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Aftermarket fuel pump

B

BRN2RDE

Joined Jan 2008
70 Posts | 0+
Southern Oregon
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
 
mp8075 said:
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
Click to expand...

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.
 
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
 
ggalex said:
mp8075 said:
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
Click to expand...

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.
Click to expand...

It has different outlet fitting...http://ktmtalk.com/index.php?showtopic=418120&st=30
 
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.
 
jof062 said:
ggalex said:
mp8075 said:
Here is a link to a pump that another user has put on his berg.... http://www.ca-cycleworks.com/products/f ... -4-strokes
Click to expand...
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?...
Click to expand...
It has different outlet fitting...http://ktmtalk.com/index.php?showtopic=418120&st=30
Click to expand...

Ah, now I see how this unit will work, thank you jof062.
Copied here for ease-of-referrence, with thanks to [email protected] 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.
Click to expand...

{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.)
 
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.
Click to expand...
The prompt and polite response was appreciated, but it's a non-answer, so caveat-emptor I guess.
 
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!!!! :bounce3:
 
Good to know info. How much was the Husky pump? Our pumps are like $400?

I sucessfully put a $40 car pump meant for a Dodge Caravan in my TL1000 street bike. It worked and the bike ran fine, but who knows if it is was right. It was one of those it fit so I put it in there deals. :twisted:

The criteria, as I understand them, are flow rate (gallons per hour), pressure (PSI) and of course the physical size of the pump (will it fit?). Our bikes have a regulator, so some excess flow "should" not be a problem, other than potentially taxing the electrical system. Our bikes have a pretty good charging system though, with 210 watts on tap. The worry I have with a car pump is that if the flow regulator in the tank can't deal with the increased flow and the pressure put out by the car pump. If that occurs and the pressure reaching the injector is too high, it can richen your mixture. The ECU calls for a certain amount of "on time" for the injector and it does not know there is more pressure behind the injector, so more fuel is sprayed for any given amount of on time for the injector.

The Husky pump looks like an ideal solution compared to a car pump. Since it is meant for a bike, it's flow specs should be appropriate. It is likely better made than our pumps too, and cheaper to boot. I will keep this option firmly in mind if my pump ever acts up.

Do keep us updated on your bike's behavior over time with this pump. This thread should be a sticky :)
 
Upadate: First the good. I recieved the aftermarket fuel pump, and except for the non barbed outlet hose, it is EXACTLY the same as the stock pump. In fact, the part number on the pump is the same as the part number on the OEM Husa pump. I cannot say whether or not it is a better quality pump than the stocker, my guess is it will be a bit of a crap shoot. Looking at both, I would guess that both are probably a $10.00 part directly out of China. Husaberg should be ashamed of what they get for the OEM one, and I am sure ca-cycle is making good money on them as well. Pump is installed, and working well.

And now, the bad. After installing the pump, the same lean condition exists. I put everything back together and the bike still ran bad. I took everything apart again, and inspected every wire. No faults could be found. With nothing else to check, I swapped out injectors. I have a spare because this is not the first time I have done this rodeo. Swapping injectors made the problem go away, but I am very certain that the actual injector was not the problem. I believe that a bad connection somewhere caused the problem because this same injector was removed last summer when the bike was running lean again. I am thinking that wiggling a wire at or near the injector fixed it.

While the bike was apart, I disconnected, cleaned and inspected every connector, and dabbed in a bit of dielectic grease. I am hopeful that the problem is gone for good, but after having the bike apart a dozen times, I am not optimistic.
 
Woof. Hang in there, BRN2RDE ... we're pullin' for you.

And make sure that you document *everything* ... with pictures as well .... for your discussion with NA Husaberg.

