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Fuel Pump problem or something else??

A

aaronc70

Joined Dec 2009
72 Posts | 0+
Knoxville, TN
I've got 8.5 hours on my '10 570, the last two rides I've been on the bike's fuel shut off and dies mid after 20-30 miuntes. The first time it restarted in about 30 minutes. Today I tried for an hour and it wouldn't restart, eventually the battery ran down. After a buddy towed me out at our club's annual tag team Harescramble ride (embarrassing with an expensive new bike), got home today and jumped it off a few hours later and it started. Could this be anything other than the fuel pump?

I really want to like this bike but so far I've had boiling fuel (removed the check valve in the vent line), white gunk in the tank causing fuel starvation (flushed filter and tank with alcohol), horrible stalling/flame out problem (remapped the FCU and got a rekluse). I also sprung for the radiator fan to avoid heating problems.

As much as I've read about this bike I was really looking forward to it and it's the first bike I've ever bought new. I have yet to have a good day out on it though. Anyways, if this could be anything other than the fuel pump, please let me know. I've checked the plug gap and no wires are affected by the shock spring rubbing. I want to love this bike but it's getting tough! :angry:
 
This sounds very similar to what i was having on my 09 450, my orange fault light went out and it would crank but not start, then i'd leave it and it would run then just stop, and after going through everything, it was a loose wire which connected to 3 others in the loom near the shock, which had no signs of rubbing!!! either
hope this helps, keep us informed
 
OK, that's worth double checking for sure. Any ideal what the wire did exactly, or what color or size it was? That might help narrow the search.
 
The wire in question, was i think red and white, that I'm not to sure about, but what i am sure about is, where the wire came from, it came from around the coil area a resister and went back to near the shock deep inside the loom where it joined 2 or 3 other wires going else where in the loom, it can seem daunting pulling the loom out and undoing it but it only took an hour or so for my friend, and my berg has been nothing but perfect since :D
 
Thansk DaleO. I had read that thread and several other similar ones. I'll check for the wire to rule that out, then go with the aftermarket fuel pump that's available. I may hit up the dealer to see if there's any waranty options on that as well.
 
I checked the wires near the shock and there was nothing rubbing. I replaced the fuel pump with the CA Cycleworks one and so far has done the trick, see this thread for more details: viewtopic.php?f=7&t=14479&start=60

I won't know for sure until I take it on a good long hot trail ride, hopefully I have finally figured this bike out.
 
Well, I fixed the problem after replacing the fuel pump. See the linked thread above for the full skinny. -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!
 
I can only hope that's what my problem is.....I too was out on an extended ride in a wash (tight area in Ocotillo Wells) doing a lot of 1-2nd gear stuff wen I gotto an open section and aired it out...came to a stop with the rest fo the group and it flamed out. Took a few tries to start but it did...all ok for a couple miles then BWaaaaaaaaaa....ka ka ka ka dead...tried for a while butno start. Thought maybe since the front tank sounded realy low we put some fuel in it even though the rear tank was 1/2 full....still nothing. I too experienced the "pull of shame" back to the trucks".

I hope it's not the boiling gas issue as I've heard besides your post...tough to redesign that part. 8O
 
rezrider said:
I can only hope that's what my problem is.....I too was out on an extended ride in a wash (tight area in Ocotillo Wells) doing a lot of 1-2nd gear stuff wen I gotto an open section and aired it out...came to a stop with the rest fo the group and it flamed out. Took a few tries to start but it did...all ok for a couple miles then BWaaaaaaaaaa....ka ka ka ka dead...tried for a while butno start. Thought maybe since the front tank sounded realy low we put some fuel in it even though the rear tank was 1/2 full....still nothing. I too experienced the "pull of shame" back to the trucks".

I hope it's not the boiling gas issue as I've heard besides your post...tough to redesign that part. 8O
Click to expand...

sorry to hear of your woes................

Please post your signature with year and model of your bike, that will help us help you.

Dale
 
Sorry, still getting use to this forum. I filled out the profile info guess I missed how to apply it to my posts...

