KTM 690e fuel pump (FI) issues

Discussion in 'Thumpers' started by DirtJack, Nov 29, 2010.

  1. Uller

    Uller Long timer

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    LukasM,

    I originally had the Can-Am quad filter. It is close to $18.00 and isn't an on the shelf part at dealers around here.

    Bobzilla cross referenced the part number and came up with the Napa 3095. It is around $3 and has the same specs.
  2. Ontario GS

    Ontario GS Budding Adv. Traveler

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    Peterborough, ON, CA
    I phoned Edelbrock's Tech Support today and they advised that the finest filter screen available is 40 microns. I questioned whether this would meet the particulate size a fuel injector would withstand and he advised it would be fine. I may phone KTM and pose the question to them or even a filter manufacturer if I have time.
  3. off-road-biker

    off-road-biker test pilot and curve junkie

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    @Uller

    Would you please re-upload the missing pics from Post #96 again?:clap
  4. slidefighter

    slidefighter Gather it up, keep on...

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    +1 please?
  5. Uller

    Uller Long timer

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    Crap, photobucket did it again......

    Sorry, I didn't change or move anything. I'll try to get them posted back up this week some time.
  6. Velociraptor

    Velociraptor TrackBum

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    Possibly already answered but I took an old one off my bike and cut it apart and it is a paper filter inside.
  7. shipwrek12001

    shipwrek12001 Shipwrek

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    4 long and one short code.... already chged the fuel pump... w/ ca cycle pump...

    failed last fall no codes, I'm sure someone has the video for that..:huh failed in my drive way a month or more ago setting the 4L1S code, chged the fuel pump... had a grnd failure a week ago, fixed that easily, then failed again yesterday 4L1S code again.... wtf........................:huh

    no sound from the fuel pump to be heard..........



    ideas?
  8. DirtJack

    DirtJack Adventurer

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    4 long and 1 short is "Fault/short-circuit in fuel pump control circuit". Since this has occurred with more than one fuel pump, it may be independent of the fuel pump itself. Looking at the wiring diagram, it looks like one way a short could be detected is that the ECU is monitoring current flow in fuel pump power line for safety reasons. Another way is that the ECU contains a resettable circuit breaker. I would check wiring in the fuel tank for possibility of shorts. I would also check the continuity of the ground wire (black-blue) to a ground elsewhere on the wiring harness. Of course, it is possible that you have had a short in more than one fuel pump. :huh
  9. shipwrek12001

    shipwrek12001 Shipwrek

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    I pulled it all apart last night........

    or it could be self abuse by ty wrapping the fpump wires too tight and the wires popping off the pump leaving me on the side of the highway...:huh ..........

    self abuse is just the best... no one else to blame... except the guy that was with me at the time, yep i'll blame him..:lol3

    so, it is back together and running...:clap

    I did think that about the wires to the tank, i pulled the battery and tray to see if anything... I did find that that wire was pinched under the battery tray, but that wasn't the fault... it was a future fault though...

    thanks to bk.rd.rnr and dirtjack for their input on possible causes... this place would be a pile of blah blah if it wasn't for people like you guys trying to help people you never met...:freaky

    thanks again
  10. Ontario GS

    Ontario GS Budding Adv. Traveler

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    Sean

    When I wrap tied my wires I happened to notice that it pulled the connectors almost apart at the pump. Cut the ties off, crimped the connectors tighter & started again. All seems fine since.
  11. shipwrek12001

    shipwrek12001 Shipwrek

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    hey John....


    I'd realy love to have a conversation with the engineer who designed the fuel system on these bikes.. the spade connection seems very fragile on a dirtbike. I did pinch the connection to make it tighter, but really,, why would anyone need to do that, this day and age of technology... a sound system speaker has a better connection....:huh and it doesn't go bouncing through the trails...:evil

    a tiny spade tip,, in a pain in the ass spot,, holding your bike together to run... seems way wrong to me...

    oh well... plan to ride for the rest of the week to work... it will be fine.. right? how many miles do you need to put in, on the road,, before the trust comes back?..... dirt riding, out of the question for now!:huh
  12. milzispete

    milzispete who did what where?

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    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

    :eek:
  13. Velociraptor

    Velociraptor TrackBum

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    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.
  14. DirtJack

    DirtJack Adventurer

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    +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.
  15. Uller

    Uller Long timer

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    To make this a little easier and bring it to the top, I'm going to quote myself and edit the original How-To. As I had mentioned before, I have changed how I am doing things since I wrote the original one and the pictures I have been asked to add back aren't really a good representation of that.

    I tried to find the pictures in both my computer and hard drive though and can't seem to find them. (Oh, and I have to apologize to Photobucket. The didn't loose my pics. These ones were at Dropshots)

    Sorry Guys. Next time I have to go inside the tank (should be a while though....) I'll take new pictures.

  16. TheMuffinMan

    TheMuffinMan Forest Ranger Magnet

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    The wiki could be updated :deal

    No worries if not.
  17. COracer

    COracer Adventurer

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    Bought my bike with 1,200 miles on it, replaced fuel pump in first 400 miles I had it with CA Cycleworks pump to remedy stalling issues. OE pump would do the restart after waiting a while, but I wanted the bike to run right all the time and not leave me stranded.

    Installed Napa filter with CA Cycleworks pump, also Rally Raid gas cap and did a full cannisterectomy. Rode for 1,200 miles without issues then one day the bike died on the trail and would not start even after hours and had to be towed home. Few days later go to the garage to diagnose, fires right up. Loaded new FI maps per the Bartron thread, I ride for a few miles and all seems better than ever, no spitting, surging or stalling. Next day bike won't fire, fuel pump does not prime when key is on. Took tank apart and checked connections, pump still doesn't prime at all.

    Replacing with a Felco pump this week, has anyone else had this many issues with their 690 FI? I have little trust in it now which really ruins the ride for me. Could it be the pressure regulator or the ECU? I haven't drilled the holes in the pump housing yet to keep it cooler, am I missing anything else?
  18. COracer

    COracer Adventurer

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    Sorry, forgot also TuneECU shows a code P1231, open short to ground for the fuel pump...cleared code and still no pump operation and it sets code again immediately.
  19. Kirkster

    Kirkster Parts Murderer

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    :jack
  20. DirtJack

    DirtJack Adventurer

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    Sounds like a short somewhere in the fuel pump power circuit.