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Old 11-29-2010, 02:09 PM   #1
DirtJack OP
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KTM 690e fuel pump (FI) issues

Just got back from several days of riding/camping in Terlingua Ranch and Big Bend Ranch State Park. Awesome weather (30's to 60's) and riding.

The problem is that the bike stopped a few times and a couple of times failed to start after stopping for a short while (this happened once before while riding in the Gila National forest earlier this year but now the problem seems to be getting worse).

When the problem occurs, you can tell that the bike will not start by turing the key to on. You can hear the fuel pump relay click but you do not hear the usual sound of the fuel pump spinning up to pressurize the fuel system. When this happens, no amount of cranking with the starter motor will start the bike; that just runs down the battery.

So how do I get it going again? Just wait. Sometimes a minute or two, sometimes 10 to 30 minutes. Eventually, when you turn the ignition on, you will hear the relay and then the friendly fuel pump sound and the bike will instantly start.

Whenever the bike does run, it runs as strong as ever. The problem is intermittent as the bike ran without any problems one day of this ride. The problem acts a bit like some sort of heat sensitivity, but it wasn't hot and the bike did not overheat. A couple of times the after-market 88 deg. C fan switch ran the radiator fan on slow gnarly hill climbs, but the fuel pump is in the tank cooled by the fuel.

Anyone have any ideas before I pull the fuel pump and filter assembly?

I've owned the bike since new and it now has about 11,000 miles on the clock.
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Old 11-29-2010, 02:18 PM   #2
SKINNY
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There have been some problems with bad brushes on the pump...and bad wiring connections...either could cause intermittent problems...it's probably worth a look inside the tank...
Mine has about 8-9k and has never missed a beat, but with your failure, I guess we should all be aware of a possible high mileage problem...
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Old 11-29-2010, 02:25 PM   #3
DirtJack OP
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Quote:
Originally Posted by SKINNY
There have been some problems with bad brushes on the pump...and bad wiring connections...either could cause intermittent problems...it's probably worth a look inside the tank...
Mine has about 8-9k and has never missed a beat, but with your failure, I guess we should all be aware of a possible high mileage problem...
Yes, of course, but the bike has always (after nothing but waiting) eventually started. I've read about the brushes falling apart, but that leads to a hard failure doesn't it?

I agree that I probably have to go into the tank.
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Old 11-29-2010, 03:56 PM   #4
NJ-Brett
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Fuel pump brush problems usually just make the pump die and not run, and if they go erratic, it usually dies quickly, but anything is possible.
What about the fuel pump relay?
Maybe that is erratic.
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Old 11-29-2010, 07:17 PM   #5
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Quote:
Originally Posted by NJ-Brett
Fuel pump brush problems usually just make the pump die and not run, and if they go erratic, it usually dies quickly, but anything is possible.
What about the fuel pump relay?
Maybe that is erratic.
NJ, you may be right, but the relay makes the same sound whether or not the fuel pump starts to run.
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Old 11-29-2010, 07:30 PM   #6
empedrado
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I recently had something similar happen. My 690E had a little over 17,000 miles when it occured. Bike would run but ran really bad and at some point would not start for awhile. Ended up being some connections that were dust fouled. I removed all the connections around the throttle body and ones that were easily accessible. Blew them out and installed dielectic grease to the connections. Bike now seems to run better than before and it has been maybe 300 miles since the problem arose with no hint of problem.

Worth a try. I had similar problems with dust causing problems on my 640Adv.
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Old 03-19-2011, 08:58 AM   #7
Kawidad
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Quote:
Originally Posted by NJ-Brett View Post
Fuel pump brush problems usually just make the pump die and not run, and if they go erratic, it usually dies quickly, but anything is possible.
What about the fuel pump relay?
Maybe that is erratic.
I have to respectfully disagree. When I had my 950 Adventure it had the same type of running issues that drove me nutz. I finally tracked it down to the fuel pump. It worked, but was intermittent and lower pressures than spec; all of which caused the bike to run, but run horribly.

I know the KTM factory sometimes uses low quality bearings that I suspect were low bid items, so that may be in play for fuel pumps too.
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Old 03-19-2011, 10:25 AM   #8
beaney
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My take on the fuel pump problems are..

It appears that most failures are in the US and Aus, and not many in europe. I wonder if the problem is caused by the ethonol in the fuel as we in europe have a very small % added compared to other markets.
I know that the ethonal has caused problems by attacking carbon and glass fibre tanks, so is it attacking the carbon brushes???

I know that the US and Aus markets are bigger and that euro failures may not be reported.

But maybe its a cause.
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Old 10-06-2012, 06:46 PM   #9
modeselector
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Quote:
Originally Posted by Renazco View Post
Done, we'll get more ordered and look into the in-line as well.









.
Excellent!!
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Old 10-21-2012, 08:21 PM   #10
modeselector
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Quote:
Originally Posted by Ontario GS View Post
AustinJake - How has the Edelbrock 3029 filter worked out for you?
Would like to know as well...
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Old 04-30-2013, 12:14 PM   #11
milzispete
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Quote:
Originally Posted by Yamaha_Rider View Post
Hi:

I have a doubt

What happens if the fuel pump dies in the middle of nowhere, without phone signal and without people in hundred miles away?

Exists some "home made" repair on site to survive and return to civilization?

Thanks!
your choices are
1. change to a better pump and filter while you have the chance
2. wish you had changed the pump and filter when you had the chance

:o
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Old 04-30-2013, 12:58 PM   #12
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Originally Posted by milzispete View Post
your choices are
1. change to a better pump and filter while you have the chance
2. wish you had changed the pump and filter when you had the chance

:o
A lot of us carry an extra pump on the bike and the tools to install it. I have never had a pump failure on my bike. I still installed the CA Cycleworks pump just to be safe.
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Old 04-30-2013, 01:08 PM   #13
DirtJack OP
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Quote:
Originally Posted by Velociraptor View Post
A lot of us carry an extra pump on the bike and the tools to install it. I have never had a pump failure on my bike. I still installed the CA Cycleworks pump just to be safe.
+1. Doesn't take much extra space/weight. I think of it as insurance (things you're prepared for never happen). My original pump never left me stranded. It slowed me down, but always restarted after waiting a variable length of time. CA Cycleworks pump has been ultra reliable now for thousands of miles.
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