MOTO MYTH BUSTERS - THE FUEL SYSTEM
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- Опубликовано: 30 май 2020
- In today’s episode we take an end to end, soup to nuts look at the complete fuel system on any 150-501 injected KTM, Husqvarna, or Husaberg including the 250/300 two stroke machines.
there's so many myths and misunderstandings out there about what these components are, how they work and what the problem areas could be.
this show will take a look at all of those parts and how they work together, how to ensure the correct functionality of the system, tools you can use for service and trouble shooting.
One myth not mentioned in the video is if you run the tank low of fuel the pump will overheat and burn up as the gas cools the motor.
Myth. The design of the pressure bypass return flow intentionally sprays this fuel over the pump to cool it.
We have an in-house way we handle fuel system maintenance and it goes a little something like this:
*replace in tank filter on new bikes at 30 hours to wix
*replace all unknown age filters to wix
*replace all wix at 100-125 hours
*replace all pumps and regulators as a maintenance item at 250-300
*we use cal cycle works Ducati race pumps as our pump and regulator of choice
*install Golan under tank quick disconnect filter on all bikes. Clean every 75 hours or so
*clean injector every 75-100 hours or so
*treat gas w Techron additive a coupe times a year
*its essential to know fuel pressure when chasing any drivability / performance issue. Make or buy a ktm specific in line fuel pressure gauge.
We’ve been running this program on our fleet and customers bikes now for almost 2 years w no break downs.
Time will tell.
MOTO MYTH BUSTERS - THE FUEL SYSTEM
TIME LINE:
system overview 1:20 - 4:25
wiring pin outs 1:20 - 6:00
pressure regulator 6:00 - 8:30
tank connections 8:30 - 12:00
tank quick disconnect 12:00 - 16:00
tank air bubbles 16:20 - 18:40
low fuel light system 18:40 - 21:30
failure points, pump: 22:20 - 25:15
fuel intake snorkel 22:15 - 27:20
how does fuel get into the pump 27:20 - 31:40
pump unit components and O-rings 31:40 - 34:20
filters 31:30 - 46:20
spares i carry 46:20 - 48:00
filters 48:00 - 51:40
hose clamps 51:40 - 52:44
clogged fuel injector field hack 52:44 - 56:10
weak fuel pressure symptoms 56:30 - 1:00:30
at home fuel injector cleaning procedure 1:00:30 - 1:04:30
if you need any parts, want us to build you a bike, have any questions, or need help with anything on your machine don't hesitate to call or email us.
702-812-6626
mike@tacomoto.co
tacomoto.co/
also join us on the best ktm / husq tech support group on facebook:
groups/EXCFE... 
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Just seeing this 4 years after it came out but such an excellent video! Thank you so much for the awesome class on KTM fuel systems! Best tech video I've ever seen too!
This is probably the best tech video I 've ever watched! Thank you!
Thanks for the props 🤘🏽
This video is incredibly helpful! I feel way more informed on not only how the bike works, but also where to troubleshoot. ❤️
At about 32:25, you asked about the point of hole in the threaded anchor, that the collar bolt screws on to - that hole allows you to drain the tank as another viewer stated, but during operation, any larger debris (like sand) that makes it's way through the 2 tiny openings in the plastic pump housing, can also drop through it (and not get pulled up against the basket filter screen, which has short legs to provide the needed standoff for all of this to happen). The collar bolt has a small well in it, to catch and hold that debris so it doesn't get reintroduced into the pump housing. Of course, if you dump your bike downhill, upside down, etc, the debris can make it's way out of the bolt, which is less than ideal - so don't do that : ) I suspect that part of the fuel maintenance schedule includes cleaning out that bolt to remove accumulation. Great videos by the way! I love your depth of knowledge and willingness to share! I also love your products on your website - keep up the great work!!
Very perceptive! I hadn't thought of that...it totally makes sense and is a great idea! I have tried to use the hole as a drain before changing a pump and I'd have been better off just pouring the gas out of the filler hole.
L)7l😊
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That hole is for a reserve tank inlet.
