Fuel Pump problem or something else??

Ruger said:

Buy the California Cycle Works fuel pump and you will solve your problem forever.

Click to expand...

I just had to replace my CA cyclework fuel pump due to it no longer pumping enough pressure. I now have my 4th, (yes, count them 1,2,3,4) pump installed in my 2010 570. 2 KTM pumps, 1 CA cycleworks pump and now another KTM pump.

Was having a problem running from cold. Thought I would post the information if it can help others.

Started a ride and from the house I could feel a slight hesitation when coming on to the gas which is not normal. After a half hour riding she started to backfire on decel, which she never does. I should say my bike is an 09 FE570 mapped set to wild with FMF powerbomb and FMF 4.1 can. So I shut her off when meeting up with a friend, she started no problem and we set off. The hesitation was still present and the backfiring got progressively worse.

5 minutes afterwards crossed a 25 foot long puddle on the back wheel but front came down halfway through and soaked the bike and myself really good, hot day so no prob for me but the bike stalled on the other side of the puddle. Had a hard time starting after, finally got it going but needed to keep revs up for it not to stall. The idle was weak an not at all confidence inspiring.

Arrived at destination and shut bike off for 45min-1 hour. She started after a couple tries but again had to keep the revs high. Headed for home to figure out problem. On the way back using the street the bike would bog under acceleration and be jerky and constant throttle. The back firing was really bad by now.

We started by testing the battery and it was losing charge, so new battery... New battery in, big would turn over alot better but would not start. Changed the spark plug for a new one and inspected connectors wires and grounds. Fixed a couple of chaffed wires which have been grounding when wet, unsure. Bike still wouldn't start. Proceeded to take out gas and put fresh gas in with some seafoam cleaner. After 5-10 minutes of letting that sit, still no go.

So off comes the tank. Checked all wires and connections again. Good pressure in the fuel line. No pressure build up in gas tank by the way. Opened gas tank to check fuel filters. Main filter is dark colour, filter beneath pump is clean. Put 12V to pump, it's turning and pumping well. Blew and sucked from other side off filter, one way valve working and mouth full of gas. Checked again good flow from pump at other side of pressure regulator.

At this point put everything back to try starting again. Hit the started button, idles likes an FE570 should. Let her idle 15-20 minutes with new gas and seafoam. Gave her some throttle, no hesitation from idle and no backfiring. but

So though I can pin point what the exact fix was or if it will last this is my experience with an ill 570 so far.

I was ready to order CA pump and fuel filter kit but am holding off for now.

Great post , this has helped me diagnose my fault

Here's the fuel filter and the pump on my 390, I've changed the filter but after reading this I'll have to take apart for upgrading fuel pump lol

The rest of the story.

My issues were not gone for good. I even had to scrap a rally after limping back on the first stage.

But to bring you up to date by this time I had installed new fuel filters and a CA pump...

I thought the filter was an issue because when I took it out it was filthy with fine black particles which I cycled out of the pump as well. Went with that for a while but not long. So after reading about the many bad pumps I got one and installed it. The bike then ran fine for 2 runs of mixed riding from some fast fire roads to muddy abandoned trails and everything in between. I would even say it ran stronger than before.

So now confident, I head off to the inaugural Fundy Adventure Rally with 2 teammates. We rode down on the the Friday afternoon without issue. The Saturday morning welcomed us with thick fog. So we set out and halfway done the first 80km leg those oh so familiar symptoms start up again. Heart sinks.... So I limp back to base and park it for the weekend and ride in the sweep truck to help out.

So I'm thinking the only thing left to do is change the injector...

Funny, one of the rally participants happens to work for Bosch and says you my friend need an $8 dollar injector but you will pay $170 for it. So funny. So I bit the bullet and got and installed new injector. While I was replacing the injector I discovered the "securing tab" on the map sensor coupler (81241085044 MAP SENSOR CPL.) was broken off. So there was nothing holding it in place. It would explain my intermittent issues with water. Anyway so I used zip ties to secure it in place, it's not moving any time soon...

So the result is the bike has been working fantastic ever since. I suppose it should the majority of the fueling system has been upgraded to new... It may be that I changed all those other things when a couple zip ties were all I needed. But at least I've a fresh fuel system and spare parts! Glass half full.

That's it for now. I hope the problem does not resurface because I will then be at a loss. I'll write back if anything comes up again. Hopefully not.

