Aftermarket fuel pump

Mine just started failing as well. 35 hours with no problems. Then it hit.

My tank was about 1/2 full when it started acting up. It got worse as my fuel got lower - which makes sense since there is less volume of fuel to keep the pump cool.

So far mine has not cut out while riding. It just won't start when hot. I think when the pump expands in the heat something must get too tight and the pump can't overcome the friction to start it spinning. Once it is spinning, it will keep going.

I am trying to contact KTM Customer Service and see if they will replace it with a newer pump. So far I haven't gotten through.

If that doesn't work I will either get the CA Cycleworks pump or the Aprilia pump assembly. Has anyone actually installed the Aprilia assembly in the Berg? That looks like a good solution if it really works.

aaronc70 said:

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? :?:

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I installed the CA Cycleworks pump on a 2010 FE 570 with 8.8 hours owned by my friend which was failing to restart when hot and finally, not at all. With the help of this thread and Dale E O, we ordered the aftermarket since no dealers had pumps and we were headed to Colorado to ride. Now, having completed about thirty hours of tough riding in Crested Butte, CO, (including two nasty high-speed falls-ouch!) the installation worked and has held. The fuel line has remained connected and the bike ran great for him.

Here is what we did. First, we roughed up the nipple on the CA Cycleworks pump with a Dremel tool rasp ever so slightly to increase purchase once we put back together; cleaning it thoroughly of any plastic when done. Then, we followed the directions for removing the tank in the service manual. Then emptied fuel from the tank into a clean container for reuse. After unscrewing the fuel pump assembly from the bottom of the tank, removing the fuel pump assembly from the tank by a few inches only so I would not have to deal with the nest of wires and lines in the tank, and then removing the pump from the plastic housing, we simply cut the stock plastic fuel line lengthwise on one side of the barbed nipple on the stock pump to allow the stock fuel line to be removed, cutting as little as possible. There was a section of the stock fuel line that was smoother without the accordian finish that the fuel line has further up the line toward the fuel filter; we wanted to preserve as much as possible to use that smooth section to re-attach to the CA pump nipple. Then, we trimmed the fuel line square above the previous cut we made, again preserving as much of the fuel line as possible. Then, we slipped an Oetiker Stepless Clamp, 9.5 mm, STD, stainless steel, part number 48548846, purchased for $0.53 from MSC Industrial Supply (Grainger may have as well) onto the fuel line. Then, carefully slipped the stock fuel line over the nipple on the CA pump. Slid the clamp down midway onto the pump nipple over the fuel line and clamp so that the clamp would not interfere with the plastic holder or wires later. We attached the wires and then adjusted the plastic ties so that it all hung in line and even with no pressure on wires. Reassembled and slipped into the tank. Followed reassembly exactly as per manual, including torques, and then started the bike. Rode and smiled. Total time was 1.5 hours not including time to remove the tank the first time.

You might need the Oetiker tool to clamp which looks like a dull 90 degree cutter; I am sure that I could use my regular cutters to clamp now but I did not know when I bought and I was anticipating future need for this and other applications where the excellent capabilities of the Oetiker clamp will shine over screw clamps. My feeling is that the Oetiker clamp places significant and even pressure on the fuel line so that it will not come lose. May the force be with it. In the meantime, I will buy another CA Cycleworks pump for my back-up kit and keep with the Oetiker clamps.


Will
2010 FX 450
2008 KTM EXCR 450 (back-up in case the fuel pump goes on the Berg)

Oh, I was wondering where you could get those special clamps like I took off the husaberg. I just used the stainless screw clamps, so far so good. Looks like you guys put a lot more thought into it than I did. Mine's still working fine, although I haven't rode the Brg in several weeks, I've been on the 200XC.

I'll be sure and report if and when the screwclamped hose blows of the end of my CA Cycleworks pump.

