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mikejones202 mikejones202
12/28/2018 9:35 AM

Here's what happened:

The bike has 43 hours on it. A few months ago the bike would not start and turned out the connector for the electric start button got water in it and the connector corroded. Replaced the starter relay and wired the main wiring harness directly to the starter button. Problem solved.

This past week while riding, the bike just randomly shut off in a corner and would not restart. We tried a new battery and it started, then put it in gear and it just shut off again and would not start back up. You can hear the fuel pump turn on, but nothing after that. I am not sure where to even start.

Someone told me it could be the fuel filter that is clogged, so I will start with that tonight.

Any other suggestions? Not very strong when it comes to electrical

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kb228 kb228
12/28/2018 10:08 AM

Does it start when its in neutral and then dies in gear - every time? Or does the starter not even turn over?

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Paul_Pitzonka Paul_Pitzonka
12/28/2018 10:18 AM

first I would check to make sure you’re getting a nice strong spark... if you are then I would lead towards checking the fuel delivery system.. possibly a clogged filter, also may be a weak fuel pump or plugged/ dirty injector... my bet is on the pump I have seen several KTMs with no start issue caused by a weak pump... check inline pressure that will give you a good indication of the condition of the fuel system... if the pressure checks correctly check the injector spray pattern have also seen the o-rings on the fuel rail deteriorate and plug injectors...

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Paul_Pitzonka Paul_Pitzonka
12/28/2018 10:31 AM
kb228 wrote:

Does it start when its in ...more

This is a good question does it still turn over? If not disregard my advice your problem is else where...

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mikejones202 mikejones202
12/28/2018 11:42 AM
kb228 wrote:

Does it start when its in ...more

It did the last time it started, now it wont even turn over. You just hear the starter relay clicking and thats it. Wont fire up.

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kb228 kb228
12/28/2018 1:14 PM

Try another battery

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mikejones202 mikejones202
12/28/2018 1:44 PM
kb228 wrote:

Try another battery

That is the plan. Thanks for the help so far. Will update later.

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mikejones202 mikejones202
12/29/2018 9:19 AM

Tried a new battery and replaced the in line fuel filter. Noticed fuel pump did not turn on when warming up the battery, she started but as soon as you give it gas it shuts off. Trying a different tank today from a buddies bike and I think it may be the fuel pump that is shot. Any suggestions?

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MX915 MX915
12/29/2018 9:51 AM

If the pump isnt turning on try replacing the small relay in the airbox, not the larger starter relay.

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mikejones202 mikejones202
12/29/2018 11:04 AM

Swapped tanks and bike starts and runs fine. Ordering a new fuel pump today

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aees aees
12/29/2018 2:24 PM
mikejones202 wrote:

Swapped tanks and bike ...more

Hold it, there is a big chance it is not the actual fuel pump, but one of the tubes of the fuel filter in the tank that is leaking (so it loses pressure when you hit the throttle). Quiet much cheaper to replace those with 3rd part then the complete fuel pump package.

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Cody427 Cody427
1/3/2019 9:47 AM

May sound stupid. But check the 10 amp fuses that are under the seat next to the battery. Mine wouldn't start after something similar and what do you know it was a fuse. Wish I would've checked before panic set in.

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Braaaphole Braaaphole
1/3/2019 4:39 PM
mikejones202 wrote:

Swapped tanks and bike ...more

Pull the fuel pump out and ensure the fuel line isn't kinked. This is a known problem.
If you do have to change the pump, search around and you can find the individual pump for a fraction of the price of the entire assembly.

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ktm-5 ktm-5
1/4/2019 9:55 AM

I had a kink in my 16 250f which I believe is the root cause of why the pumps take a shit. B4 mine died I replaced both inside fuel lines, eliminated inside filter and little outside filter with an external filter. Zero problems so far and only cost me about $70 to fix

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