.

You might need the Oetiker tool to clamp which looks like a dull 90 degree cutter; I am sure that I could use my regular cutters to clamp now but I did not know when I bought and I was anticipating future need for this and other applications where the excellent capabilities of the Oetiker clamp will shine over screw clamps. My feeling is that the Oetiker clamp places significant and even pressure on the fuel line so that it will not come lose. May the force be with it. In the meantime, I will buy another CA Cycleworks pump for my back-up kit and keep with the Oetiker clamps.


Will
2010 FX 450
2008 KTM EXCR 450 (back-up in case the fuel pump goes on the Berg)
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August 2nd, 2011, 11:05 AM   #83
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Re: Aftermarket fuel pump

Oh, I was wondering where you could get those special clamps like I took off the husaberg. I just used the stainless screw clamps, so far so good. Looks like you guys put a lot more thought into it than I did. Mine's still working fine, although I haven't rode the Brg in several weeks, I've been on the 200XC.

I'll be sure and report if and when the screwclamped hose blows of the end of my CA Cycleworks pump.
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August 3rd, 2011, 07:56 AM   #84
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Re: Aftermarket fuel pump

I had problems with the CA pump mainly due to over tigntening the clamps beacause of the no barb issue. The other problem I had was using too long of a piece of non-flexible fuel line between the pump and the filter which caused a kink in the flex line above the filter after I shoved everything back in the tank. All this happened the night before a race and I didn't have time to come up with a better installation solution so I put the original pump back in and haven't bothered to switch it back out yet. I recently bought an 11 300XC so the berg is just sitting at this point.
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August 12th, 2011, 05:31 PM   #85
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Re: Aftermarket fuel pump

I started installing my CA Cycleworks fuel pump today, as per willmia's instructions, and suggestions from others. I thought I would post some photos...

Here is the new fuel pump. I heated the outlet port with a heat gun. It didn't take much heat. I then pushed the tip of an arrow into the opening and allowed it to cool. If you look closely you can see that the port is now slightly flared out. I also took an engraving vibrator tool and made some lines around the port to increase the friction. I didn't want to remove any material so I didn't use a dremel. The engraver just sort of pushes the material around - sort of like miniature speed bumps.


Here is the stock fuel pump (with the Profill filter). Notice that the stock outlet port has three sets of barbs causing the bulges in the line. I tried to heat the tube and pull it off. It didn't work. Not much heat and the tubing started to bubble. I then tried cutting slits as willmia suggested. That was a bother, so I opted for a different approach. I just cut around the hose just below the top barb. I could then pull off the tubing with little effort.


Here is the cut fuel line, with just enough room to mount a clamp.


Unfortunately, that is as far as I got. I thought I could use my fuel injector hose clamps, but this interior hose is much smaller than the external ones. I could not find a clamp small enough at any local auto parts store. So I ordered some from MCS Industries Direct, as suggested by willmia. Thanks willmia for posting the part number - that really helped. So now I get to wait for more parts to come...
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August 12th, 2011, 06:33 PM   #86
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Re: Aftermarket fuel pump

Thanks for the pics! - ET
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August 13th, 2011, 04:04 AM   #87
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Re: Aftermarket fuel pump

Looks like your doing it the right way! WIsh I would have had some pics like this to help when I did mine, keep up the good work. To clarify one of my older posts, I used fuel injection specific screw clamps, not regular type screw clamps for plumbing applications.
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August 13th, 2011, 07:21 AM   #88
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Re: Aftermarket fuel pump

I've just bought some of these to refit the OE fuel pipe when I finally get a pump sorted.
http://www.ebay.co.uk/itm/7mm-9mm-PE...item3f0c80eb33
I'm still waiting on Husa/KTM's decision on wether to change my pump (7 months/65hrs old) as a 'goodwill' gesture. If they say no I intend to try and source the pump elsewhere. There's ABSOLUTELY NO WAY I'm paying the 270 I've been quoted from the dealer.
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August 13th, 2011, 09:33 AM   #89
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Re: Aftermarket fuel pump

Those are the type of clamp I tried to find locally, but failed. I found plenty of 11-13mm and 13-15mm, but no 7-9mm.

I bought my bike in Nov 2010 and KTM has agreed to good will a pump for me. It just takes time.
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August 25th, 2011, 12:48 PM   #90
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Re: Aftermarket fuel pump

Finally got the 570 back up and running today with a new OE fuel pump provided under warranty. As I understand it from the dealer handling the claim, they were told by the importers to contact Husaberg/KTM in Austria and raise a claim with the factory direct with a view to getting the pump replaced as a goodwill gesture as each case is being looked at individually. Glad to say the claim was passed. Many thanks must go to Scott at Gear4 Motorcycles (I bought the bike from them in December last year) who handled everything and had a new pump on my doorstep less than a week after the claim being granted by the factory.
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