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Fuel Pump or filter or get a Honda lol

Joined Dec 2009
274 Posts | 21+
Skidaway Island GA
Hey all it's been awhile and Yes I've read the stickies on FP issues.

Hot stalling on 2010 FE 450 80 hours (Note: original FP warrantied by KTM at 10 hours due to standard FP hot restart issue I did the swap) FP was the "original" version since they didn't have the "new" version available.

SO I'm back in this spot again after having fun on the bike for almost 2 years. I stall out when the bikes hot but it will restart after a minute. This is even when on the street after fan kicks on. Not sure if I should replace the fuel filter or the fuel pump but given the cost of the FP ($512 for the assembly) I figured I'd ask the forum. I'm a day's drive from a dealer in Atlanta.

I have done all the heat mods common to this bike (fan/90c switch/coated midpipe/foil under tank/vent ball out) and I just can't help but think that running that darn mid pipe under the tank is just plain Stooopid. I digress!

I'm going to pull the tank and see whether I can determine if the fuel filter is clogged, not sure how to completely determine that. Husband (who doesn't ride) sez I should just get a HONDA but I won't give up on my Sven Husaberg. Thanks!
 
My 2 cents ? Stick with it don't fold into the dark side ! A visual inspection would suffice I would be looking for any holes of tears or ovbvious signs of the filter being collapsed or " sucked in". The cycle works pump seemed to get good press too. Don't give up !
 
berglsmerg said:
My 2 cents ? Stick with it don't fold into the dark side ! A visual inspection would suffice I would be looking for any holes of tears or ovbvious signs of the filter being collapsed or " sucked in". The cycle works pump seemed to get good press too. Don't give up !

Oh don't worry I won't give up, I LOVE my Berg! Husbands' just jealous :roll: I did order the Mahle filter kit that someone else rec'd in another post. Less than 1/2 the price of dealer on Fleabay http://www.ebay.com/itm/281081119843?ss ... 1438.l2649 so that's coming. I've considered the CA FP and it may come to that but kind of intimidated by the fuel line connections/alternatives.
 
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Pretty sure I saw the oetiker style band clamps kits on fleabay, and there was a thread about the hose/clamp/fitting arrangement iirc. Don't forget the pro fill pre filter to stop the rot at the entry to the tank. Thanks for
The link to the Mahle filter I gave up trying to source one here in aus !
 
Your symptoms sound very much like my really bad day my first year. I closely monitored all of the thread traffic about the pump, injectors, filters, etc. I installed the Profill tank filter and the pump input filter. I also tried the in-line CanAm filter, but found it too much hassle so I went back to the quick disconnect.

And when KTM announced the in-line mini-filter at the rail, I quickly ordered one and installed. That was my doom. Ran great the first day. I am pretty sure it started melting shut the second day. It was a cool and overcast day but my bike was running super hot. Way hotter than on any other ride. The fan was on most of the time and when it got really hot, the bike would die. After it cooled a bit, it would go again. It was really frustrating to have the bike die in all of the rocky sections.

I am pretty sure it was running so hot because it was running lean. I thought the injector was partially clogged, so I ordered a replacement. When I put it in, I also pulled out the KTM in-line filter. Ran great after that - and stayed at normal temperature levels. I then had my injector tested and it was fine. So, I am pretty sure it was the clogged in-line filter. KTM later discontinued that 10 micron filter and came out with a 20 micron version. I haven't installed one of those. From what I have read, you need 10 micron to protect the injector.

I then installed a Trail Tech radiator fluid temperature gauge. My theory is that I might get an early warning of my filters getting clogged when my bike starts running hot. Right now, with my FMF 4.1 exhaust, it generally runs at about 215-220 degrees F regardless of the day and the trail. So if it gets much higher than that, I may need to replace my filter.
 
DeeG said:
I also tried the in-line CanAm filter, but found it too much hassle so I went back to the quick disconnect.
I use both. Cut the fuel hose in 3 pieces and move the filter as much forward you can. The quick disconnect will be moved more in under the tank but I can still operate it.
 
DeeG and Jon,
I have not installed the external inline filter kit. Mainly because of all the problems I've heard of.

I did have KTM send my a replacement pump assy back in June of 2011 and I replaced it all. Bike had 10 hours. They sent me the ORIGINAL assy not the revised FP since they weren't available at the time. A KTM dealer is 350 miles away so it's not feasible to haul it to one at the moment.

Now at 80 hours I think this 2nd OEM FP has failed just like the beginning FP. It's exhibiting the same cycle. Bike gets hot/fan on/slow speed bike stalls. Wait a bit bike starts & runs fine till hot again. This is on the street going back & forth into town.

I have contacted KTM but no word yet. I'm considering my options and it looks like I'll have to buy an aftermarket FP and splice it in. Will any of these work? http://www.ebay.com/itm/180860032672?ss ... 1438.l2649 Shows a proper barb for the fuel line.

or this one without the barb. http://www.ebay.com/itm/271122387845?ss ... 1438.l2649

I can't see whether the CA Cycleworks pump has a barb or not. I do think that my injector is fine or else I'd have issues when the bike is running.

Thanks all!
 
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jon andersson said:
DeeG said:
I also tried the in-line CanAm filter, but found it too much hassle so I went back to the quick disconnect.
I use both. Cut the fuel hose in 3 pieces and move the filter as much forward you can. The quick disconnect will be moved more in under the tank but I can still operate it.

I did that first, but the tight bend in the fuel line caused the fuel line to rupture while out on the trail. That was the first (and only) time I used my tow strap to tow me out. I then inserted it in place of the QD like most people do, but thought it was too much bother.

I have found that if I buy quality gas (and use additives as necessary) and just leave the system alone it works great. Other than faulty fuel pumps, every other failure has been the result of me messing with it.
 

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