I am so glad I found your channel. I learn more in 1 video here from you than a semester of automotive school.
Thank you Mike for the fuel injection 101. I just bought my first fuel injected bike, FE350, and you have taken away my fear and trepidation of the system.
This video is amazing! I really appreciated the “field hack for clogged fuel injector”. The detailed views of parts and detailed explanations are great. I watched about 5 videos before this one and yours is the only one that made it clear.
No matter how much a guy thinks he knows there's always more to learn. Thanks a bunch for this. Lots of great info, tips and tricks.
Another amazing vid Mike 👌🏽.
400h on my 19 KTM 500 exc and no failures so far but i am learning a lot from your experience and honesty.
Awesome video with more helpful info than anyone offers
Great video. Learned a ton and feel far more educated in my fuel system.
Without knocking your other videos, your myth busters are my favourites - keep up the excellent work!
Thanks amigo for the encouragement and support 🤘🏽
Great video, its a pleasure to watch videos like this from subject matter experts!
I'm just seeing this. SUCH an amazing walk through the fuel system and tracing of a drop of fuel. I know so much more about my bike. THX so much!!!!!
This is an awesome video. I learned a ton of different things about the fuel system, and troubleshooting. Great job I would love to see more similar videos like this.
Awesome vid, thank you so much for the detailed explanation of all the components and trouble shooting ideas.
Thank you for the excellent video! Very informative and answered a few questions I had about the fuel system on my 500.
Nice video. Clear and concise.
Outstanding! Since buying a 500XCFW, I've been down the rabbit hole with various channels. Yours are very thorough. I've absorbed a lot. Many diagnostic tips and great presentation of all parts. I dig the idea of backflushing the injector in the field if necessary.
Great video, thanks for the effort you've gone to to educate and bust myths!!
Great video! I just replaced my filter! I suggest tying a safety wire or fishing line to your lower outlet so it’s easier to pull the fuel pump back to the bottom of the tank. It really helps guide it into place.
Nice tip!! Thanks!!
Great video, thank you Mike.
Also @ 49:30 -- Another key design advantage to the ZipTy filter is that it can [optionally] support also adding the KTM/HQV in-line filter in to their filter for additional filtration. Not required, but you can run it too, it snaps in.
Yes, correct on that
This was an amazing amount of valuable information! Outstanding!
Great video thanks for sharing it. And great tip/idea on the fuel psi gauge!
Awesome video. Great info and love the trail hacks
That was fantastic Mike, you continue to impress me with your knowledge, well Done! You get my money $$$ every time, TacoMoto Rules! Of course I subscribed several times thru the years,
Phenomenal Mike. Thank you!
Hey Mike. Awesome videos, absolute Masterclass of technical information. I just got my '20 EXC and really enjoying learning all I can about the bits and pieces. I'm still looking for some good guides regarding the main wire harness. I'm having a hard time identifying all the relays and dongles on the backbone. Any tips/resources you know of would be awesome. And obviously if you make a video of the electrical assembly, that would be absolutely premium! :D Keep up the good content! Stay safe out there!
That was great info! I've always wondered what the hell the "black" stuff was inside the filter. This is definitely a KEEPER!
Thanks for the video, very interesting and helpful.
An other great video. Excellent information. The fuel pump on ktm huskys are the weak link. The race teams change the fuel pump every ten hrs. For this reason. Any time my bike has had issues it’s Been the fuel pump
Thank you, brilliant work through...
thank you very much for this super informative video, learned a great deal, appreciate it! :)
Excellent video!
amazing explanation. Thank you!
Thanks for the education
Awesome explanation!
excellent service education video!
Great video. I enjoyed it very much. Would like to see comments about the pumps themselves and recoomedations thereof.. Thanks Mike.
AWESOME info and video!!!!
Dude so much info. Thank you. Thank you very much.
Keep checking out our stuff
Insightful video on the fuel system. Thanks! FYI the clamps are Oetiker, developed in Switzerland in 1942
Thanx Mike. Great stuff
Excellent explanation to fuel injection. it sucks to have to maintain all of these expensive and finicky parts. Im liking the carb idea more and more, simplicity is king.
