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May 20th, 2011, 01:02 PM   #1
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What is the failure rate and cause of FE450 fuel pumps?

Hello Group,
Well, took delivery of a new 2011 FE450 on May 12/11, and after 2.6 hours of riding over three days, the fuel pump failed. Dealer now says pump is on back order, ETA approximately five weeks. The pump failures are being blamed on sediment from the fuel tank bonding process contaminating the gas. I read a number of messages in this forum about this issue before I purchased this bike asked the dealer. He said it was a known problem where sediment was left in the tank during the tank manufacturing bonding process and that they were advised to flush the gas tanks upon delivery of the bikes. This tank was flushed. I don't know if the flushing was a Husaberg service advisory or information found on the dealer network. You may want to ask your dealer. However, it now appears likely if any sediment contaminated fuel was pumped through the fuel system prior to the tank being flushed, for example during final factory check of the bike, that the filters could be plugged, the fuel pump damaged, the fuel pump fuel starved and burn-out, or the fuel injectors plugged. So buyer be more aware than I was. And be aware that an unexpected fuel pump failure could result in a possible crash and even injury, depending upon what you were doing at the time of the failure. You get no warning sign; the engine just cuts out. So the question remains, sediment caused problem or simply crappy fuel pumps.

Chat later,
Blaine
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May 20th, 2011, 10:56 PM   #2
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Re: What is the failure rate and cause of FE450 fuel pumps?

Check here...

viewtopic.php?f=7&t=14479

There seems to be an aftermarket solution.

BBB.
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May 21st, 2011, 08:41 AM   #3
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Re: What is the failure rate and cause of FE450 fuel pumps?

"made in china" and made to OEM spec and price point.

Not all chinese made components are of low quality, however, fuel pump failures are the most common cause of fuel injected engine malfunctions. Around here it seemed there was rash of "390" fuel pump failures on new bikes. Apparently the pumps are the same for the 3 engine sizes.


A snapshot of my experience as a fleet mechanic. Every one of our gas powered GM vehicles has recieved fuel pump modules due to failure at one point or another. However none of the Fords have(that I recall without looking at my files), and we run more Fords. They are maintained with the same plan of service, products and fuel source. Food for thought.....

jz

PLEASE NOTE: This is not a commentary on FORD vs CHEVY or a bag on CHINA fest, just professional experience and commentary on spec'd components and quality control.
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May 26th, 2011, 07:36 AM   #4
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Re: What is the failure rate and cause of FE450 fuel pumps?

I just took posession of a new 2010 FE450 and doing all the prep work to it right now before it gets dirty. Once I got the bike, I opened the gas cap, and sure enough there was a white film all over the inside of the tank neck. Not to take any chances, I didn't start the bike, emptied the fuel and flushed it with rubbing alcohol as some people suggested. I don't think the rubbing alcohol did anything as the white film was still there ie not moving. To make sure nothing got plugged on the dealer test run, I checked the fuel filter and it was clean.
So, what I'm saying is, rubbing alcohol does not do anything to the white stuff from what I saw. So, how do you flush it and with what? Seems like this white residue is coating the tank and maybe breaks down after a period of time and gradually starts floating and plugging the filter? I dunno.

Will take it for its first ride this weekend, so hopefully won't get stranded.

P.S. After reading horror stories about removing the tank, I was dreading the exercise, but it turned out to be pretty easy. I guess people that complain about this never had to do jetting on a 08-11 WR450.
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May 26th, 2011, 09:21 AM   #5
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Re: What is the failure rate and cause of FE450 fuel pumps?

Hello Marvfr,

The white sediment is from the bonding process when the tank was manufactured. The dealer here simply flushes the tank with gasoline when they receive the bike. The sediment can plug the filter, damage the pump, or plug the injectors. If fuel was run through the fuel system before the tank was flushed, for example during production line checkout, there is a good chance some damage was done to the fuel system. I am still waiting for a replacement pump.

This same pump is used in the 2011 KTM 250 / 350 SXF, and I cannot find any complaints about the pump in the KTMTalk forum. So hopefully, once the fuel system is clean and the pump proves to be reliable, that is the end of this problem. Mine quit after five minutes of riding so it was not one of the many heat related problems affecting the fuel system that can affect the Husaberg. But the unknown factor with the pump can really affect the confidence level riding these bikes.

The Husaberg pump is a KTM pump. Ninely per cent of the Husaberg is KTM parts. Here is a quote from the KTM 250 SXF webpage:

"Out there in offroad heaven you have your hands full without having to think about the mechanics of the motorbike. We know what that means from our own experience so thatís why every screw and every technical detail on your KTM is checked umpteen times, right there, where it is supposed to be. You can really be confident that your bike is never going to let you down."