Anywho...I have a 2011 FE 570 with the aftermarket rear tank/subframe. When I took the bike in last Saturday the service mgr didn't comment about my "suggestion" that it might be the fule pump. Made me feel like it was news to him but with all the problems seen here I doubt it was news then again, the dealer I bought it from is rahter new with Berg's. Maybe I'm the first one. 8O
 
Anywho...I have a 2011 FE 570 with the aftermarket rear tank/subframe. When I took the bike in last Saturday the service mgr didn't comment about my "suggestion" that it might be the fule pump. Made me feel like it was news to him but with all the problems seen here I doubt it was news then again, the dealer I bought it from is rahter new with Berg's. Maybe I'm the first one. 8O[/quote]

I have the same bike with the sub tank and I just went through the same senario with my dealer, MS Motorsports. I have had problems for months and they act like they never heard of the overheating and stalling problems? Now it finally died so I took it back and they replaced the fuel pump, WOW it runs again. If they would have listened to me in the first place I would have had a much better riding season!
I would not recommend that dealer to my worst enemy! :angry:
 
Thanks to you and everyone else who has posted on the fuel issue. I loved my new 2011 390 FE until at 5 hours the bike started to bogged out, stall and be difficult to restart. Luckily the weather was rainy and a cool 12 degrees C so I did not have a long wait to restart.

My dealer is out of business and I cannot get Husaberg on the phone. And the other dealer nearby cannot look at it until a fews days before a planned 4 day trip into the backcountry. So after reading of the many, many similar problems I have ordered the CA pump, a set of filters and will fix it myself. I do not plan to spend much time determining if my problem is gunk in the tank, clogged filters or a bad pump. Thanks to those who have posted about this issue, saving me hours of diagnosis. And thanks for the helpful hints and photos of the process to correct the issue.

Will report back when the parts have arrived and are installed.

PS I will making another donation, this site has saved me hours of frustration, again.

PPS Husaberg/KTM is not doing itself any favours by ignoring this problem. Love riding the bike but not sure if I can trust it. I will be advising people to think twice before trading an extremely competent, dependable Honda CRF for a Husaberg.
 
Update: I received and installed a CA-Cycleworks fuel pump, a new inline filter and a new filter for the bottom of the pump. Just returned from a 1.5 hr ride and everything seems great!

When I pulled out the pump I found the pump filter completely clogged with the white gunk that has been frequently reported by others. I cleaned a lot more crap out of the tank but a white film coated the inside after I was finished so I had a rad shop properly flush it out. (It would not surprise me to learn the old pump is okay, but the new one went in.)

Several people have posted comments about the challenge of attaching the fuel line to the barbless outlet of the CA-Cycleworks pump. Unlike Husaberg, they seem to be paying attention as my pump arrived with a barbed outlet, two fuel line clamps and a segment of fuel line. And the pump fit perfectly in the stock housing without the screws or wires others have mentioned. I purchased some additional, and better quality, fuel line and clamps instead of trying to use the original line after cutting off the old pump and inline filter. The only difficulty I had was getting everything back into the tank without crimping a hose. (In hindsight I would have reduced the length of hose.)

Good Luck

PS Still no call from Husaberg
 
It's a good report, and congratulations on your solution. Cause is key, however. The fuel pump cannot be the source of the white gunk, and it cannot coat the fuel tank with the white gunk. Unless the source of the white gunk is determined and eliminated, you can have every expection that the problem will recur.

You might consider changing fuel or fuel source. I for one do not put any fuel in my bikes or truck that has ethanol in it. I have a 2011 FE570S, and using ethanol-free fuel I have not had the fuel pump problems that you and others have described. I certainly don't have sufficient information to prove that ethanol fuel is incompatible with something on the Husabergs, but I can assure you that my 570 continues to run like a scalded dog.
 
Ruger,

You are correct, the fuel pump did not cause my problem. My bike would not run because no fuel was getting through the crap in the filter (or filters). A dealer, not mine unfortunately, says they have seen this problem and sometimes the pump is okay, and sometimes it is not. I assume the gunk is not good for the pump and some die before the gunk problem is solved.

I have not had ethanol in my tank; I avoid it in any engine where I think there is a chance the fuel will sit longer than a few weeks. I also use fuel stabilizer. I do not believe fuel put the gunk in my tank. With many others reporting similar problems I am going to assume the gunk was the result of a poor manufacturing or assembly process. Now that the gunk is gone from the tank, pump and filters I cannot think of way it can come back. If I am wrong and the problem returns I will definitely be riding a Honda again! I hope not though, I was out in the woods again today and it sure is nice to ride!
 
Me again with an update and question.

I have ridden the bike for 5 hours since installing the new fuel pump and filters. Everything seems perfect except for a mild, but persistent, backfire on deceleration. Acceleration and power are excellent, although I really have only ridden the bike during the run in period so my frame of reference is limited.

I have read on other threads that backfire is due to a lean fuel mix. Can anyone tell me if a partially kinked fuel line would change the mix? And it it could, why would the condition show up under deceleration when no fuel is being called for, and not under acceleration when it is? I found it challenging to stuff everything into the tank and have some concern that maybe I did partially kink something.

Thanks
 
Holy crap! I had some serious pressure problems but was fortunate that never happened. I put the CV4 blanket on the tank and haven't had any pressure problems since.
 

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