Amazing video, thank you
Awesome run down 👍
Excellent information. Thanks for sharing all the details!
WIX 33095 filter spec is 11 micron nominal rating from the WIX website.
Ok awesome into. Thanks for that
Awesome Mike!
outstanding video
You da Best Man !..thx a lot !😊
Fantastic video, really helping me solve an issue with my 2014 not starting after sitting for 3 years. New fuel, changed Fuel pump (now working and priming), had back pressure at the gas coupling so assumed injector blocked or not opening - If I use a 9 volt battery to active and backwash the injector on the bike I get flow. However when connected to bike electrics, injector not opening. Could this be the pressure regulator, or a relay somewhere?
I recently checked the fuel pressure on my 2019 KTM 300XC-w TPI and it read around 42lbs of pressure. Even though the issue on the bike was not the fuel system I’m wondering if that’s a low pressure reading or about right? I’m not sure but I don’t recall you saying in the video what the ideal pressure should be. Thanks for all the informative videos, really good stuff since these newer dirt bikes are getting more and more complicated to work on.
Dope video, keep it up!
I’m not seeing on your website where I can buy the 9v connector to keep the injector open for cleaning.
We’ll have that available a little later this month
Not the sexiest dirt bike video ever...but this content is gold! especially if you like riding in remote places.
Great video. Curious can that manifold pressure sensor get dirty/oiled? I have a odd off idle rough running engine, I've tested everything from fuel pressure to injector, etc. I can kind of make it go away with some tps adjustments but never perfect and wondering if that sensor might be sending bad data
Looking at that Earls filter, I would say that the paper element in the consumable filters have much more surface area. I would just use the Wahle. As for the external filter, I prefer the size of the Golan, but the Zip-Ty filter disk is much easier to clean and verify cleanliness.
Good video. Lots of real world information.
I presume that you know the KTM fuel pumps discharge at 100PSI because you've measured it. Then how can the WIX, NAPA etc carburetor fuel filters cope with that pressure? How do you know that the filter element hasn't failed since you can't inspect it?
So either keep using the OEM Mahle filter hoping it doesn't burst or use a serviceable in-tank filter that can take that pressure.
Great, thanks!
Really great info and totally appreciated.
I was hoping that you would talk about the stock fuel pumps as opposed to some of the aftermarket pumps.
Everything talked about and shown was the stock fuel pump.
What did you have in mind.
Maybe just bad luck but I’ve been through several pumps in a short period of time and not sure what to make of stock reliability as opposed to any of the aftermarket offerings. After seeing this video paranoia says carry a pump at all times. I must pick up on some of your testing gadgets, though, good stuff.
Some guys never see a failure. That you’ve had multiple says there’s something going on with some other part of the system.
A spare pump motor is good insurance.
Great video Mike! Is there a point when you just replace the stock pump as a preventative maintenance deal? Or wait till it starts making problems? Thanks for all the good information! Cheers!
John M - Same question or if there are indications of a pump starting to fail. I would assume pressure output would be a start.
I had a Mahle stock filter split at the seam when I was alone and a long way behind a locked gate on a hot summer day. Got towed out eventually but it was a looonngggg 20 hour day.
Thanks for the informative video. I am new to these fuel injected four strokes and need all of the help I can get. Im hoping you sell all of these service parts as a kit on your website. If you cannot transfer fuel to other riders tanks what do you do with any fuel in your tank while out on the trail so you can remove and service the pump assembly?
Your Grampa must have been Malcolm Smith. I learned a lot and spent a fortune at Taco Moto!
Does the 9.99 filter only on your site include the hose clamps? Or do I need to order the one with hoses also to get the clamps? Also do you recommend changing the filter at the bottom attached to the pump? You never mentioned replacing that one that I can remember. The filter kit from Rocky Mountain is like $80 but has both filters
Excellent explanation. Thank You. I just have one question do fuel pump run continously? I have issues with my sxf 250 ’17 pump is pumping gas only about 1-2 sec and then stop. Is it Ok? The bike have uneaven idle and does not reach more than 30 % of engine speed.
