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Fx450 problem

Joined Nov 2009
62 Posts | 0+
Wicklow, Ireland
So I bought my Minted Fx450 all kitted out with 30 hours on the clock, I've now just racked up 55 hours never had any issue. Took the bike out for a spin today never had any issue the normal show off start of the Efi berg and off I went, stopped 5mins into the ride and adjusted my pants and went on again but after 2 mins the bike stalled crossing a muddy crossing, so hit the button right up it starts went 20 meters and stalled again! So go to start and its just no joy, its ticking over but its like its getting no fuel. I cleaned all the contacts that I could and then put the bike over on its side and start pressing the fuel lines in hope it would come back after 15mins of abusing the button the bike started. Was running bad and spluttery and cleaned its self out after a few mins but still was not running well. Eventual it started to run okay and I went for a easy spin to try "clean out anything" and started to work alright started to do some gnarly climbs bike over heated once and left it to cool down started no problem and then after 10mins over heated again and then could not be started after that had to wait another 20+mins before I got some joy.

Got the bike back to the van in the end got home unloaded and hit the button still not starting so opened the trottle full and closed it twice and it came to life, jumped on and rode 3 meter stalled and then back to not starting.

What could it be? I'm 2T minded this is my first 4T. Btw I was not cranking the trottle when trying to start the bike. I've never had this issue with my berg before.

A day now on and my bike starts, Dealer reckons its the Sparkplug cap and seen it a few times with the newer bergs I'm going to give that a go, getting the new one in a day or 2 with a new plug. After postin on ktmtalk they see it as a injector or fuel pump issue, I am looking to clean the injector anyway of doing this? Do you have to send them off or can you try clean it yourself?
 
I just remember something I might add to that. 2 days before this I was messing in the workshop fitting up my friends 520 Fmf exhaust to see if I notice the diff and the bike cut out on the stand when I fitted back on the standard, I had just washed it the day before but when I went to restart it it took a good min to get the bike started again. After that I just turned it off again and never started it till the sunday that this all happened.
 
Bet it is the plug cap!!
But I had a similar problem on my fe 450, turned out to be a broken wire in the loom near the shock, keep us posted
 
things that have caught me out.

Bike stopped and would not start after the warmup lap of a race getting on the grid. would not start but would crank. turned out to be the fuel pump connector had slipped off jumping, I bent the clip back to make it stay on better but it's not ideal. I push the starter button briefly and listen for the fuel pump to wirr up.

disconnect fuel hose join under the tank (left side) does fuel spit out? I always forget to plug it in when putting the tank back on. no fuel here could be blocked filter in tank / no pump

spark plug

any flashes on the ECU light on the dash (if you have one)?
 
Check all the obvious stuff first as mentioned above, only takes 10 mins to cover all basic stuff.
After checking all connectors, battery earth, plug & cap shorting. Pump priming ok? Any flash codes? fuel flow?
If happy with all the basic searches then do a 5 min idle for good measure, i say this because you changed the exhaust which may affect mapping sensors ?
After that, like johny says, one of the main problems is a break in wiring from pressure or chafing and quite a few have been the wiring running above top of shock.
If its none of the above then you have to be looking next at the comment below which you may have already read on KTMtalk. Good luck !


WE FEEL WE HAVE FOUND THE PROBLEM, UPON REMOVAL OF THE FUEL PUMP AND PRESSURE REGULATOR WE FOUND THAT THE FUEL LINE HAD BEEN ZIP TIED FROM THE FACTORY TOO TIGHTLY TO THE WIRING AND THE RIBBED FUEL LINE HAD COLLAPSED AND WAS LETTING A SMALL AMOUNT OF FUEL THRU AND AS THE HEAT FROM THE MTR WARMED THE FUEL TANK AND ITS CONTENTS THE RIBBED FUEL LINE GOT SOFTER AND EVENTUALLY COLLAPSED COMPLETELY. WE ALSO REPLACED THE OLD PUMP WITH A NEW ONE AND WE RUN THE ENGINE FOR ABOUT TWO HOURS AND STOPPED AND STARTED THE ENGINE NUMERIOUS TIMES WITH NO PROBLEM
 
Thanks for the replys guys should have my new plug cap tonight and few other bits so going to take of the tank and get a good look. I want to take off the tank as I have not done it yet and feel the need to learn a bit about the bike, felt useless when I could not do a thing when I was stuck.

Bike is priming alright, forgot to listen to it when it was not starting but I still think it was going to check that line though. No flash codes coming on just the Fi as you try to start it but then goes out.

Is there a filter coming off the gas tank or in the tank?
 
There are two filters for fuel tank one inline and one on the end of the pump.
Is it me or are the 010 models having more problems than 09?
After 27 months of riding thro uk mud and rocks i,ve never had an issue. Maybe lucky or is it dust/sand in the US that clogs them up or in your case Dave Irish peat :)

You could do a pressure test to check first (pop to dealer if not sure) this should read 48-54 PSI under any load.
If you get a low reading, you need to look at changing the fuel filter, renewing fuel line, replacing fuel pump.
If there is any dirt in the fuel line then dont forget to clean or replace the injector as well.
 
Ha the bike has not seen real Irish peat yet :D I've had no issues with my 10 over the 25 hours other than this, hope it will be the last though :D I'm sure I'll be back motoring at the weekend 8)

Going to check the fuel line and double check everything over, I must report back up my finds If I have any.
 
Just a update, Took fuel tank off and cleaned the lines aswell as checking over the wires everything A okay. Put the new plug cap on and the bike was running as good as new, I think the cap really did sort the problem. Never had 1 issue with starting today while all the other guys where gutted looking at me hitting the magic button :D 3rd gear pinned :bounce3:
 
Thanks for the update, and for everyone elses feedback. I had been following the thread. I didn't have anything to offer but I do have an 10 FX450 but no problems yet the bike only has about 7 hrs on it, good luck and keep us posted :mrgreen:
 
If you still are having issues, I read on KTMTALK someone had the exact same issues you where having. It ended up there was some kind of white slimmy substance collecting on the fuel filters restricting flow. This will make your bike run lean, get hot, and puts a lot of extra stess on the fuel pump. After they cleaned out the filters, lines, etc., their bike was good as new. Hope that helps. Nothing worse than being stranded on our $10k machines... :roll:
 
HI GUYS AS DEALERS WE HAVE SEEN ALOT OF PLUG CAP ISSUES.IT IS GOOD TO CHANGE PLUG AT SAME TIME AS THE ARKING OF THE CAP TRACKS THE PLUG CAUSING MISSFIRE AND STALLING.THERE DONT SEEM TO BE MANY ISSUES WITH FUEL SYSTEM & INJECTORS IN UK PROBABLY AS DUST IS A VERY RARE THING TO SEE HERE.GOOD TO SEE YOU BACK ON THE ROAD DAVE.REGARDS HTM
 

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