I had problems with the CA pump mainly due to over tigntening the clamps beacause of the no barb issue. The other problem I had was using too long of a piece of non-flexible fuel line between the pump and the filter which caused a kink in the flex line above the filter after I shoved everything back in the tank. All this happened the night before a race and I didn't have time to come up with a better installation solution so I put the original pump back in and haven't bothered to switch it back out yet. I recently bought an 11 300XC so the berg is just sitting at this point.

I started installing my CA Cycleworks fuel pump today, as per willmia's instructions, and suggestions from others. I thought I would post some photos...

Here is the new fuel pump. I heated the outlet port with a heat gun. It didn't take much heat. I then pushed the tip of an arrow into the opening and allowed it to cool. If you look closely you can see that the port is now slightly flared out. I also took an engraving vibrator tool and made some lines around the port to increase the friction. I didn't want to remove any material so I didn't use a dremel. The engraver just sort of pushes the material around - sort of like miniature speed bumps.


Here is the stock fuel pump (with the Profill filter). Notice that the stock outlet port has three sets of barbs causing the bulges in the line. I tried to heat the tube and pull it off. It didn't work. Not much heat and the tubing started to bubble. I then tried cutting slits as willmia suggested. That was a bother, so I opted for a different approach. I just cut around the hose just below the top barb. I could then pull off the tubing with little effort.


Here is the cut fuel line, with just enough room to mount a clamp.


Unfortunately, that is as far as I got. I thought I could use my fuel injector hose clamps, but this interior hose is much smaller than the external ones. I could not find a clamp small enough at any local auto parts store. So I ordered some from MCS Industries Direct, as suggested by willmia. Thanks willmia for posting the part number - that really helped. So now I get to wait for more parts to come...

Thanks for the pics! - ET

Looks like your doing it the right way! WIsh I would have had some pics like this to help when I did mine, keep up the good work. To clarify one of my older posts, I used fuel injection specific screw clamps, not regular type screw clamps for plumbing applications.

I've just bought some of these to refit the OE fuel pipe when I finally get a pump sorted.
http://www.ebay.co.uk/itm/7mm-9mm-P...arts_Vehicles_CarParts_SM&hash=item3f0c80eb33
I'm still waiting on Husa/KTM's decision on wether to change my pump (7 months/65hrs old) as a 'goodwill' gesture. If they say no I intend to try and source the pump elsewhere. There's ABSOLUTELY NO WAY I'm paying the £270 I've been quoted from the dealer.

Those are the type of clamp I tried to find locally, but failed. I found plenty of 11-13mm and 13-15mm, but no 7-9mm.

I bought my bike in Nov 2010 and KTM has agreed to good will a pump for me. It just takes time.

Finally got the 570 back up and running today with a new OE fuel pump provided under warranty. As I understand it from the dealer handling the claim, they were told by the importers to contact Husaberg/KTM in Austria and raise a claim with the factory direct with a view to getting the pump replaced as a goodwill gesture as each case is being looked at individually. Glad to say the claim was passed. Many thanks must go to Scott at Gear4 Motorcycles (I bought the bike from them in December last year) who handled everything and had a new pump on my doorstep less than a week after the claim being granted by the factory.

I finally installed a CA cycleworks pump, filter before the injector and cleaned the injector. The bike runs better than ever and i feel confident that I will not be left behind anymore :cheers: . Be careful when you flare the outlet of the pump if you use the stock fuel line because it is a tight fit. With a very slight flare and the correct clamp I think it should hold together fine. BTW.. my stock pump was made in China...thanks KTM for finding the worst pump and then not standing behind it. I love my bike now that it appears to be sorted but I will not buy another KTM.

lets just imagine there's some people who ride husabergs, that have no idea about,how to start to do what youve done, and are talking about and would love pictures :shock: lol lol

johny said:

lets just imagine there's some people who ride husabergs, that have no idea about,how to start to do what youve done, and are talking about and would love pictures :shock: lol lol

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I just followed the pics and advise of DeeG on the previous page when installing the fuel pump. There is a posting somewhere on the forum about how to install the filter just before the injector and to clean the injector I just soaked the tip in cleaner and back blew compressed air thru it.

