Aftermarket fuel pump

Well yesterday my 450 left me stranded twice with the same hot bike no restart problem. No fuel pump engagement until after cooling down 20 minutes prox. Then it restarts as if nothing happened and I can hear the pump spin up.

I getting so that I can tell when the fuel pump is going to stop working soon when I restart and it hesitates and stumbles trying to get started. I've called my dealer and he acknowledged the problem but said that the magic replacement pump isn't available for 5 weeks!!!!!!!!!!!!!! :angry: He gave me the KTM customer relations number and said to file a claim but the number is continually busy. I'm not happy, I don't feel comfortable riding this bike anymore when I ride by myself.

LadyBerg said:

Well yesterday my 450 left me stranded twice with the same hot bike no restart problem. No fuel pump engagement until after cooling down 20 minutes prox. Then it restarts as if nothing happened and I can hear the pump spin up.

I getting so that I can tell when the fuel pump is going to stop working soon when I restart and it hesitates and stumbles trying to get started. I've called my dealer and he acknowledged the problem but said that the magic replacement pump isn't available for 5 weeks!!!!!!!!!!!!!! :angry: He gave me the KTM customer relations number and said to file a claim but the number is continually busy. I'm not happy, I don't feel comfortable riding this bike anymore when I ride by myself.

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I also am waiting for a new fuel pump for one that failed after 2.5 hours on a 2011 FE450. I was told these were available in the US on June 8/11, but maybe they have slipped. How are these new "magic pumps" identified? Different color? Different part number?

Cheers,

Blaine

This ones brown..
http://ktmtalk.com/index.php?showtopic=423944&st=15

I'm a bit reluctant to post my status after there's still others experiencing problems with their fuel pump systems but here goes...

I finally got a hold of KTM east coast on Fri. After explaining my situation, the fact that my dealer was 8 hours away and I didn't think that another closer dealer would support me, plus my experience as a BMW mc tech (ages ago folks) the KTM service rep sent a fuel pump assy directly to me and I got it on Sat. Mind you it's the original FP assy but a newer build date. Couldn't believe it!

The rep commented that this unit may fail as well but I was willing to do the work. I pulled the bike apart Fri night, and when the assembly came I installed it fairly quickly but it does take some careful work with the QR fuel line connectors. (I'll write what I did in another post if others are interested).

I nervously refilled the tank and radiators and hit the button, a start, ohhhhh good! I've ridden the bike 2.1 hrs/55 miles on the street trying to duplicate the situation where the FP would fail on a hot REstart. This means hot hot hot, fan running, fuel percolating, heavy clutching, accel, as much as I legally could run it up. No problem, NONE Smoother accel, no popping on decel. I'm now ready to head back into the woods and maybe a local HS. I did order the CA cycle works FP and am going to see if I can fabricate a nipple or mechanical method to retain the fuel hose on the straight barb as a back up.

That's great news LB. Glad it's working out.

I dug into mine to swap out filters last night. Despite flushing the tank with zero miles on the bike, the screen on the pump was maybe 50-60% blocked with tank goo.

We'll see what that does for me. Hopefully that will cure the bogging issues. I'll have to wait and see on the restarting.

Good News LB! I've got my CA cycleworks pump in the tank, wraped my header and put some heat shield on the tank bottom. I'm going to seal the header wrap with silicone spray tonight and try to put it all back together. I'll post with an update when I get a chance to ride it and get it good & hot. I'm definetely looking forward to the days when I can spend all day on the bike and not be stranded or flaming out evey couple hundred yards.

aaronc70 said:

Good News LB! I've got my CA cycleworks pump in the tank, wraped my header and put some heat shield on the tank bottom. I'm going to seal the header wrap with silicone spray tonight and try to put it all back together. I'll post with an update when I get a chance to ride it and get it good & hot. I'm definetely looking forward to the days when I can spend all day on the bike and not be stranded or flaming out evey couple hundred yards.

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Well I got my bike put back together last night with the new pump and everything mentioned above. Its starts really quick and the fuel metering seems spot on. I let it idle till the fan came on and rode it up and down the street a little. Seems just about perfect finally. I won't know for sure until I'm able to get it on the trail, but that may be a week or two. Hopefully this has it fixed! :bounce:

Wow! I am suprised with all the fuel pump issues. I bought a new leftover 2010 FE 450 and now have 300 hard miles with no issues. From day one I have added:

* No white crap in tank from day one
* Header Wrap
* Removed the Gas cap ball and valve check
* Installed Can-Am Filter
* CV4 Tank wrap plus a ton of tinfoil tape around all other areas
* Removed Screen in Exhaust

I have had fuel boiling and radiator anti-freeze boil over in super slow rocky sand washes in Colorado, but never any starting issues. Always starts first press of the button, hot or cold.

