First issue with my "08" 990......20K miles

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by 4corners14, May 11, 2013.

  1. 4corners14

    4corners14 Been here awhile

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    Oct 3, 2008
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    686
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    Seattle
    I haven't even started to try and figure this out yet, as I just made it home.... We were on an exploratory trip around all three forks on the Snoqualmie river today and as I was headed to the last leg (South Fork) the 990 started to act like it was running out of gas. Anything past 5,000 rpms it would start to fall on it's face. Pull the clutch in and it revs freely. I only had 90 miles on the tank and no low fuel light yet. It was pretty dusty on the 2 forks we did make, but I can't imagine that the filter was that plugged? If the fuel pump starts to go, would this be a common scenario...where it appears to be fuel starved, but only under load?

    Where should I start? :deal
    #1
  2. ciedema

    ciedema мотоциклист

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    On the road! Finally!
    Fuel filter, not pump is a good starting place.
    #2
  3. Zuber

    Zuber Zoob

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    Classic symptom of a clogging fuel filter. The RPM's will continue to drop as it gets more and more clogged. If it dies, you can just let it sit for a while and it will run again, for a while. This is not good for the pump.

    The fuel filter on the 07-08 bikes was a little small. KTM increased the 'tea bag' pre-filter and the main filter glue was fixed. I've seen these fall apart after they dried out. Get a filter and the two o-rings. Not cheap, bou probably won't need to do it again for 40k miles.
    #3
  4. MAXVERT

    MAXVERT OG on da OC

    Joined:
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    Sun Valley Idaho, Baja Arizona
    I've got well over a hundred thousand miles on the 990's
    and the fuel pumps failing IMHO is a rare occurrence.
    Much over hyoed on this forum by those that fail to perform
    the routine maintenance on the fuel filters.
    Or continually run the fuel so low that the pumps over heat.
    They are liquid cooled.

    Have you ever changed them?
    Do that first.

    Max
    #4
  5. 4corners14

    4corners14 Been here awhile

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    Seattle
    .....hope that's all it is!
    #5
  6. dirtdiver

    dirtdiver Long timer

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    My 2008 (at 20K miles)would run fine then every once in a while when I jumped on the throttle it would sag bad. No power, the revs dropped, etc... If I kept real easy on the throttle then no issues.

    Then the problem went away.

    A month and a thousand miles later the bike was running great. Then all of a sudden it just died. Nothing would bring it back. it left me and Mrs DD high a dry in Mexico. We had to hitch rides/taxi/bus/friends out of Mexico. You have not lived till you have yourself + your 50y/o wife in riding gear and boots and backpacks trooping through Mexico trying to get to the border. Sweating the whole way. I am pretty sure she had never ridden a greyhound bus prior to that.:lol3

    Until you figure it out I would be always worried about the fuel pump leaving you with no recourse but to walk.

    DD
    #6
  7. FakeName

    FakeName Wile E Coyote SuperGenius

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    So what caused it?
    #7
  8. gefr

    gefr Life is a trip

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    #8
  9. DSM8

    DSM8 Where fun goes to die....

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    #9
  10. FakeName

    FakeName Wile E Coyote SuperGenius

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    It does, and thank you.
    #10
  11. 990west

    990west Adventurer

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    May 4, 2013
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    the stock filter and o-ring package prices from KTM will make your eyes water. I am waiting on parts right now for my 2011. Only 2000 miles so I can only think I got one hell of a dirty load of fuel on the last fill up. Symptoms exactly like yours. First time I have needed to get a tow truck home on any bike I have owned so I guess I have been lucky.
    #11
  12. DSM8

    DSM8 Where fun goes to die....

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    Check out the link from Gefr he has sourced an economical replacement to the stock stuff worth checking out.
    #12
  13. 990west

    990west Adventurer

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    I have one on order with Gefr as well. Unfortunately I had it ordered from the dealer before discovering him but at least I will have a spare.
    #13
  14. dirtdiver

    dirtdiver Long timer

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    The filter looked OK. It was the fuel pump.

    DD
    #14
  15. dirtdiver

    dirtdiver Long timer

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    I have heard that heat can kill the fuel pump. Some say that if you like to run your tanks low then the pump will not get the cooling it needs and it will have a shorter life.

    So, in my case the fuel pump did fail. I like to run my tanks down to near when the light comes on +- 10 miles. The particular trip it actually failed I had just run my tanks down to the fuel light plus another 10 miles. I filled up and then about 5 miles later the pump stopped pumping. It was also a hot ride that day in Baja with high speed (80-90 mph) highway run of about 150 miles before it died.

    I dont do anything different now but I can tell you it was a PITA, breaking down south of the border with no other people (with us) and my wife on the back. She is a good sport but it added to the anxiety of the whole situation.

    DD
    #15
  16. EastSideSM

    EastSideSM Isn't that dangerous?

    Joined:
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    Definitely sounds like when my fuel pumps have quit. The points start to go and it gets worse and is intermittent until it finally gives up the ghost. Mine have lasted about 20,000 miles, I am on my third one right now. If I were to go on a trip I would keep a spare with me. Which reminds me I should order one soon to have on hand.
    #16
  17. 4corners14

    4corners14 Been here awhile

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    Seattle
    .....finally found the time to replace the filters. Thanks GEFR! Have another set of filters as spare to bring along and picked up a couple of GEFR's fuel pumps as well. Starting a 3700 mile loop from Seattle on the 30th, N to S on the UTBDR followed by a S to N on the COBDR with a couple of nights in Steamboat Springs at the KTM Rally. Hoping that the filters were the issue. I've been running it around the neighborhood with no problems. Sure wouldn't want to do that replacement out in the middle of the desert....my floor jacks to damn heavy to pack with me.

    Thanks for the help guys! :freaky
    #17
  18. shawty950

    shawty950 Been here awhile

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    Location:
    Brisbane Australia
    2 years ago I was on a 5000k round trip and got to the point where the bike would not do 100kph(56mph).
    We ended up camping for the night on the side of the road on a cattle property...pulled the left tank off and pulled the pump...the pre-filter was blocked....cut the filter media off and fashioned a new pre-filter from an air filter skin. It's still in the bike.
    Here's the campsite
    [​IMG]

    The making of a pre-filter(this was taken at home a week or so later when checking the temp fix)
    [​IMG]
    [​IMG]
    [​IMG]

    I now have some new Gefr filters waiting to go in....but will keep my "temp" fix in the toolkit for "just in case" :evil
    #18