viola-tor's MPG problem thread

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by viola-tor, Mar 12, 2012.

  1. grinns

    grinns Semper Fi

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    May 4, 2010
    Oddometer:
    1,331
    Location:
    Rainy, Wa
    I don't know if someone answered this yet, but the sensors probably have a reference voltage coming out of the ECU and it might be shared. From my dealings with my bike if a sensor or something is screwy it seems to run super rich and mileage drops in the 20's. (when I had Map sensor problems)

    First I would check the what the reference should be and what the reference voltage is at the sensor. If this is wrong I would disconnect the sensors then test it at the ECU.

    If its right at the ECU, I would start looking into the wiring. Ktm's wiring is so ugly it wouldn't surprise me if you had a short or partial short somewhere.
  2. Roeligan

    Roeligan Belgium power!!!

    Joined:
    Aug 9, 2005
    Oddometer:
    543
    Location:
    Belgium
    And they still can fail due to heavy rain (don't ask how I know :cry)
  3. viola-tor

    viola-tor Needs to ride!

    Joined:
    Feb 27, 2008
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    2,071
    Location:
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    It's starting to seem that a wiring/connector could very well be the culprit. This all started after I did the Canni/Flappi and put it back together. Makes sense to me... I'll dig in again and give a slight twist to every connecter pin I can find and use the contact cleaner William has recommended (ordering it now).

    Good thing I love this bike! :huh

    And I must add: The crashbar and bashplate stud mods are SOOO nice if you have to tear into your bike on a regular basis. :deal
  4. Geek

    Geek oot & aboot

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    Oddometer:
    32,124
    Location:
    8000ft.
    Diek: hate to see you having these problems brother: I might know where you can find a set of carbs if you finally decide you just want to be done with it. :(:

    While you are cleaning all of the connectors throw some dielectric grease on them too. :deal
  5. grinns

    grinns Semper Fi

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    I have almost gone to carbs a few times. :rofl Sadly I carry an extra 500 dollar fuel pump and filters. :evil
  6. WilliamSven

    WilliamSven samobilemechanic.com

    Joined:
    Sep 20, 2012
    Oddometer:
    24
    as a mechanic that is a specialist in fuel injection.. . .

    I am highly, far and beyond offended that someone would do such a thing to a fine EFI bike.

    the ONLY type of conversions I would not find offensive - a diesel motor swap, and can only be done on some other types of bikes, and really only practical if frame is free and gas motor is blown,

    Or buying & building a microsquirt, and using stock KTM injectors, or more dynamic lb flow ones, and using bits and pieces of ends of the ktm wiring plus to interface to the microsquirt.

    carbs on a 990 ?? .....stone knives and bear skins ..wash your mouth out with ethanol

    .. the other day, YESTERDAY, I worked on an australian made 1991 mercury capri turbo...rare kinfolk to a cosworth escort... owner got quoted like $1600 for new distributor & main computer. ( not my quote )

    I had a 1-on-1 with the old performance coupe, 45-60 min in ..some no ox and a slight 5 degree twist on the hall effect sensor wires way inside the distributor, what could also be called an ignition module or pickup sensor,... and bang zoom.. the tach test wire started throwing signal again. (cap n rotor still off ) ...then back together and it was up to full power again. . The hall sensor wasnt my first guess... I no ox'd the ecm contacts and cam sensor, to no result.

  7. viola-tor

    viola-tor Needs to ride!

    Joined:
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    I have a date with the garage today, going to tackle as many electrical connectors as I can get my hands on to clean with Deoxit, and give the pins all a slight twist.

    Any tips/thoughts about servicing the rubber O-rings on the connectors? Q-tip and alcohol? Simple Green? Then light grease or oil?


    And another question: Is the "Air Inlet Temp Sensor" that is reading as an error code the same as the "Ambient Air Temp Sensor" that is listed in the Microfiche? If so, it's only $16, so that'd be easy/cheap to replace.


    Diek
  8. Katoom119

    Katoom119 Mmmm....Orange Kool-aid

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    I would imagine so because I can't think of any other reason why the ECU would want to know the temperature of the outside air. It would have to know this to match the A/F ratio to either cold, dense air or hot, not-as-dense air.

    Wheeler said it sounded like a sensor went bad. It would make sense that if that sensor went bad the ECU would default to dumping in more fuel as a limp-home mode instead of leaning it out to the point where it might not even run....

    Do you realize that if this is the problem you've spent how much time/effort/$$$ in extra gas for a $16 part? I'd almost have that damn thing overnighted.
  9. viola-tor

    viola-tor Needs to ride!

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    And what is the part number for the TPS? I don't see it listed as such...


