Hey everyone,
Drove 1.5 hours to ride yesterday, and when I got there, my bike wouldn't start. Made the dumb mistake of not starting my bike before making the drive. I started the bike a month ago to make sure things were good and let the battery charge since it had been sitting a while for winter. While I was there I tried swapping the gas, checked the kill switch wiring, choke on/off, etc. Bike wouldn't fire. Fuel pump fuse under seat was blown so I replaced it, and it blew again immediately. After that happened I put another fuse in with the pump unplugged to see if the fuse would pop without the fuel pump on the circuit, and the fuse was fine. Seems like my fuel pump just died randomly with no symptoms or signs. Is this common with these new KTM fuel pumps? My bike has 70 hrs on it. Starting to wish I just waited for a yz250fx since I've never had this problem before. I'm going to clean my tank before I put the new pump on and install the sock fill filter. Hoping I won't have this problem again.
Thanks for any info
I know a ton of guys with these generation bikes and I haven't heard of any fuel pump issues. I would just chock it up to a bad pump of maybe a piece of trash got by some of the filters or something.
Regarding the 250FX I have two riding buddies with 2025s and on two separate occasions they have had issues, one with a bad map switch causing it go into a sort of limp mode and the other with a seemingly fine battery that would let it turn over but not fire a new battery fixed it but still.
Thanks for the response.. I've read if it's not the pump it could be the voltage regulator, wiring harness, or bad ground. I'm going to replace the pump, but if that doesn't fix it, I'm just going to take it to a shop so I can stop throwing parts at it. It's weird to me that it ran fine a month ago and now won't start. Fuel pump fuse keeps blowing, and I can't hear the pump prime, so I'm hoping it's the pump and not something electrical or wire harness related.
On the off road models, it is easy to run the pump dry since the pickup does not go all the way down in the low sump of the tank. This is a known issue. Running fuel pumps dry is not ideal for them. Have you ran the tank very low many times?
It sounds like either a short in the harness or in the pump. You could ohm out the pump positive and negative pins and see if it is open or shorted.
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Thanks, I'm going to test this today. Really hoping the harness isn't shorted because that doesn't give me a lot of hope for future reliability.
I haven't ran the tank low, but I've let the bike idle quite a bit to get the oil temp up before riding. If the fuel pump is what the issue is, I'm not going to let it idle more than a couple mins in the future.
The harness might be pinched somewhere. If you find and fix that you should be good going forward.
Thats really only an issue for the dual sport guys that are riding fire roads or pavement all the time. If you are riding offroad it splashes up and onto the fuel pump pickup area easily.
I have ran my XC down to the fuel light coming on and only had maybe an inch or two of gas on each of the wings on the bottom side and still didn't have any fueling issues with cutting out or anything.
I'll take another look at it if the fuel pump doesn't fix the issue. The fuse didn't blow with the pump unplugged, so it seems like that is the most likely issue right now. I just have some anxiety about it since the bike wouldn't start after running a month ago and no prior problems/symptoms. I'll update once I have some more time to look at it. Going to use the downtown to clean the fuel tank and get any dirt out of it.
Cleaned the tank, changed the fuel line filter, replaced the fuel pump, and added fresh fuel tonight. Bike stopped blowing the fuel pump fuse and started up. I let it idle to warm up and gave it a few revs to clean anything out then it died. I realized if you let the bike idle too long the pump will dry up and it’ll die. Shook the bike around to get the fuel pump wet again and it fired back up. So I think it’s good to go for now. Still a little scared it’s gonna die on me randomly again, but hopefully it’s good to go now.
Don’t let your bike idle too long with the new fuel pump style I guess
Going to change the spark plug and check the boot for cracks while the tank is still unbolted tomorrow since that seems to be another common cause for idling issues. Once it’s back together, I’ll ride it around the block and see what happens. Has anyone else had any issues with idling for longer periods of time? I’ve been checking the current 350 idling thread too.
Four strokes will often overheat if they idle too long unless you have a fan. Put more gas in it to keep the pump submerged if you want to idle a long time. Going from blowing a fuse to not makes me think you found the issue.
Yeah that was me. I did a whole bunch of shit and it ended up being the fuel pump. I had got a replacement pump but not a whole module and it worked for like a day and a half. I haven't ridden the bike for a long ride yet but I think its fixed.
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