-- E-Ticket
 
BRN2RDE said:
Upadate: First the good. I recieved the aftermarket fuel pump, and except for the non barbed outlet hose, it is EXACTLY the same as the stock pump. In fact, the part number on the pump is the same as the part number on the OEM Husa pump. I cannot say whether or not it is a better quality pump than the stocker, my guess is it will be a bit of a crap shoot. Looking at both, I would guess that both are probably a $10.00 part directly out of China. Husaberg should be ashamed of what they get for the OEM one, and I am sure ca-cycle is making good money on them as well. Pump is installed, and working well.
Click to expand...

My ca-cycle pump should be here today. I tore into mine on Friday in preperation for the replacement. Were you able to get all this done wihout those speceal oetiker pliers? Seems to me just using FI hose and clamps will do the job. I noticed the ground connection on the pump was extremely loose on mine. I will make sure it is secured on re-assembly. I am taking pictures and will post them up when I am done. I am also installing the Can Am inline filter at the same time.
 
No special tools required. Hose clamps work well if you replace that cheapo plastic line with good injector quality fuel hose. Hose clamp do not work well on the plastic line because there is no 'squish room' in the hose. You need to change out the line anyways to fit the non barbed output of the new pump.

I too have a filter installed after the quick connect under the tank. Not the Can-Am one, I found a filter from Napa that is very small and very cheap that was suited for a diesel application so it handles the pressure. It was around $4.00 I believe. It has been on there for several months now and is working as it should.I will post the part number when I get home tonight.
 
Thanks for the confirmation on what I was thinking. I bought FI grade fuel line and clamps already. I should have mine replaced this week. Hopefully that ends the fuel pump issues I have been having after the tank gets hot.

The other fuel filter part # would be good to have, the Can Am one is pretty large.
 
And the saga continues..... Aaarrrggghhhhh! As previously mentioned I got everything back together, and she ran great. Today I went for a little ride around my place and it ran fantastic. For about 6 miles. Then it outright quit on me. It simply won't fire, like it ran out of gas. The fuel pump still cycles as it should when you bump the start button, but it won't start. I have spark, tested with a screwdriver arcing to a ground.
I can only guess that one of the connectors that I so meticulously cleaned came apart? I will manually add a bit of fuel to the throttle body tommorow to confirm if it is a fuel or spark issue before I take it apart for the millionth time.
I love my Husa, and had probably 3000 trouble free miles on it before this gremlin took over, but I am getting tired of tearing it down. Might be time to consider moving on....
 
OK, Got it fixed. Again. The non barbed fuel hose connection blew the line off. Looks like the fuel line I got was not the quality it appeared and went a bit soft when the fuel got warm. I replaced that with hopefully better line, and better clamps. So far, so good.

And the inline fuel filter that I added awhile back is a Napa Gold 3027. Very cheap, but has been working very well for 5 months now. If you look at the application for what it fits, you see a couple vermeers with a cummins diesel engine so it is good for a pressurized system.
 
BRN2RDE said:
OK, Got it fixed. Again. The non barbed fuel hose connection blew the line off. Looks like the fuel line I got was not the quality it appeared and went a bit soft when the fuel got warm. I replaced that with hopefully better line, and better clamps. So far, so good.

And the inline fuel filter that I added awhile back is a Napa Gold 3027. Very cheap, but has been working very well for 5 months now. If you look at the application for what it fits, you see a couple vermeers with a cummins diesel engine so it is good for a pressurized system.
Click to expand...
Whew! At least your new problem was one that made sense and was *somewhat* easy to find.

Keep on truckin', sir!! E-Ticket
 
Thanks for your update. Totally makes sense too - I wonder why they would not put a barb on the fuel pump outlet operating at 50 PSI?

The NAPA fuel filter sounds like a great idea. Good enough for a big rig, good enough for a 'Berg :lol: Just from appearances, the stock filter does not impress me greatly. I have the Can-Am one on mine. Another thing I really like about putting a filter in the line before the injector - it is always there between the dusty outside world and the oh so sensitive injector when you take the tank off.

I may replace the cheap plastic stock hoses in the tank (OEM pump still working fine, knock on wood) with FI rated line and clamps, and safety wire the connectors to the pump while in there.
 

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