My replacement OE pump looks VERY similar to the old unit but does not have the part No. on it. Also the pump sounds different when running, much quieter. The old pump always made a distinct whirring sound even from new. This may or may not be significant but as for longevity/reliability only time will tell. I just hope it's not going to be a regular replacement every 65hrs or so!

I finally finished installing the CA Cycleworks fuel pump.

Here are the two types of hose clamps that are approved for fuel injection pressurized lines; Oetiker (and crimp tool) on the left, and screw type on the right.



Flaring out the pump outlet port made it more difficult to get the hose on. If I were doing it again, I wouldn't do that. In fact a standard barbed outlet would be almost impossible to install with these stock fuel lines. Perhaps that is why CA Cycleworks did not include barbs.



It was a real pain to install the CA Cycleworks filter - DO NOT USE THIS FILTER. It does not fit inside the housing, so I had to remove it - also a pain.



I switched back to the Profill filter.



The hose now has a different twist on it than the stock pump, so it puts a lot of pressure on the housing and the top kept popping off. Others have used screws to secure the housing. I opted to use some bailing wire on each side. I routed it through the inlet hole in the bottom and out the larger holes on the top. It did not require any drilling, but it does make it harder to install the pump housing in the tank.



Be sure to secure the wires to the pump. They can pop off really easily.



I have not yet tested this. I hope it works!

DeeG said:

I finally finished installing the CA Cycleworks fuel pump. ...........

I switched back to the Profill filter.

................
I have not yet tested this. I hope it works!

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Great solutions, DeeG ... and thanks for the pics!

I still have an un-used ProFill pre-filter sitting on my shelf and it is snowy white. I notice that the one in the pic has a brownish tint to it. Is that coloration due to dust/dirt/munge in the fuel tank?

Thanks! E-Ticket

E-Ticket said:

DeeG said:

I finally finished installing the CA Cycleworks fuel pump. ...........

I switched back to the Profill filter.

................
I have not yet tested this. I hope it works!

Click to expand...

Great solutions, DeeG ... and thanks for the pics!

I still have an un-used ProFill pre-filter sitting on my shelf and it is snowy white. I notice that the one in the pic has a brownish tint to it. Is that coloration due to dust/dirt/munge in the fuel tank?

Thanks! E-Ticket

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I am not sure. The filter was white when I installed back in the spring. It doesn't look dirty. I think it just changed color from being in the fuel.

DeeG said:

E-Ticket said:

DeeG said:

I finally finished installing the CA Cycleworks fuel pump. ...........

I switched back to the Profill filter.

................
I have not yet tested this. I hope it works!

Click to expand...

Great solutions, DeeG ... and thanks for the pics!

I still have an un-used ProFill pre-filter sitting on my shelf and it is snowy white. I notice that the one in the pic has a brownish tint to it. Is that coloration due to dust/dirt/munge in the fuel tank?

Thanks! E-Ticket

Click to expand...

I am not sure. The filter was white when I installed back in the spring. It doesn't look dirty. I think it just changed color from being in the fuel.

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Coolio ... thanks for the quick response.

BTW, how is your Pro-FILL filter sock held on to the fuel pump. Did you remove, and re-install, the circlip over the mounting stud?

Thank you so much that, was invaluable now if my pump goes down I think I'll have more if an idea about how to go about replacing it.
There is one thing that's been on my mind, I'm in the uk and so far I've not heard about any pumps going down in the uk, and mostly seem to be failing in the states! Opinions please

johny said:

Thank you so much that, was invaluable now if my pump goes down I think I'll have more if an idea about how to go about replacing it.
There is one thing that's been on my mind, I'm in the uk and so far I've not heard about any pumps going down in the uk, and mostly seem to be failing in the states! Opinions please

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I'm in the UK. AFAIK I was the first claim my dealer had handled but the first one in the UK? Only KTM will know that.

One other difference on the new pump versus the old which I forgot to mention is the OE filter on the pump base is more substantial and a better fit.