Cheers,

Blaine
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May 27th, 2011, 06:12 AM   #6
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Re: What is the failure rate and cause of FE450 fuel pumps?

If BERGS don't have any issues, its not a BERG, and you wont have sites like this ..


ZAGA
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July 18th, 2011, 08:45 AM   #7
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Re: What is the failure rate and cause of FE450 fuel pumps?

Originally Posted by markvfr
I just took posession of a new 2010 FE450 and doing all the prep work to it right now before it gets dirty. Once I got the bike, I opened the gas cap, and sure enough there was a white film all over the inside of the tank neck. Not to take any chances, I didn't start the bike, emptied the fuel and flushed it with rubbing alcohol as some people suggested. I don't think the rubbing alcohol did anything as the white film was still there ie not moving. To make sure nothing got plugged on the dealer test run, I checked the fuel filter and it was clean.
So, what I'm saying is, rubbing alcohol does not do anything to the white stuff from what I saw. So, how do you flush it and with what? Seems like this white residue is coating the tank and maybe breaks down after a period of time and gradually starts floating and plugging the filter? I dunno.

Will take it for its first ride this weekend, so hopefully won't get stranded.

P.S. After reading horror stories about removing the tank, I was dreading the exercise, but it turned out to be pretty easy. I guess people that complain about this never had to do jetting on a 08-11 WR450.
Just an update and another data point. My pump failed with first symptoms at 6-8hrs and now have 15. In a race two weekends ago it almost put me over the bars on a 4th gear WOT hill climb as it cut out. It did it couple more times after that so I lost all confidence. I had two more races this weekend and right before it, I decided to test the bike to make sure I got rid of the stumble by cleaning the fuel filter again (plugged with the white stuff of course), and this time it didn't only cut out but had the classic "dead fuel pump on hot restart" syndrome. Twice. 20mins later each time it re-fired and I limped to the truck with my buddies pissed that the flow of the ride was toast. So, no racing for me this past weekend because of it.

Just for the record before I started the bike I did all the prep as described above and also added the header wrap, reflective tape, Evans coolant. Still happened.

Gonna talk to my dealer so what can be done as I'm not too keen on the non-barbed ca pump.
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July 18th, 2011, 10:21 AM   #8
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Re: What is the failure rate and cause of FE450 fuel pumps?

I recently started having fuel pump related issues on my '10 FX450.
While researching the problem I discoverd that the same fuel pump is used in Aprilia RXV/SXV's.
A call to my Aprilia dealer gave me some information.
It seems that Aprilia was having the exact same issues with the fuel pumps and they traced it down to a tolerance issue inside the pumps causing them to start having problems once hot.
Aprilia initiated a recall and replaced all the pumps and have had no further problems.
btw: the Aprilia fuel pump is cheaper than the KTM/Husaberg and is an exact match.
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July 18th, 2011, 11:14 AM   #9
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Re: What is the failure rate and cause of FE450 fuel pumps?

Originally Posted by JodyH
I recently started having fuel pump related issues on my '10 FX450.
While researching the problem I discoverd that the same fuel pump is used in Aprilia RXV/SXV's.
A call to my Aprilia dealer gave me some information.
It seems that Aprilia was having the exact same issues with the fuel pumps and they traced it down to a tolerance issue inside the pumps causing them to start having problems once hot.
Aprilia initiated a recall and replaced all the pumps and have had no further problems.
btw: the Aprilia fuel pump is cheaper than the KTM/Husaberg and is an exact match.
Excellent find JodyH!

Why wouldn't Husaberg/KTM do a recall if its the same problem is beyond me.
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July 18th, 2011, 11:57 AM   #10
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Re: What is the failure rate and cause of FE450 fuel pumps?

Originally Posted by JodyH
I recently started having fuel pump related issues on my '10 FX450.
While researching the problem I discoverd that the same fuel pump is used in Aprilia RXV/SXV's.
A call to my Aprilia dealer gave me some information.
It seems that Aprilia was having the exact same issues with the fuel pumps and they traced it down to a tolerance issue inside the pumps causing them to start having problems once hot.
Aprilia initiated a recall and replaced all the pumps and have had no further problems.
btw: the Aprilia fuel pump is cheaper than the KTM/Husaberg and is an exact match.
Excellent, sir! Do you have a link and part number? Cheers! E-Ticket
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