I am a new owner of 2011 fe570s,purchased 2 months ago with 40hrs on clock.Went to ride last week and while letting it warm up she began to lose idle and shut down. So I checked for spark and theres plenty with new plug.IT will start and run lean for a few second when I spray starter fluid in air box,so next I removed injector and cleaned and tested with 9v battery,all seemed good,line from tank also clear.Next I removed gas line from tank,turn key on and gas sprayed from tank conection? can pump still be bad? I also cleaned small hole on inside of intake.All was good there.Also checked all fuse and none were blown. Any ides will be hightly appreciated.Thanks in advance.om George from Pennsylvania.
possible fuel pump problem?
- Thread starter georgemilchick
- Start date
Classic symptoms, George.
There are at least two design flaws on your bike. BTW, I have a 2011 FE570S, too. I've solved them both.
First, the factory fuel pump is failure prone. Why? Because it's supposedly cooled by the fuel, and the fuel gets too hot because of the tank's ridiculously close proximity to the exhaust mid-pipe. Whatever you may do to insulate the tank or the pipe, the fuel pump is a problem that absolutely must be solved. I pushed my bike 6 miles, so I've been there. The solution is the California CycleWorks fuel pump. They've redesigned it to make it much less susceptible to heat. Beware of the hose they provide with the pump. The one they sent to me was slightly oversized, and despite the use of a high pressure hose clamp it wouldn't stay on the hose nipple on the fuel pump and the bike stranded me yet again. You need 5/16" high pressure fuel line and a hose clamp made specifically for high pressure fuel injection usage.
Second and as stated above, the fuel tank has less than a half-inch of clearance from the exhaust. My solution was to coat the exhaust mid-pipe with a high temp paint, cover it with an exhaust wrap, and put heat reflective tape on the underside of the tank. I also replaced the radiator fan thermo switch with a lower temp unit.
There are several relevant threads. Look under Fuel. If you have any questions, please let me know. I've solve these problems and now my 570 is stone reliable.
There are at least two design flaws on your bike. BTW, I have a 2011 FE570S, too. I've solved them both.
First, the factory fuel pump is failure prone. Why? Because it's supposedly cooled by the fuel, and the fuel gets too hot because of the tank's ridiculously close proximity to the exhaust mid-pipe. Whatever you may do to insulate the tank or the pipe, the fuel pump is a problem that absolutely must be solved. I pushed my bike 6 miles, so I've been there. The solution is the California CycleWorks fuel pump. They've redesigned it to make it much less susceptible to heat. Beware of the hose they provide with the pump. The one they sent to me was slightly oversized, and despite the use of a high pressure hose clamp it wouldn't stay on the hose nipple on the fuel pump and the bike stranded me yet again. You need 5/16" high pressure fuel line and a hose clamp made specifically for high pressure fuel injection usage.
Second and as stated above, the fuel tank has less than a half-inch of clearance from the exhaust. My solution was to coat the exhaust mid-pipe with a high temp paint, cover it with an exhaust wrap, and put heat reflective tape on the underside of the tank. I also replaced the radiator fan thermo switch with a lower temp unit.
There are several relevant threads. Look under Fuel. If you have any questions, please let me know. I've solve these problems and now my 570 is stone reliable.
check your plug cap to wire connection, it may be corroded, snip off a 1/4" without tugging on it and rescrew to plug cap. you may have loosened the connection when changing your plug
thanks for replys,so I should just accept pump is bad? I here it turn on with key and does spray fuel from tank fitting.But bike wont start. Is there any other way to test this or should I just order new pump? I have added reflective shield under tank and also toggle switch to run ran while riding tighter trails to keep things cooler.I did read a lot on this site about this problem ,but just wasn't convinced.that pump was bad.
If fuel is spraying , then the bike should at least start, if it's a bad fuel pump. Someone correct me if I am wrong due to low pressures etc.
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You could make a tool to test the fuel pressure. 1 quick disconnect coupling, 1 tee-piece, a length of fuel hose with enough hose clamps and 1 100 psi gauge with a nipple to connect it to the hose.
Build it together and put it in between the fuel hose quick disconnect.
The expected fuel pressure should be between 45 and 55 psi.
Can be a handy tool to have home and is cheaper than buying a new fuel pump if it turns out the oem is alright. KTM changed the fuel pumps between 10-11 so they got more reliable. But for sure, some -09 and -10 works just fine and some with -11 and -12 have had problems, so it could be the pump.
I guess you have checked it as it looks like you have done your homework, butdo you have that small black plastic 10 micron inline filter? If you have it it should be inside the hose just before the injector. That could be it.
What happens when you don't let it warm up at idle and start it cold and just give normal gas and drive the bike?
Build it together and put it in between the fuel hose quick disconnect.
The expected fuel pressure should be between 45 and 55 psi.
