Aftermarket fuel pump

E-Ticket said:

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?

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You remove the circlip to remove the stock filter, but you do not reinstall it. The Profill filter is just a pressure fit, and then the way it sits in the black plastic housing prevents it from falling off. But if the plastic box popped open, the filter could fall off.

It might be possible to install a circlip, but it would be challenging due to the shape of the filter. No way to put serious pressure on the clip.

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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That could simply be due to which country/region got the bulk of a production run using the bad fuel pump.

So maybe just timing and luck.

DeeG said:

E-Ticket said:

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?

Click to expand...

You remove the circlip to remove the stock filter, but you do not reinstall it. The Profill filter is just a pressure fit, and then the way it sits in the black plastic housing prevents it from falling off. But if the plastic box popped open, the filter could fall off.

It might be possible to install a circlip, but it would be challenging due to the shape of the filter. No way to put serious pressure on the clip.

Click to expand...

Thanks, concern over how it's mounted is one of the reason that I hadn't installed my Pro-FILL filter sock. The stock filter "cage" supplies a bit of support and alignment to the black fuel housing. It was feeling a bit "ooky" not having the cage in place. But you've given me some more ideas options on securing the fuel pump housing -- so I may install it yet.

Thanks, homie! E-Ticket

Went out for the first decent ride tonight after fitting the new pump. Bike felt as good as new and then after around 40 miles the thing stopped. WTF!!!!!!! But the pump sounded OK?.....Then I twigged. I'd forgot to reconnect the low fuel light when I replaced the tank and I'd RAN OUT OF F*****G FUEL! What a W**KER :cuss: :cuss: :cuss: :cuss: :cuss: :cuss: :cuss: :cuss: :cuss: :cuss: :cuss: :cuss: :cuss: :cuss: :cuss:

pegscraper said:

Went out for the first decent ride tonight after fitting the new pump. Bike felt as good as new and then after around 40 miles the thing stopped. WTF!!!!!!! But the pump sounded OK?.....Then I twigged. I'd forgot to reconnect the low fuel light when I replaced the tank and I'd RAN OUT OF F*****G FUEL! What a W**KER :cuss: :cuss: :cuss: :cuss: :cuss: :cuss: :cuss: :cuss: :cuss: :cuss: :cuss: :cuss: :cuss: :cuss: :cuss:

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LOL! Sorry to laugh ... but can really feel your pain.
Hopefully your walk back wasn't too bad/long -- but at least it wasn't a re-occurence of a mechanical failure!

Glad you're back running! E-Ticket

Speaking of the low fuel indicator - is there an easy way to test it?

After installing the CA Cycleworks pump I put a small amount of fuel in the tank to test it. I didn't have enough fuel to prime the pump, so I added a little more It fired up. I expected the low fuel light to be on, but it was not.

I then rode around for a few miles and it still didn't come on. I think I removed the sensor to make it easier to pull out the fuel hoses, and I didn't notice which direction I reinstalled it, so I don't know if it is in the high or low position. But either way, I expected it to come on.

I then filled the tank by adding 1.7+ gallons out of 2.1 total. Shouldn't the light have been on with less than .4 gallons remaining?

PS - I then rode my bike up a nearby canyon (paved) and back. 40 miles it ran perfectly!

According to the specs the 570FE for the US market has a total fuel capacity of 8.1 litres and the fuel light comes on with approx 2.6 litres left in the tank so, in answer to your question, I would say yes, the warning light should have been on with less than .4 gallons/1.51 litres left.

pegscraper said:

According to the specs the 570FE for the US market has a total fuel capacity of 8.1 litres and the fuel light comes on with approx 2.6 litres left in the tank so, in answer to your question, I would say yes, the warning light should have been on with less than .4 gallons/1.51 litres left.

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The fuel level indicator can be installed in two positions to change the low fuel-level warning.
The following is what's stated for my 2010 Husaberg FE 390:

== The marking 1 on the fuel level indicator point upwards (as delivered): 2.6 liters (2.7 qts.)
== The marking 2 on the fuel level indicator point upwards (optional): 1.6 liters (1.7 qts.)

I believe this same information is stated in your owner's manual.

Cheers! E-Ticket

So either way, the low fuel light should have been on. Any tips on how to test and debug it? That is a feature I would like to have working.

DeeG said:

So either way, the low fuel light should have been on. Any tips on how to test and debug it? That is a feature I would like to have working.

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Have you seen this post DeeG?
How to fix low-fuel light? (FE570)

Those pictures and info you posted on the previous page are excellent, well done :cheers:

Davo - thanks for that link. I did a search, but somehow missed that thread. Next time I pull the tank I will do some probing.

No back to main topic of this thread - fuel pumps...

Okay--got my CA Cycleworks pump installed per some of the great directions here. Used the Oetiker clamps, cut the stock fuel line to release from the original pump, etc.

Ran a really nasty Harescramble race in 95 degree heat, high humidity and so much dust I could barely see. I wish I had fared as well as my bike did. It ran flawlessly and re-started numerous times while fully heat-soaked. Can't say the same for the rider :lol:

FWIW the bike has no tank insulation, no fan, etc.

FYI for anyone with the CA Cycleworks pump:

Got to the trail yesterday and my '10 FE570 wouldn't start. Sure enough the end of the submersible fuel hose had popped off the un-barbed end of the CA Cycleworks pump. I figured that would happen at some point. So I roughed up the nipple and tried to flare it out a little bit as I'd seen someone do in another thread. Also went a little tighter on the FI camp and attempted t safety wire the hose to the pump housing. The bike starts and runs fine now. Hopefully I've fixed this and won't be stuck in the parking lot (or out on the trail) again.

My bad for not attaching it right the first time, hopefully this doens't happen too often, otherwise the pump is working great.

Took me 2010 FE450 out this Turkey Day weekend to do some riding and was hit with the bad fuel pump issue. Bike would run for a few miles and then crap out. It wouldn't start again until it completely cooled down.

Before I talk to my dealer, are the new fuel pumps KTM is supplying fixed or should I just get a CA Cycleworks pump and be done with it?

I installed the CA Cycleworks pump (which was a pain) while I waited for the KTM replacement (they were on back order at the time). I now have the CA Cycleworks as a spare.

Thanks. I just ordered the aftermarket pump. I need some experience with removing the tank anyway... LOL

OH boy. It took me over an hour to read all the postings for fuel issues. I just bought a 2011 570 FE and have put in 40 miles new. Put a new slip on and Vortex ECU. Started the bike and ran for a few then the pump stops. I am so bummed knowing and hearing the pain you guys share with this issue and now I have to do the same. I am not sure or confident about the Husaberg 570 FE being stable and trusting her to make it back to camp. Are your issues resolved on your bikes? Geez, I thought I was making head way with some mods. I just bought this bike less than two weeks ago... Been a yamaha rider since 1981 with no bike issues. I hate to put the 570 for sale. Please advise.

So, yes there is a fuel pump issue... you already know that. Supposedly it's related to the ethanol used in the USA gasoline. Maybe, maybe not. The original pump was made in China and so is the CA Cycleworks pump. I'm told the new pump from Husaberg is now made in Italy. Never verified that. Now my story.... My pump didn't fail but as a precaution I installed one of the early CA Cycleworks pumps. This is the one without the nipple barb on it's pressure output. Well, it failed. Turned out that the supplier for CA Cycleworks had some bad ones. CA Cycleworks supported me well and sent me their upgraded and tested one that now has a barb on the nipple. It's been running fine all this season. Will it hang in there?... hope so. CA Cycleworks tells me it will.
As far as selling the FE570, it's you're call. My son rides a Yamaha WR450. We've had to work on it too - one electrical problem and some carb work. But the difference between riding the two is pretty significant. When we switch bikes I can't get my son off the Husaberg and I can't wait to get back on it! It's awesome.
I haven't searched, but why would you change the ECU? I'm in Colorado and my 2009 berg's injection is perfect. I've ridden it in the Wisconsin and up at 14,000' here.

After some time original fuel pump, caused by overheating from exhaust pipe, will die. Not instantly, period of cooling will be longer and longer, but changing it its inevitable. It's not question of US ethanol or whatever, it happen here in Europe on 390, 450 and 570. No exceptions. One year ago I bought new original pump and works fine. Based on the serial number we found out that same pump have been used by Piaggio Group (Beverly 300-500, Nexus 300-500, Scarabeo...). First "Piaggio" pump have been instaled few weeks ago on 450 and it works OK.

Thanks for your feedback guys. I was able to get some help with wonderful fellow from KTM/Husaberg. They assisted with addressing my issue and making sure I was happy. What a great team of guys. Thanks Abe and Brian!