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April 18th, 2011, 11:49 AM   #1
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Aftermarket fuel pump

Did someone find an aftermarket fuel pump that will fit into our tanks? I believe that mine may be going bad, and would like to swap it out to see if that is causing my issues.

For those curious, my 09 450 seems to have a 3 hour failure switch. On the last 3 races I have done, I make it about 3 hours and the bike begins to run poorly, like it is being starved for fuel. I have checked, cleaned, and replaced the injector, as well as added an inline fuel filter past the quick connect, so I am pretty sure that is not it.

I did find a burned fuel pump wire under the tank, which I replaced last fall. Bike ran great all winter, but yesterday at a local ISDE, it began to act up again near the end of the ride. I am very sure it is a fuel issue, and the only thing left is the fuel pump. I just hate to replace an expensive part on a guess....

Thanks,

BRN2RDE
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April 18th, 2011, 01:54 PM   #2
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Re: Aftermarket fuel pump

What about thermal runaway on the injector solenoid?
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April 18th, 2011, 01:59 PM   #3
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Re: Aftermarket fuel pump

Here is a link to a pump that another user has put on his berg. There is a thread on KTMTalk about it in the husaberg section. I plan on replacing mine with this one very soon as I have the problem where mine gets hot and the bike won't start until it cools down.

http://www.ca-cycleworks.com/products/f ... -4-strokes
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April 18th, 2011, 06:26 PM   #4
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Re: Aftermarket fuel pump

Originally Posted by mp8075
Here is a link to a pump that another user has put on his berg. There is a thread on KTMTalk about it in the husaberg section. I plan on replacing mine with this one very soon as I have the problem where mine gets hot and the bike won't start until it cools down.

http://www.ca-cycleworks.com/products/f ... -4-strokes
I see this pump is listed for Husky bikes. Do we know what if anything needs to be tweaked for this pump to fit in our 09+ FE/Xs? At the rate that people are having trouble with these pumps on various FI bikes of all makes, I can see just having one in the toolbox for the eventuality.

Thanks for the legwork on this issue, to those who have had to deal with it before us later-adopters bought in.
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April 18th, 2011, 06:53 PM   #5
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Re: Aftermarket fuel pump

So I took the bike apart after work this evening. I found that the fuel pump control wire, right at the plug where it connects to the fuel tank, has a crack in each wire housing. So though the wire does not appear to be burned, or even able to ground itself, I can see bare copper in each wire.

I am not convinced that this is the problem because of no apparent burn or arcing, but it clearly needs to be replaced. SO, where the heck would I find that plug? The plug has to be replaced because the crack in the wire housing is right at the plug, too close to splice the wire.

I also removed the fuel pump, and everything 'looks' good in there. I'd still like to replace the pump, but wonder how or if the mentioned pump will work with the cool aluminum housing that came with the sub frame fuel tank, or if I should just go with a stock one?

At this point, I am 100% convinced that the problem is a lean out condition. Exhaust is a clean as a whistle, no soot whatsoever. Figuring out why it is leaning out sure would be nice. I am still taking suggestions, should the wire thing not pan out.

BRN2RDE
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April 18th, 2011, 07:16 PM   #6
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Re: Aftermarket fuel pump

Originally Posted by ggalex
Originally Posted by mp8075
Here is a link to a pump that another user has put on his berg. There is a thread on KTMTalk about it in the husaberg section. I plan on replacing mine with this one very soon as I have the problem where mine gets hot and the bike won't start until it cools down.

http://www.ca-cycleworks.com/products/f ... -4-strokes
I see this pump is listed for Husky bikes. Do we know what if anything needs to be tweaked for this pump to fit in our 09+ FE/Xs? At the rate that people are having trouble with these pumps on various FI bikes of all makes, I can see just having one in the toolbox for the eventuality.

Thanks for the legwork on this issue, to those who have had to deal with it before us later-adopters bought in.
It has different outlet fitting...http://ktmtalk.com/index.php?showtopic=418120&st=30
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April 18th, 2011, 07:38 PM   #7
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Re: Aftermarket fuel pump

I just ordered that aftermarket fuel pump. When I get it, I will report on exactly how it fits. Now, I just need that plug in, and I should be riding again next weekend. Hopefully. Maybe.
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April 19th, 2011, 07:39 AM   #8
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Re: Aftermarket fuel pump

Originally Posted by jof062
Originally Posted by ggalex
Originally Posted by mp8075
Here is a link to a pump that another user has put on his berg.... http://www.ca-cycleworks.com/products/f ... -4-strokes
I see this pump is listed for Husky bikes. Do we know what if anything needs to be tweaked for this pump to fit in our 09+ FE/Xs?...
It has different outlet fitting...http://ktmtalk.com/index.php?showtopic=418120&st=30
Ah, now I see how this unit will work, thank you jof062.
Copied here for ease-of-referrence, with thanks to lostalaskan@ktmtalk.com for figuring out this workaround:
... change ... the line that runs from the nipple to the inline filter.The OE pump has a barbed nipple,the replacement is smooth. The OE uses a plastic flex line that's about 6" long,I cut it off and used 5/16 ID fuel injector hose and clamped it. The bottom intake is the same so the OE prescreen fits perfectly.
{Edit: Initially I wrote here about the potential of an alternative Delphi T-11 small-engine spec-pump, but the lead played out to a dead-end.
A Husky board TE310 rider posted about employing a larger-bodied (35 or 38mm) car-based pump, EG AC Delco EP490, Walbro GCA338 (~$120), with many other opportunities for crossover and widely available. My worry with that solution is the car unit likely draws much more current (>5A v. <2A stock?) and flows unnecessarily more fuel than our stock pump though the pump pressure is probably fine-- the pres. regulator would just return more fuel and hopefully not wear out over the long run. blah blah blah. Still hoping we'll find multiple solutions.}

BTW, does anybody know what the stock pump pressure and then the post-regulator pressures are?

(Maybe an abbreviated Sticky in the Fuel section is in order to simplify future victims' finding this great solution, once discovery of all reasonable options is played out.)
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April 19th, 2011, 09:05 AM   #9
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Re: Aftermarket fuel pump

For what it's worth...
This from ca-cycleworks in reply to an inquiry on the subject of using their Husky TE-spec replacement FI pump in our FE/X HGBs:
Thanks for writing! We had this pump made based on one supplied to us by a Husky dealer. The Chinese manufacturer was familiar with the part number from the OEM pump, 1100-00072.
The prompt and polite response was appreciated, but it's a non-answer, so caveat-emptor I guess.
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April 20th, 2011, 06:36 AM   #10
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Re: Aftermarket fuel pump

I have installed this pump. It fits the OE set up perfectly.I also run the 70 degree aux tank. The output nipple is smooth on the pump from CA Cycle, the OE is barbed. The elecicical hookup spades were a little short so I did the "Dale-EO" safety wire trick on the top cover. This has solved the shut down issue I was having with my 390.
Tim at Edelmans did get me a pump from Husaberg and was 99% sure that they would warrenty the pump. When I first called the pump was on back order and I could not afford to pay for the OE if they wouldn't cover it,so I took matters in to my own hands. Thanks for all the info on this forum!!!!
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