Thanks for that! Solid info.

I'm so annoyed at that injector markup nonsense that I'll pay your new Bosch friend $340 if he tells me how I can get the injector for $8!

fuel issue

Hi guys new to forum having problems with my 570 not restating when hot doesn't stop or run rough but when you stop it it want restart. Got home run it same thing pulled air cleaner out sprayed carby cleaner down the throttle body then runs again, any ideas would be appreciated.

I can't believe that either , another great post. Mine still playing up after the fuel pump and filters .
Going Spain in May so I'm gonna have a look at map sensor coupling [emoji12]thanks

Cdnberg have you got pics of the component at fault please
Thanks

Took the throttle body off cleaned and inspected as well as inspecting plugs to sensors and injector but all appears ok here ?

I've also been plagued by a stalling issue which I'd believed to be solely fuel related until recently.

Background:
I've had the bike (2010 FE570) since new in spring of 2011. Ran great for the first 1-2 years. After being left stranded in the woods a few times I replaced the original fuel pump with CA cycleworks and the stalling problems went away...for a while. A couple of years ago the bike would start to stall again when hot, maybe 20-30 minutes into a ride. It would start back up fairly quickly and usually at least get me home. I changed the tank filter and no change or improvement. It was dark brown and in need of change anyways. Earlier this year the stalling got much worse and it would often not re-start. When it did eventually re-start the throttle was erratic and would bog and lurch and spit and sputter and backfire and run terribly.

Work done this spring:
I sent off the injector for ultrasonic cleaning. Probably needed it anyways. I installed a Zipfly racing 10 micron fuel line filter to keep the newly cleaned injector clean. I also adjusted my TPS so I had a reading of 0.61 volts (up from 0.58 something). With a positive attitude I took off for an asphalt ride 30-45 mph with a full tank of fuel. 13 miles in it dies, exact same symptoms as before the injector cleaning, filter installation, and TPS adjustment. I let it cool down for 20 minutes, restarted, and within seconds it was running very poorly again (should have been cooled down by then), I barely made it home and it stalled 4-5 more times on the way.

Thinking that I'd gone through the fuel system thoroughly I set my sights on the electrical system. I'd changed the spark plug last season and it only had maybe 20 hours on it. I did check it and it looked fine. I cut 1/2 inch off the plug end of the spark plug wire and reconnected it. I disconnected 90% of the electrical connections on the bike, cleaning each one and applying dielectric grease. I also increased the TPS so it read 0.64 volts. The first improvement I saw was in starting the bike. In the past, it always took forever to start when cold. When hot it starts fine (provided it had not just died) but cold it was always a beast and I sometimes used starting fluid. Now it starts up immediately. I took it for a 45 mile asphalt ride (30-45 mph) on a warm day. It was running great. I was very pleased. I was just a few blocks from my house when it died. It started right back up and seemed to run the last few blocks home okay (no sputtering). I was running late for a kids soccer game and could not do any troubleshooting at the time. This was last Saturday. I could not ride it again until Monday evening. Took it out for 20 miles (asphalt, 30-45 mph) and it started right up, ran great, no stalling. I plan to get out again tonight for a longer ride to see what happens.

The good news is whatever electrical (or other) issue I had, it seems to be much better now, AND the bike starts great when cold. The bad news is I'm still not comfortable taking her out to the middle of nowhere. If I learn anything new I'll be sure to share.

When it stalls , can you check for spark ? Before it cools down ? Maybe carry a spare spark plug and check it when still hot . Could be stator or coil failing when hot

The 10 micron inline filter, where is it located? I've seen it repeated often by reputable sources that there should be NO inline filter in the injector housing because none of them are reliable, and that 10 micron was small enough to swell and clog - at least in the injector filter location.

In other words, I think I agree with statements that the only filter after the pump should be in the quick disconnect between tank/pump and injector, and that it should probably be 20 micron (unless it's confirmed and verified 100% that a 10 micron filter won't clog there).

tourist: The filter is in the line just downstream of the quick connect, actually replaces the male end of the disconnect. It has a 20 micron basket type disposable filter and a 10 micron stainless steel screen filter (or appears to be stainless). I attempted to attach a photo above.

webmonstro: Great suggestion. I'll carry a spare spark plug on my next ride, hopefully tomorrow.