New Fuel pump!!

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My cousin has 2012 fe390. Went through 2 pumps already. And he is sooo careful with his bike. He babies it. Connecror at the pump was also getting loose and losing contact. It's upsetting bike brand reputation. Supposed to be the best of the best....
 
I have ordered the ca Cycleworks pump as I retested the Quantum pump.
I stripped out the tank again re positioned and tightened all the hose clamps, Carefully positioned the hoses through the tank. Rechecked all the connections.I could hear the pump cycling with the starter but only if I put my ear up to the rear of the tank.

Still the bike won't start.It was running ok on the origional pump other than the hot fuel problem.

So the Quantum HFP-389 HQ4 ($ 60 US plus $$v 40 US shipping to me)pump as advertised by Quantum fuels USA (as a total match for the Fe/Fx 450) does not seem a trouble free good match for the husy EFI.

I poured fuel down the throttle body and the bike starts, I split the hoses and there is fuel there. The only change I have made is the fuel pump and the bike was running before that.

Jeff Slaven from Slavens Racing recommends the Cycleworks pump I dont think it is worth trying cheaper susbstitutes.

There was a hint on Keyless (starter button only) starting after a pump change,to get the fuel through, it was in the big long fuel pump thread, couldn't find it. Would appreciate if someone who knew would post it again.
 
Hey Rainerio,cheers, I changed out the pump end filter and the inline filter in the fuel line in the tank, I hear there is another small inline filter in the tank end of the clip together hose, not sure how to get to that one.I was going to get a fuel pressure test at the local KTM workshop.Ignorant about the fuel regulator?
 
The one in the fuel line is next to injector. KTM sell one to replace that one and puts it at disconnect easy to check/replace. For regulator I think it’s in the tank. Look at manual to be sure.
 
Can anyone point me to a thread on measuring fuel pressure.. have tried a search but cannot seem to see anything.
Im presently on my 2nd Fuel pump (its a cycleworks) but bike isnt starting. new filters.
Gas down the throttle body and it fires.
 


Here's a link to checking fuel pressure,fuel pressure from the pump,it can be affected or displaced by changing the diameter/length of the of the fuel hose of poor seals with hose clips, or problems in the regulator. I am trying to get everything set up as good as it was (the old pump was running the bike good so it can't be too much)interested to hear how you get on Kiwiberger as you have the same response from the new pump insert as me. I get a Cycleworks pump on Friday,so will post up any progress or findings
 
I have also just bought the "custom-fit" Quantum Fuel pump off eBay. It would have been nice to get some installation instructions with it as I've never swapped a fuel pump before. I'm going to fit it this week so hope I have more joy with it than you.

Will let you know how I get on. Fingers crossed.
 
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This (Slavens clip) is the same process as the 70 degree fuel pump replacement other than the removal from the tank. You remove the fuel regulator first, Be sure to take note which is the fitting to the regulator from the pump and which is the fitting for the return flow to the pump.Put a coloured cable tie on the fuel pump hose at the regulator end.

One of the biggest mistakes you can make (thanks to previous thread by Jon Anderson for highlighting this issue for me) is to put the regulator back in the tank without the alloy filter clip on top. Big mistake!! If you do this the screws go too deep and puncture the internal moldings inside the tank. Hence the tank won't pressurize.

I made this mistake managed to repair the tank with epoxy resin but it was time consuming and bit of a nightmare repair. If you want a description on this repair anyone PM me to get the detail as it is long and involved.
The Quantum pump was not the problem as I had holed the tank.
Anyway I replaced it with the Ca Cycleworks pump 2018. The result is pretty cool it seems to be a much stronger pump and fires the bike up with a touch of the button.
I will keep the quantum pump as a back up.

Also you have to really line up the new hose clips on the regulator right,to ensure you can get it all back into the hole in the tank. I found the stainless steel coil type hose clips easier to fit, and move around, than the screw in clips that Ca Cycleworks supply.
 
so i had a bit of a delay on getting back to this since my last post.
Full disclosure, when i first chaged the faulty fuel pump on my 09 450 a few years ago, i used some rubber fuel hose between the fuel pump and the fuel filter.
fast forward a few years and my 'berg had been sitting unused for about a year, and when i went to start it, same symptoms as the first time when the fuel pump died... no fuel pump noise when hitting the start button. So i ordered a cycleworks replacement pump, but when I opened the tank up, i found the rubber fuel hose was quite sticky, and the fuel filter was quite black, and the fuel pump wasn't working because the impellor appeared to be stuck. obviously the rubber fuel house was a bad move.
anyway i replaced the fuel pump and fuel filter, there appears to be significant fuel pressure now, but not measured as per the video (thanks F 70X) but the bike still wont fire.
There doesn't appear to be any inline filter in the quick disconnect joiner on the outlet of the fuel tank.. I think the early models didnt have it?

Is there another filter before the injector?
I tried to remove the injector from the throttle body but found it extremely difficult to get to.. I guess maybe my injector has a blockage as well?
 
Probably gunk in the injector. You can remove the injector by unscrewing from the top. It's difficult and you need a flexible screwdriver with the correct bit. If you cant or give up you have to unfasten the throttle body and take it out on the right side.
Whatever way you do it dont use the two phillips screws when you install the injector! On the throttle body's right side there is a plastic cover with two allen bolts. Change out them to the two phillips and use the allen bolts for the injector! That way you will have an easier job removing the injector in the future as you can use a 3mm allen key with a round end ;)
 
Hi, i learnt from fellows here in germany to be very carefull which rubber hose you are using in the tank to avoid cloging the filter after some years. there are hoses availble suitable for in/under fuel operation, they are different from the normal fuel hoses you are using outside. dont know why. also learnt that the piaggio vespa 300 and ducati using the same fuel pumps. so maybe a worthwhile check at your local dealer.
 
Carsten said:
Hi, i learnt from fellows here in germany to be very carefull which rubber hose you are using in the tank to avoid cloging the filter after some years. there are hoses availble suitable for in/under fuel operation, they are different from the normal fuel hoses you are using outside. dont know why. also learnt that the piaggio vespa 300 and ducati using the same fuel pumps. so maybe a worthwhile check at your local dealer.
Click to expand...

Thanks Carsten, I have pretty much came to the same conclusion.. unfortunately I wish I had known this a few years ago!
 
kiwiberger said:
Are the screws Phillips or Pozi?
Click to expand...

Phillips.

24345584468_11d9a13231_b.jpg
 
jon andersson said:
Phillips.
Click to expand...

Thanks ended up buying a new impact driver, and got the little rascal out, assuming there is no filter inside??.. I guess its just a replacement job? best place to buy a replacement injector?
Its a Keihin and marked K WF04 .. tried googling that partnumber but nothing found.
 
kiwiberger said:
Thanks ended up buying a new impact driver, and got the little rascal out, assuming there is no filter inside??.. I guess its just a replacement job? best place to buy a replacement injector?
Its a Keihin and marked K WF04 .. tried googling that partnumber but nothing found.
Click to expand...

Open the injector with a 9V battery. Blow compressed air against flow direction to clean it up. Worth a try as it will cost you nothing.
 

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