990 adventure fuel issue

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by Jeremiah Johnson, Jul 24, 2013.

  1. Jeremiah Johnson

    Jeremiah Johnson Adventurer

    Joined:
    Jan 20, 2013
    Oddometer:
    11
    Location:
    Manitoba Canada
    Wondering if anyone with the 2012 adventure might have had this problem:

    Riding down highway, engine dies. There is fuel coming out of the fuel overflow tube at the bottom of the bike. Turn on the key, can hear fuel pump running, but fuel pours out of overflow constantly and bike wont start.... Nearest ktm dealer to me is 8 hours away...
    #1
  2. alongat

    alongat Long timer

    Joined:
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    Oddometer:
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    Location:
    Toronto, Canada
    Did this just start suddenly or was the bike displaying other odd behaviours prior to stalling / spitting fuel, etc? Did you ride off road prior to this? There are a number of posts relating to preventative measures designed to avoid situations that sound similar to what you are describing; those related to the evap / canister system and those related to the fuel cap "flap" - I don't know if these would help but have a read through these links to see if any of this jives...

    Decanisterectomy for 950/990:

    http://advrider.com/forums/showthread.php?t=905992

    Flapendectomy for 950 / 990:

    http://www.ktm950.info/how/Orange Garage/Fuel Tanks/Flapendectomy/flapendectomy.html
    #2
  3. alongat

    alongat Long timer

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    By the way, are you sure fuel is coming out of the overflow tube rather than the fuel line (or lines) coming out of the fuel tank petcocks? In addition to the links I provided, I know that there is a crossover vent tube that runs between the tanks along the top so if you have had the front side pieces or dash/headlight areas of the bike apart for any reason, you could have disconnected or pinched that crossover tube.
    #3
  4. Jeremiah Johnson

    Jeremiah Johnson Adventurer

    Joined:
    Jan 20, 2013
    Oddometer:
    11
    Location:
    Manitoba Canada
    It did start suddenly, no other issues before that.

    Upon further investigation, the fuel is coming from the air box drain line.. air filter is soaked with gas... will continue searching for source...Any ideas or known issues??

    And thank you very much for your help!
    #4
  5. alongat

    alongat Long timer

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    Sorry, I'm stumped on this one - hopefully somebody else has an idea...
    #5
  6. Hootowl

    Hootowl Long timer

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    Check the fuel line coming from the left tank where it enters the airbox and connects to the TB's
    #6
  7. Jeremiah Johnson

    Jeremiah Johnson Adventurer

    Joined:
    Jan 20, 2013
    Oddometer:
    11
    Location:
    Manitoba Canada
    yep that's it, pin hole in fuel line just below where it attaches to tb's. Going to remove and just splice a new piece of fuel line until the new one arrives. Thanks
    #7
  8. Hootowl

    Hootowl Long timer

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    Good that you found the problem. Make sure to use FI rated line
    #8