16 ktm 250f kinked gas line fix??

ktm-5
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ktm-5 5/1/2018 8:53pm
5/1/2018 8:53pm Edited Date/Time 5/1/2018 8:54pm
Also this is the style clamp I plan on using
lumpy790
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lumpy790 5/2/2018 2:13pm
5/2/2018 2:13pm
Do you have the special tool to crimp them?
ktm-5
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ktm-5 5/2/2018 2:15pm
5/2/2018 2:15pm
lumpy790 wrote:
Do you have the special tool to crimp them?
Yes I do
ktm-5
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ktm-5 5/3/2018 2:23pm
5/3/2018 2:23pm Edited Date/Time 5/3/2018 2:29pm


Any idea if this fuel line will work? I got it from advanced auto, they didn't have gates brand or the golan filter. Or is it best to go to orileys and get the other brand? Cq5035 is what they said was part number by auto quest I believe

The Shop

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Byron909
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Byron909 5/3/2018 2:28pm
5/3/2018 2:28pm
No man. It has to be SUBMERSIBLE rated hose. What you have there, the inside and outside are not the same.
I doubt anyone stocks it. Order online.
ktm-5
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ktm-5 5/3/2018 2:31pm
5/3/2018 2:31pm Edited Date/Time 5/3/2018 2:42pm
Oh man...lol OK I will do that. They told it was submersible because I told them that's what's I needed...lol Do u think it will work outside the tank to eliminate the qd and hose? And when I order thus stuff is 5/16 the same as in the tank and out? For hose and filter?
Byron909
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Byron909 5/3/2018 3:12pm
5/3/2018 3:12pm
Yes will work outside. Any good fuel injection hose is fine.
The in tank is like 7mm, but yes 5/16 work fine inside.
ktm-5
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ktm-5 5/3/2018 3:21pm
5/3/2018 3:21pm
Byron909 wrote:
Yes will work outside. Any good fuel injection hose is fine.
The in tank is like 7mm, but yes 5/16 work fine inside.
OK thank u I truly appreciate all of the help
ktm-5
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ktm-5 5/3/2018 4:40pm
5/3/2018 4:40pm Edited Date/Time 5/3/2018 4:43pm
Byron909, does it matter which filter I get? I see they have 2 different styles long or short any suggestion? Are these servicable?
Byron909
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Byron909 5/3/2018 4:52pm
5/3/2018 4:52pm
Gave you the part number..
You want the mini( on right) in 5/16 barb
ktm-5
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ktm-5 5/18/2018 12:23pm
5/18/2018 12:23pm
Alright got my kinked fuel line fixed, thanks a ton byron909.
2
CarlinoJoeVideo
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CarlinoJoeVideo 5/18/2018 7:07pm
5/18/2018 7:07pm
That mini filter looks great!
ktm-5
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ktm-5 5/18/2018 7:09pm
5/18/2018 7:09pm
Thanks, I thought it turned out pretty good
Pgd09yz450 5/19/2018 3:45am
5/19/2018 3:45am
ktm-5 wrote:
OK thank u I'll call my local dealer tomorrow
CarlinoJoeVideo wrote:
The fixed fuel pump I got actually has a longer hose believe it or not. They said the long hose gave it more room to bend...
The fixed fuel pump I got actually has a longer hose believe it or not. They said the long hose gave it more room to bend instead of just kinking. I donno, still doesn’t make sense to me... hahaha

Mine original pump hose was kinked but worked fine as well, I swapped it out to be safe. Kinda a sketchy ya know!
CarlinoJoeVideo wrote:
Maybe I retract my statement. I found a photo and maybe the unkinked one is shorter? [img]https://p.vitalmx.com/photos/forums/2018/04/09/254585/s1200_97F814C5_8D3B_4A03_807B_3B1639C3A2A8.jpg[/img] The only downside of doing it yourself is making...
Maybe I retract my statement. I found a photo and maybe the unkinked one is shorter?