I have new 2020 FE501, and I run out of fuel with 3.5-4 inches of fuel left in tank, I haven't checked yet but my lower fuel pump cup holes may be plugged or not drilled, so that is some thing to watch for. I'll know more when I take apart.
The hole is there to drain the tank (if you undo just the plug the assembly is still held in the thank by the hose fitting)
Yes, clever. I can see it doing that. Good call
I have exc tpi 250 2019 i have 20 hours on it. i noticed inside fuel tank fuel is spraying and i can see somthing like air bubbles so im guessing there is some crack on hose or on pump joint with filter. otherwise bike runs fine at mid-high rev and full tank but when is on fuel reserve it start bogging (i think then it starts to suck air through this crack). Also in 6 gear at low rpm bike also have running issues.
Hi Mike, how long will you let a bike sit before you drain the fuel pump components and final line and how done? And do you also try to get fuel out of that injector for no gumming up?
I had a buddy with Husaberg 570 have a fi problem on a CO ride. Bike started popping really bad and eventually wouldn't run. We checked every thing we could think of including back flushing the injector. Turns out the intank filter had a split in it, length wise. The injector would initially spray, then the system would lose pressure and stop. We didn't think about the filter being split. :-( .... And what do you think about running a small amount of 2 stroke oil in the gas to help lube the pump ?
That first 10 micron filter in the disconnect, is it in the male or female side?
And is it cleanable, or do you need to get a new hose n' end fitting?
I'm in the Philippines with a duke 690. Mostly the same parts. Difficult to get parts here...
Nice informative video. Thanks!
Hi great and very informative video. I purchased one of your gauges and tested 3 bikes 2 350s and a 300. All the pressure readings were between 40-42 psi none were 50. I am 100% sure your gauge is accurate and pumps are performing so my question is whats the best way to troubleshoot this low pressure?
Amigo. Your results make me think there might be a calibration issue on the gauge. How do all these bikes run?
the gauge is correct because i got a spare gauge and i was the same. They all run ok but the 4t have the normal flame outs and the 2t runs ok
Very strange. Are all the filters clean / new?
For cleaning the injector, or more accurately, helping to keep it cleaner, what is your opinion of a couple ounces of fuel injector cleaner like Seafoam every few tanks of gas?
Can you reference the video on fast idle and idle adjuster relationships. You mention it but I could not locate it.
is there an inline filter at the injector as well? Also, seems like it would be a bear to get at the injector and disassemble in the field
The only problem I have ever run into with the use of the band screw type hose clamps is the people who over tighten the clamp and cut into the fuel hose. That said I recommend the screw type clamps that are a fully enclosed band.
That’s valid. Low quality fuel line will also get chewed up by the openings in the screw type clamps as well.
Correct torque on good quality lines is ideal 👌🏽
That’s valid. Low quality fuel line will also get chewed up by the openings in the screw type clamps as well.
Correct torque on good quality lines is ideal 👌🏽
I'm thinking, why do they put the filter into the high pressure hose (the hose which is directly connected to the pump), instead of the low pressure hose (the one that goes out of the tank). In that case, there would be less pressure on the fuel filter that we all know has a cracking issue, probably from very high pressure. What do you think M ?
Mike, any thoughts on reasonableness, considering cost, time and effort, to build an entire fuel pump assembly so that I could easily switch between stock and monster IMS tanks?
What you called the anchor Nut with a hole under it is a fuel tank drain port.
Hi Mike...my low fuel light has stopped working...if the bulb is ok then how do i test if the thermistor is faulty or not?...is this possible to do without removing the pump from the tank? 🤔
I do know on that quick disconnect with the little button if you don't use grease or oil lube those I rings will tear easy,seen those on water lines on filet steamers, McDonald's maintenance for 25 yrs
O rings
Mike, in general this is basically like most systems, I have a AJP Pr7?
What could cause my 2016 350 to backfire and bog _ cut out on deceleration then fire strait back up again and so on have done filter change and injector but still does it.