Cross fingers that I have continued luck!

aaronc70 said:

aaronc70 said:

Good News LB! I've got my CA cycleworks pump in the tank, wraped my header and put some heat shield on the tank bottom. I'm going to seal the header wrap with silicone spray tonight and try to put it all back together. I'll post with an update when I get a chance to ride it and get it good & hot. I'm definetely looking forward to the days when I can spend all day on the bike and not be stranded or flaming out evey couple hundred yards.

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Well I got my bike put back together last night with the new pump and everything mentioned above. Its starts really quick and the fuel metering seems spot on. I let it idle till the fan came on and rode it up and down the street a little. Seems just about perfect finally. I won't know for sure until I'm able to get it on the trail, but that may be a week or two. Hopefully this has it fixed! :bounce:

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Well, I was able to sneak of to a friend's house last night and rode the 570 in some super tight, two-stroke enduro style single track. It was 92deg F out and the fan was running almost constantly for 45 minutes or so. The bike did great and it looks like I may have this thing lined out finally! I'm not goign to trust it to take me deep in the mountains alone, but hopefully after a few trail rides with buddies to back me up I'll be able to go solo.

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!

Great news!

Can you please tell us how you were able to secure the fuel lines to CA cycleworks pump, as it does not have a barb, and some who have tried have had the output fuel line pop off under pressure.

Dale

DaleEO said:

Great news!

Can you please tell us how you were able to secure the fuel lines to CA cycleworks pump, as it does not have a barb, and some who have tried have had the output fuel line pop off under pressure.

Dale

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HusaGlue. It's made from boiled marmots.

DaleEO said:

Great news!

Can you please tell us how you were able to secure the fuel lines to CA cycleworks pump, as it does not have a barb, and some who have tried have had the output fuel line pop off under pressure.

Dale

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I used fuel injection style hose clamps (not the normal type hose clamps) . I tightened them not too hard and not too loose. I've only heard of one person on here having them pop off, is there more than one? I've got about 5 hours or so on the bike since the fix.

Just thinking out loud, is the output of the CA cycleworks pump plastic? and if it is couldn't the very end be slightly heated with a small flame and then flared a little bit to act as kind of barb to help keep the hose on. Thankfully I have not had any of these issues, croosing all my fingers know , but maybe this is something can help others that are having this problem.

Bigblue; had exactly the same idea in my mind. I plan not to use a flame but a heat gun instead, more controllable and it should not scortch the plastic quickly by accident. The pump is most likely thermoplastic so heat will soften it up. Maybe use some big iron nail or countersunk drill bit's head to flare the outlet slightly.

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

tumpelo, great minds think alike , sounds like a great idea but hopefully I will not have to try it but if you do please post a reply if it works or not.

You know, a funny thing happened on the way to replacing my pump - the old one started working fine.

On my first ride, the bike wouldn't re-start. It would fire, then die, then it'd have to sit for a few minutes. It sounded just like the overheating pump issues that everyone had. So I wrapped my header, put reflective tape on the tank, and swapped the coolant for water with water wetter. I also ordered up the aftermarket pump to have on hand, although I didn't install it.

While the second ride out wasn't nearly as hot as the first, I had no restarting issues except once just at the end of the day. The bike was stumbling quite badly though. So I ordered a new filter and pump screen. The stocker was 80-90% clogged when I swapped it out, despite me rinsing the tank out when the bike was new. Either I didn't get all the tank goo, or just running it for ten minutes at the factory and dealership during the PDI was enough to suck all that in.

I've done another few rides on the bike since. No really hot days (I AM in the Canadian Rockies after all...), but the tight and rocky singletrack that we ride has had the fan humming and the coolant bubbling at times (not the fuel as I originally thought), so there's plenty of heat there. So far it's fired right up every time. My bike is working perfectly. I no longer cringe when I go to re-start it. It is just a totally awesome and very cool looking bike!

Now if I could just stop falling off the thing on the big rock steps and multiple log jumps, I'd be set. Can't blame the bike at all for that though....

Davo said:

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

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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've just started getting this pump problem after 65+ trouble free hours use on my 570. Happened again for the 3rd time in 2 weeks last night and as it was pretty warm with no breeze so had to wait for almost 1 hour for it to cool & restart. Then rode home as if nothing was wrong. The first 2 times it happened I wasn't really sure where the fault was so I took a small multi meter out with me yesterday just in case and confirmed it is defininately the pump or maybe the electrical connecters in the tank? Noticed last night while waiting for the bike to cool that the tank (and fuel in it!) was quite warm although not actually boiling. The header is wrapped and the tank underside has the foil blanket heatshield fix applied.What the hell going on with these pumps? When it fails it's completely dead, not even trying to spin slower and maybe give a reduced flow, just DEAD. There is NO indication of imminent failure, just straight from normal full power behaviour to total fuel starvation and engine cut. Then on restart sometime later, completely normal. :angry: :cuss: :angry: :cuss: