Aftermarket fuel pump

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So I've got the CACycleworks pump in now.

Really really hard to start still.

Starts up straight away when its been running for a while.

But starting it when its been sitting overnight or cooled down it won't turn over and I get the odd backfire.

Any ideas?
 
Can't get it to turn over anymore, brand new fuel pump. Battery goes flat after trying so much, so its back on the charge, any ideas?
 
By turning over you mean cranking or getting it started? If it won't crank or cranks slowly = poor battery or bad ADC on the camshaft.

If it cranks nicely but won't start then hmmm... Whats your idle screw set at?

Try pulling the choke/enrichment and see what it does then. When I had the stock throttle body it wouldn't start if the choke was pulled, even when cold. After getting the idle screw spot-on it usually starts in 1 second after priming fuel system first and then cranking.

Mind you I have 95h stock black top fuel pump without any problems. Changed new Mahle fuel filter at ~50h and installed Gates submersible fuel hoses with regular hose clamps for easy maintenance in the future. The fuel filter helped starting a bit, as the old one was black as night.
 
Just getting it started I guess, I thought cranking it was another word for starting it lol.

Idle screw it set to max. Pulling the choke out or leaving it in makes no difference
 
Ca cycle works pumps have barbed nipples and work fine.Take channel locks with a rag over the teeth and crush the nipples on the old fuel pump within the stock hoses.Order some small high pressure hose clamps off the net.Safety wire the fuel pump housing and electric leads in place.Good luck skred
 
Ok, one last problem.

Had the bike die a few days ago. Knew exactly what the problem was.

Pulled the fuel pump out today and one of the wires uncliped itself

Anyone ideas how to make these guys stick? I've zip tied the the wires so there is excess at that end so this didn't happened but obviously it did.
 
Yes you need to remove the tank. I installed the CA Cycleworks pump without any problems. The conections on the new pump dont have the locking tabs so I just soldered mine instead of safety wiring them. 2 years now and no problems at all. Bike runs better then new. 2010 FE390
 
While I had my tank off I also covered the bottom in an adheasive heat blanket to help keep the heat out of the tank. Couldn't hurt....
 
I'm removing the tank tomorrow and replacing the faulty fuel pump. I was thinking that when I remove the tank I could also replace fuel filters. How many filters there are? Someone has told me that when not driving in dirty environments there is no need to add all those small fuel filters because they bring more problems..
 


Whats the trick to disconnect the lines(black/gray/green coupling in photo) connecting the fuel pump to the pressure regulator? On my KTM 690 they came right off but I am having a hard time disconnecting them on my 570.
 
so the fuel pump died on my HFE450.. took it apart and waited for the replacement to arrive... but I have forgotten which connection is to the fuel pump, and which one is the return hose where it exits the tank..I guess its the fuel pressure regulator?? see attached photo..
 

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I am looking to do preventative maintenance and would also like to know any recommendations. seems like this site is a bit slower than others:furious:

zimi said:
Hi, I bought a 2010 FE450 with 110hours. I red about the fuel pump issue on pre-2012 models and was looking on ebay to find a spare one if mine dies.

There are a lot of different seller, and some very cheap ones, did somebody tried one of these?

Intank Fuel Pump Fits KTM Husaberg FE 250 350 501 390 450 570 2009 2013 | eBay

New Intank 30mm Fuel Pump for Husaberg KTM 390 450 570 81207088011 2009 2013 12 | eBay

New Intank 30mm Fuel Pump 2009 2013 Husaberg KTM 390 450 570 81207088011 | eBay
Click to expand...
 
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