    [​IMG]




    ORDER
    QTY
    REF.
    NO.
    PART NO.
    THROTTLE BODY
    DESCRIPTION
    990 ADVENTURE
    ORANGE
    RETAIL
    PRICE EACH
    KTM Twins
    PRICE EACH

    1
    61041001000
    THROTTLE BODY CPL.
    1
    $1,053.99
    $1,053.99

    50
    61041040000
    INTAKE TRUMPET
    2
    $7.99
    $7.99

    60
    61041085100
    PRESSURE SENSOR
    3
    $117.49
    $117.49

    61
    61041085150
    RUBBER SUPP. PRESSURE SENS.
    3
    $4.99
    $4.99

    63
    57013070100
    PVC-CLAMP 7,9 MM HEYCO 3355
    1
    $0.99
    $0.99

    64
    61041085060
    SUPPORT PRESSURE SENSOR
    1
    $4.99
    $4.99

    65
    0016050121
    SCREW FOR PLASTIC 50X12
    2
    $0.49
    $0.49

    66
    61041080000
    AMBIENT-AIR TEMPERATURE SENSOR
    1
    $15.99
    $15.99

    67
    0081500181
    SCREW FOR PLASTIC D=5X18
    2
    $0.99
    $0.99

    68
    61041088000
    ROLLOVER SENSOR
    1
    $43.99
    $43.99

    69
    61041088050
    SHIM 4,3X15X1,25MM GALVANIZED
    2
    $0.99
    $0.99

    70
    0985040203
    FLAT HEAD SCREW DIN7985-M 4X20
    2
    $0.49
    $0.49

    71
    61036023100
    VACUUM CONECTION
    2
    $10.49
    $10.49

    72
    61041095050
    HOSE 3,2X8,5 L=50 MM
    1
    $2.49
    $2.49

    73
    60141095125
    HOSE 3,2X8,5 L=125 MM 06
    2
    $3.49
    $3.49
  10. Unkgd

    Unkgd Been here awhile

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    Oddometer:
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    Diek,
    I would use silicone grease on the rubber O-rings rather than light grease or oil. Depending on the rubber compound (which appears to be very soft) petroleum based oil or grease may attack the rubber. Silicone (Dow Corning or Parker O ring) is generally very benign with most rubber/synthetic materials.
  11. Gustavo.Ramos

    Gustavo.Ramos Been here awhile

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    Accross the pond
  12. viola-tor

    viola-tor Needs to ride!

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    Update:

    Bike is STILL down, trying to patiently move forward. It's killing me, but have no choice. Gorgeous fall weather in Texas...

    A mechanically minded friend came over today, gave a lesson in diagnosing the wiring harness, which we found to be okay (relating to the TPS and temp sensors, which are operating fine). Air temp sensor was also tested using heat-gun, it is working.

    His educated guess is that the FUEL PUMP may actually be the issue, specifically the pressure regulator which is at the top of the fuel pump "tower." The hypothesis being that if there is a piece of crud in there that it could be stuck open and is screwing with the fuel pressure, thusly dumping fuel in, creating all the errors. Still don't know why I'm getting an air temp sensor error code...

    The pressure regulator looks like it can be removed (but not taken apart as far as I can tell), but is not offered for sale as a separate component. Entire fuel pump assembly is $500. Anyone know of a drop-in compatible regulator? :ear:ear:ear:ear:ear

    Need to source the two large o-rings that mate the pump to the gas tanks too, one of them is shredded and KTM wants $47 each!!!! :huh:huh:huh:huh:huh Anyone have a connection on those with specific sizes?

    Thoughts? :ear:ear:ear:ear:ear:ear


    We are going to hook it all back up and do a fuel pressure test with the bike running, but don't know when. I guess I need o-rings and need a few other bits to make that happen.
  13. bikyto

    bikyto Dans le doute...gaz!

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    2,199
    Location:
    Northern Cali
    The oring:
    1201T321 MIL-Spec Viton(R) Fluoroelastomer O-Ring, AS568A Dash Number 932, Packs of 10
    From mcmaster online

    It's $14 for 10. This is the upper one. I doubt you'll have to change the lower one. I've never had to.

    My spare pump isn't available at this time or i would have sent it to you.
  14. viola-tor

    viola-tor Needs to ride!

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    You are a boss! :clap
  15. bikyto

    bikyto Dans le doute...gaz!

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    Craig at CJ designs stocks them too. Upper and lower I believe. :)
  16. KTMADV

    KTMADV Hammer Down

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    Sep 16, 2012
    Oddometer:
    179
    Location:
    Willows Ca
    Put the carbs on and be done with it. Its very easy and your bike will run great and smother.
    I just put carbs on my 2007 ktm 990 adventure and thats the best thing for the bike.
  17. viola-tor

    viola-tor Needs to ride!

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    That's not off the table. How involved is it? Pretty much plug-n-play?

    Which carbs? From a 950, or some exotic?
  18. AdvGa

    AdvGa Long timer

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  19. viola-tor

    viola-tor Needs to ride!

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  20. AdvGa

    AdvGa Long timer

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    Hope you get things worked out.

    The cost is pretty substantial to do a Carb conversion for most... thought you might like to know the facts.