The only downside of doing it yourself is making sure the hose is clamped and won’t ever come loose. Maybe use the same type of hose clamps as the factory?
How was the fuel pump to replace, any tips I have to do mine soon
CarlinoJoeVideo
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CarlinoJoeVideo 5/19/2018 7:21am
5/19/2018 7:21am
It’s not hard. I used safety wire to pull it through the tank.
Ctone23
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Ctone23 8/20/2019 5:48am
8/20/2019 5:48am Edited Date/Time 8/20/2019 6:00am
I'm so glad I found this thread, thank you Byron and ktm-5! If you happen to see this, or anyone else, what kind of fuel cap sock did you use? I don't see any on motosport that fit my 2015 Husky FC 350

EDIT: Nevermind I found a fuel sock from Twin Air. I ordered the parts and will give it a go tomorrow. I'm not super clear on how long the hoses should be on the inside and outside but I ordered 3 of the hoses so hopefully that is enough. Cheers!
Byron909
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Byron909 8/20/2019 6:20am
8/20/2019 6:20am
No sweat! Thanks
Yeah i use twin air socks. Never a issue on both tank styles, 1/4 turn and screw cap styles.
The inside line from pump to regulator isnt that long. I never measure/d, but id guess around 8 inches. Outside not much at all. Maybe two sections a few inches each roughly. Maybe from filter to injector hair longer depending on your model.
A buddy has a 350xcf with like 250 hours on it now. We did this stuff when new. Hes replaced about everything on engine, but
Never a fuel issue once.
Ctone23
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Ctone23 8/20/2019 7:16am
8/20/2019 7:16am
Byron909 wrote:
No sweat! Thanks Yeah i use twin air socks. Never a issue on both tank styles, 1/4 turn and screw cap styles. The inside line from...
No sweat! Thanks
Yeah i use twin air socks. Never a issue on both tank styles, 1/4 turn and screw cap styles.
The inside line from pump to regulator isnt that long. I never measure/d, but id guess around 8 inches. Outside not much at all. Maybe two sections a few inches each roughly. Maybe from filter to injector hair longer depending on your model.
A buddy has a 350xcf with like 250 hours on it now. We did this stuff when new. Hes replaced about everything on engine, but
Never a fuel issue once.
That's good to hear. My bike sat for a while and won't start so i'm working to get everything sorted out. I will post pics of the before / after and report if my bike starts up. Hoping the upgraded fuel line / filter and a new spark plug will get her started up.

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Ctone23
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Ctone23 8/22/2019 5:44am
8/22/2019 5:44am
Welp, got the kink fixed but my bike still won't start. Here's the timeline if anyone has any suggestions:

1. Got bike out of storage, pumped what I "thought" was all of the old gas out of the tank, turns out the pump I used to get the gas out could not reach the bottom of the tank, so I unknowingly attempted starting the bike with old gas mixed with new.. YIKES
2. Replaced Air filter
3. Replaced all of the fuel filters (inline and fuel pump filters)
4. Replaced kinked hose in fuel pump assembly (seems somewhat common on this model)
5. Replaced spark plug
6. Checked wiring and saw not spots rubbing, no tears, main fuse looked fine.
7. Bike will turn over and push out air but wont start
8. Inline fuel line doesn't have a lot of pressure (indicating a clogged injector) when I disconnect it, and seems like normal flow.