Can be a handy tool to have home and is cheaper than buying a new fuel pump if it turns out the oem is alright. KTM changed the fuel pumps between 10-11 so they got more reliable. But for sure, some -09 and -10 works just fine and some with -11 and -12 have had problems, so it could be the pump.
I guess you have checked it as it looks like you have done your homework, butdo you have that small black plastic 10 micron inline filter? If you have it it should be inside the hose just before the injector. That could be it.
What happens when you don't let it warm up at idle and start it cold and just give normal gas and drive the bike?
thank you,now I understand,it doesn't have correct pressure.My bike don't run at all and fine inline filter has been removed. the only way it will start is with starter fluid.
I noticed that my fuel pump got more quiet the worse it got...Unfortunately you probably don't have any way to compare it to new. Anyway, it probably is the pump, they do lose their seal towards the end of their life causing low pressure(mine did).
Seems like the pump then yes.
1 - You got spark and it runs with starter fluid
2 - Injector is clean and spray fuel
3 - No inline filter
What's left is the fuel pump and people in this thread have had the same experience with new pump as a solution.
1 - You got spark and it runs with starter fluid
2 - Injector is clean and spray fuel
3 - No inline filter
What's left is the fuel pump and people in this thread have had the same experience with new pump as a solution.
Hey fe390vt
Sound advice from Ruger and Jon.
I also have the FS570 and I had to go through most of this, too. Even after fixing the fuel pump my bike still had running issues which ended up being related to the emissions control system on some 'Bergs.
I'm not sure if your bike has the head and exhaust breather hoses & canister installed (mine did) but there are a few references on this site on how to check and remove it. My symptoms caused my fuel tank not to breath sufficiently and the bike would starve of gas when running hot, or after a restart, effectively because of a vacuum air block in the fuel tank and lines. I put a breather hose on the gas tank cap and problem sorted.
Awesome bike BTW! I'm off for ride on mine now
Rich
Sound advice from Ruger and Jon.
I also have the FS570 and I had to go through most of this, too. Even after fixing the fuel pump my bike still had running issues which ended up being related to the emissions control system on some 'Bergs.
I'm not sure if your bike has the head and exhaust breather hoses & canister installed (mine did) but there are a few references on this site on how to check and remove it. My symptoms caused my fuel tank not to breath sufficiently and the bike would starve of gas when running hot, or after a restart, effectively because of a vacuum air block in the fuel tank and lines. I put a breather hose on the gas tank cap and problem sorted.
Awesome bike BTW! I'm off for ride on mine now
Rich
Oh, I didn't think of that one because all that crap is normally removed by the dealer before you buy it new.
Wow, I figured that down in nzed that no one would think to restrict the can... More sheep than sheeple. The US versions should be de restricted, but I own a 390...
ha ha... yeah... they don't have all those silly laws here, but I had to get a US imported FS because they never sold them here... Anyway, at least thats not an issue on the 390
RVJ is right! The smog gear and the factory exhaust can are two big reasons why my 570 simply didn't run well or reliably. When I removed the smog gear and replaced the exhaust can with an FMF slip-on, I noticed such a drastic improvement that I was sure that my bike now ran like the engineers who designed the engine intended.
But it was after I made those improvements that the fuel pump failed. The smog gear makes the engine run poorly, the exhaust can creates far too much backpressure and gets hot enough to fry an egg on it, but the fuel pump will strand you miles from home.
But it was after I made those improvements that the fuel pump failed. The smog gear makes the engine run poorly, the exhaust can creates far too much backpressure and gets hot enough to fry an egg on it, but the fuel pump will strand you miles from home.
my bike has been de-smoged from the day one.Also aprovic muffler installed.I ordered ca cycleworks pump yesterday from AOMC. Ill let everyone know how it all works out.
George,
If the hose that comes with the CA Cycleworks fuel pump goes on the fuel pump nipple too easily or can't be clamped hard enough to stay on when you try to pull it off with your hands, go down to your local motorcycle shop and order Helix Racing Products 5/16 inch high pressure fuel line. It comes in a three-foot package. I think the Helix P/N is 75861, and the Parts Unlimited P/N is 0706-0191.
Also, be certain to use hose clamps that are specifically designed for high pressure fuel line use. They're easy to identify - it's a solid steel band tightened by a threaded bolt and nut. Standard hose clamps with the screw-type tightener bearing on diagonal cuts in the band are not suitable for this application.
If the hose that comes with the CA Cycleworks fuel pump goes on the fuel pump nipple too easily or can't be clamped hard enough to stay on when you try to pull it off with your hands, go down to your local motorcycle shop and order Helix Racing Products 5/16 inch high pressure fuel line. It comes in a three-foot package. I think the Helix P/N is 75861, and the Parts Unlimited P/N is 0706-0191.
Also, be certain to use hose clamps that are specifically designed for high pressure fuel line use. They're easy to identify - it's a solid steel band tightened by a threaded bolt and nut. Standard hose clamps with the screw-type tightener bearing on diagonal cuts in the band are not suitable for this application.
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