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in tank fuel line couplings

Joined Nov 2010
6 Posts | 0+
I sure could use some help. My 2010 FE 450 has the intermitent dead fuel pump issue when it gets hot.
placed order for new pump today with CV thermal blanket. My deal is i can't figure out how to get the fuel
line couplings inside the tank apart. they have a gray ring around the connection. there are flat spots on the
od of the gray piece. I messed with it for a while and stopped before I did damage any words of wisdom would
be geatly appreciated. Thanks
 
They are a pain to get apart!! i think there must be a special tool for it. I ended up using a small needle type tool to spread the flats apart inside the ring and it came apart. Be carfull, as they break eay. I think a good auto repair shop that does FI would have the right tool. Good luck!!
 
that's what i thought a special tool. My Husaberg technician at the dealer said they were quick disconnect fittings.
so after reading your post, and the info from the dealer i gave it another go. one came apart as a quick disconnect, but i wouldn' call it quick. what a pain. the second one i use a small pointed tool per your sugestion
and got them apart. tougher than i thought it should have been, just glad i didn't break anything.
thanks for the help. waiting for new fuel pump. ordered CV thermal blanket. thinking about icing fuel before ride.
I also have the exhaust heat wrapped.
 
I have the same problem - the bike just dies and you can hear that the fuel pump is not priming the injector. Only thing to do is wait a few minutes (say 5 minutes) and try and fire it up again. Don't crank the motor for nothing cos all you'll do is kill the battery...

I dont think it has anything to do with heat - I think its dirt in the fuel. I just replaced my fuel filters today, so hopefully the problem will go away.
 
Be sure to use the right tool / AS YOU WOULD ON ANY HIGH PRESSURE FUEL LINE
releasing one tab at a time with a pointed pick will damage the tab and connector / you will have problems later with the connector
make sure all four tabs are snapped over line flange when connecting lines
It's a great connector but you have to use the right tool/ OR care hiking BOOTS
 
thanks for the heads up on the right tool. my boots are wore out from last outing with fuel pump going dead.
running 2nd in the Florida FTR series when pump locked up and i was done. I was enjoying the best run ever. Read some of the threads on this site with regards to 2010 FE 'Berg fuel pumps. There have been issues with the pump locking up when it gets too hot. They commeneted the internal clearances are a little too tight for the temps the pump operates at. my fuel was boiling good when it stopped running. I had gone down and bike was laid over on about a 30deg angle with tires high and still running, back side of berm. I think the pump may have dry ran a bit and finished it off. You will know if it's a bad pump. jog the starer, normal operation you will here the fuel pump energize. when it's locked up you will here a relay pop under the tank, part of computer, but no sound from the fuel pump, dead. no EFI lights flash. just dead pump. Let it sit, it will cool, and then it will start. mine came back to life after a mile push back to the truck. my Dealer has a warranty claim in with Husaberg for the pump. if you hear the pump run, then i believe it could be dirt. it's died on me 3 different times. if it sits in the garage for a while it will fire right up, like the next morning you tear into into it to fix the problem Runs fine, you think all is well, not the case. I'm replacing the pump as i can't take any more DNF's and long hikes. the guys on this site claim that once they replace the pump problem fixed. It will get worse over time. i have 15 hours on the bike, it started at 9 hours. I'll let you know if the new pump cures the problem and how they handle the warranty.

Where might one find the right tool for the connectors ? no experience in this area. thanks
 
great information on the pump ,thanks
I made a tool from soft plastic tubing about 3/8 ID 3/4 long cut lenght wise opened it up put it around the male part of the connector close it around the fuel line and push it into the connector/ this should release the four lock tabs
Go to a automotive shop and ask to see a fuel line disconnect tool you will get the idea of what you need,
check at a auto parts store they have the fuel line disconnect tool in different sizes.
KTM shops should also have the correct tool
first time I had the in tank fuel line apart I did not get all four tabs lock in place only two were locked on to the flange, after about 100 miles the connection came apart from movement and fuel pressure had a 13 mile walk back to the truck!! My Fault
My 2010 FE 570 has over 7000 miles now and has been bullet proof runs great, Just in the last month I've got the suspension and handling working better than any bike I have owned( to many to count)
have a great ride
haskell in Idaho
 
Had the same problem, I just used a small screwdriver and released the tabs, it seemed the O-ring was more of a problem being dry and not wanting to release, so I had to force it more than I wanted to.

I had to purchase the pump because the dealer wasn't going to take my word for it that the pump was bad, I did all the troubleshooting for him and still he wouldn't believe me. He also said that I needed to be cautious with these forums and don't take them to serious, I say thank God for these forums, because the dealers don't always know what's the problems nor the solutions.

Bike hasn't stalled since, but I did spend a small fortune getting it where I no longer had Issues.

But even with all the trouble It's still the best dirt bike I've ever had or ridden
 
My pump died today after several thousand miles and about 125 hours. At first if I let it cool it would put in enough fuel for the motor fire for a few revs and then die. Then nothing. Tried it again when I got home and no light, no run.

You need to have Oetiker pliers for the fuel line clamps. They are the same as the clamps that hold the quick disconnect on. They are a one time use clamp and IMHO are superior to screw type clamps because unlike the screw type clamp they have a flat surface all the way around on the clamping side, and they don't cut into the line like a screw type one can.

You also need to spend the dough on good pliers. The good ones have an anvil that comes down on top of the little loop on top of the clamp. I paid $65 for mine from the snap on tool truck. With these good pliers you can't over tighten the clamp, no matter what diameter it is, and the anvil makes sure that the correct amount of tension is applied to the clamp.
 
thanks so much for the advise Haskell and Dale "E"O. we have a snap on truck that stops by work here.
I'll be picking up the snap on pliers. I'm not counting on warranty for the pump, but thought i would ask.
Shoals outdoor sports in AL have been great guys to work with, so we'll see what happens.
13 miles? walk, dang, i was belly aching about 1/2 mile. you are right about this bike, it's fantiastic, i love it,
i'm coming off a 08 yz450 and that bike hasn't been started since i bought the 'Berg.
you are right about the forums i have learned so much from the people on this site.

I had TF Racing in Myakka City www.tfsuspension.com respring it for a fat boy, 230lbs and
he revalved the rear shock, no charge, as he said he learned something about them.
it handles unbelievable. i would never know there is no rear link in the back.
This thing turns like magic, it is sooo fun to cut underneath the 450 jap bikes in corners as you
know they are going wide, nothing they can do. I'm not sponsored by them but you can't go wrong with SOS
and TF. Looking forward to getting this behind me and riding.
How have you guys found the valves holding up on the 'Bergs?.
my yz has 120 hours on it, new piston, rings, cam chain at 100hrs, but valves were still in spec. I chug the motor.

Thanks again for you help guys.
 
:cheers: Have the same issue on my berg 15.5 hrs and pump has left me stranded twice I took it back to the dealer they said they will make it right. called them today said they will have husaberg warranty the pump but parts are on backorder now. :( Im glad theyre going to fix it but I wish this issue would have been resolved before
 

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