Byron909
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Byron909 8/22/2019 7:46am
8/22/2019 7:46am
Does it have spark?
If it does not, unplug one of the kill switch wires and try again.
If it it still does not have spark after that, you might look into the condenser.
Ctone23
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Ctone23 8/22/2019 7:54am
8/22/2019 7:54am
I put a new plug in the bike but I haven't checked for spark. I'll try your suggestions and see what happens.
charlie68
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charlie68 8/22/2019 9:03am
8/22/2019 9:03am
If your bike was stored for a while and the gas went bad, I would clean or replace the injector.
Ctone23
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Ctone23 8/22/2019 9:09am
8/22/2019 9:09am
charlie68 wrote:
If your bike was stored for a while and the gas went bad, I would clean or replace the injector.
Thanks, do you know if a 12v will open up the injector or does it have to be a 9v?
T-Fish
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T-Fish 8/22/2019 11:02am
8/22/2019 11:02am
I’m either blind or I missed something, but I don’t see anything saying you’ve ruled out the pump itself or the relay.
Ctone23
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Ctone23 8/22/2019 11:56am
8/22/2019 11:56am
T-Fish wrote:
I’m either blind or I missed something, but I don’t see anything saying you’ve ruled out the pump itself or the relay.
I would like to definitively say that pump is or is not the problem. The manual was no help at all, I've watched a lot of videos and sort of self diagnosed that my pump is still working. When I disconnect the line, gas comes out, it doesn't spew out which would indicate a clog in the injector, but I don't have a way to test if the line has 50 psi or whatever the correct number is. I'm not even sure where the relay is, or what to look for.

Being a noob is tough sometimes lol. I need to find a full service manual like I have for my Suzi RMZ 250, makes things a lot easier.
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T-Fish 8/22/2019 3:57pm
8/22/2019 3:57pm
Ctone23 wrote:
I would like to definitively say that pump is or is not the problem. The manual was no help at all, I've watched a lot of...
I would like to definitively say that pump is or is not the problem. The manual was no help at all, I've watched a lot of videos and sort of self diagnosed that my pump is still working. When I disconnect the line, gas comes out, it doesn't spew out which would indicate a clog in the injector, but I don't have a way to test if the line has 50 psi or whatever the correct number is. I'm not even sure where the relay is, or what to look for.

Being a noob is tough sometimes lol. I need to find a full service manual like I have for my Suzi RMZ 250, makes things a lot easier.
I just sent you a PM.
1
Ctone23
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Ctone23 8/22/2019 6:47pm
8/22/2019 6:47pm


Video of my bike attempting to start for anyone interested
Aventador
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Aventador 12/21/2020 7:43pm
12/21/2020 7:43pm
Did this turn out to be fuel pump pressure regulator?
lumpy790
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lumpy790 12/29/2020 8:28pm
12/29/2020 8:28pm
ktm-5 wrote:
I think I got it fixed [img]https://p.vitalmx.com/photos/forums/2018/04/15/255765/s1200_20180415_183839.jpg[/img]
I think I got it fixed



My Poly hose test failed.

Aventador
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Aventador 12/30/2020 2:04pm
12/30/2020 2:04pm
I suppose I should post my experience here for future reference. The bike cut out coming into a 3rd gear corner on the track. Then I carried on riding and it seemed fine for the rest of the day. I went to another track and the bike cut out 2 or 3 times. I thought it was an electrical problem so I took all the connectors apart and sprayed with WD to get the water out. Ran the bike for the rest of the day and it seemed fine. Then I went for another ride and as soon as I got the bike out on the track it would barely run, just kept stalling and I got 1/2 a lap in.
I took the bike home suspecting a fuel problem. I took the pump out and the pipe was kinked. I replaced the fuel filter and heated the pipe up with a heat gun to remove the kink. Still stalling. Took the plastic pipe off and replaced with rubber, still stalling. Replaced the fuel pump pressure regulator, and still stalling. I then removed the filter and put a pipe on it all the way, still stalling.
I replaced the pump and it fixed the problem!
I took the bike to the track, ran it for 3 sessions no issues then the bike started sputtering and wouldn't run. I took the fuel pump out and the outlet pipe had come off the pump. Problem is the outlet is shorter than the original KTM pump and the rubber EFI hose couldn't get a decent grip on it, too much flex, even though it was clamped tight with EFI style screw clamps. I replaced the rubber pipe for plastic and used the proper ear/o clamps and problem solved.

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