Hi Mike, question about the plastic 90 degree fitting that the injector connects to between the throttle body: There are 45 degree angled variants of this part available from some aftermarket suppliers, made of aluminum, called fuel rails, that supposedly improve the "flame out" tendency of the 4 strokes. Is this yet another myth or is some fuel flow improved by having a more smooth transition of the fuel direction in the tube to the injector?
How do you replace the regulator. Does it pull out of the plastic housing
Hey thanks do you have an idea to what could have happened to chad reed in gb ?
I don't see the shorter hoses mentioned on your website for the longer Earl fuel filter. Got a link?
My stock plastic filter failed (cracked) at 40 hours and do not want to replace with another plastic.
We don’t have them. Here’s the filter we’ve been using and having great success with.
tacomoto.co/products/f
own a 2017 sx250f, and i believe the 2017 xc come with both the “fi” and low fuel indicatir lights where as my sxf doesnt have an indicator light, offhand do yiu know if they bith use
The same fuel pump? Or would my bike because it uses the keihin tbi a wamrning light isnt possible.
Ultimately Im currently installing the voyager pro (which i currently found Rotweiller moto , for my Ktm recently , which im sure youre well aware that eveyones out if stock till june or. So)
I recently started having a problem with my 2019 300xcw tpi where it is having trouble staying at idle when starting from cold. The bike seems to be starving for gas. I played around w the air screw. Turning it out to raise idle.(which I know it’s not an idle screw) and turned it in as well. I believe it came three turns out. Went to 4 and in to 1 1/2. Both had adv fir a ride but the problem seems to get worse each time I run the bike. Just today when I was testing start/air screw/ and bog problem that bike always had when cold I stalled it and the gas light came on. Thought that was strange. Any ideas? Going over to a friend who has same bike to swap tanks to see if something internal. But if prob still exist could it be injector?
Thx for vid. Was nice to see how it all works.
Also yesterday went for a ride with air screw at 1 1/2 turns and then stopped and bike sat for two hours. Started up and revved it a few times to warm it up and took off. About 100 yards in the bike stalled. Restarted and then 50 yards more the bike tried to stall again.
Also bike has 68 hrs on it. And is coming out of hibernation from a New England winter. Have about 5-6 rides on it since then. With new gas. But like I said. I noticed every ride the idle at start , staying running/ bog when giving it throttle have gotten worse w every passing ride.
What was the final issue? Was it ever resolved?
I have a 2014 xcf 250. When cranking motor should it pump gas? it pumps the second you stop cranking and that seems wrong. Anyone any advice?
Is it possible that the second capped off hole is to allow a connection to a second tank, such as the Dakar bikes have?
That’s a plausible thought for sure.
If gas flows thru it I assume you could drain gas from it. Maybe a good place to drain sediment or ethanol/water goop that can form during storage. ??
So wouldnt putting on a strong elbow allow you to break the pump now instead of the cheap elbow ?
Where can I buy your fuel pressure gauge for troubleshooting from?
Never ever ever had a problem with the filters it’s always the pump about every 150hrs the pump takes a crap. Or is starting to have 300 hrs on my 500 on the second pump
Hi - sorry to spark up an old thread.
What advice do you have for a bike running very rich?
how many hours does the pump go in general?
I built the same in line psi tester , has anyone played around with increasing the fuel pressure as a way to richen em up ?
That’s not tuning. Adjust afr in the map
@@TACOMOTOCO ya for sure the mapping is the way to go , just wondering as it used to be done in the early days of automotive efi tuning.
Can a bad fuel pump on a bike cause the overflow valve to leak gas? I just filled up and I’m immediately leaking gas through the overflow valve
Some one please get back to me
I’m trying to understand.
In one part of the illustration, you say there’s 100 psi going into the filter, then you say 50 psi?
I’m not sure about why you don’t think that just because the filter isn’t filled with fluid that it’s not likely that the high pressure would damage the filter element.
Wouldn’t that be less likely if the filter was filled with fluid, thus equal pressure on all of the element instead of no resistance of pressure on the outside of the dry area?
Do you sell a complete in tank fuel pump system to use in a spare oversized tank?