KTM Fuel Pump Replacement | Save Money

In this video, I share my experience with a failed KTM Fuel Pump and how you can save money replacing yours.

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Mario Orsini
PO Box 64
Bunker Hill, WV 25413

[michaellatela]

Yesterday I was left stranded by the dreaded KTM oem fuel pump failure, but only 45 miles from home. I ordered the pump and kit from Rottweiler. Thanks for the tips Mario. Always look to your channel for wisdom.

[rbrucerogers]

Add me to the list of folks who have been helped by your fuel pump videos. Mine failed at 15, 000 miles, while I was 2 hours from home. I was able to have it towed to my brother & sister-in-law's house near-by. Ordered two Quantum's - one to install and one as a traveling spare. Installed the pump pretty easily. Thanks for making it much less intimidating!

[farfi]

Canada calling! Huge thumbs up Mario!

Was only going to replace my filters and came across this video. It made absolute sense to replace the pump before the OEM failed and now I have a spare. I ordered the kit from Quantum on Monday and it was in my mailbox by the time I got home from work Tuesday. In Canadian dollars the whole thing including shipping was $203.00.

On a 2017 1290 SA R the crash bar stays in place with lots of room.

The only thing I would suggest to get are the two pump base O rings in case they rip like the one did on mine. The one that ripped is 3mm X 60mm. They aren’t cheap from KTM. My dealer gave them to me for free since they had a few laying around. $75 otherwise!!

Thanks again Mario. Ride safe!!

[bricaud]

Perfect instructions. Just replaced the pump and filters on my 1090. And removed the failed guglatech drop in filter- the bag had separated from the collar and was floating loose in the gas tank.

[tdeaf]

Thanks for the advice. 2018 KTM1290 SAR pump failed at 17K miles. Quantum shipped fast and works great so far.

[bluebaaron]

this just happened to my 2016 SAT at 16, 200 miles. Started bogging when temps got warm, then cut out entirely. Got the fuel pump failure message. Was also getting a lot of vapor out the tank vent hose. Good news is I already had kit on hand (bought it when I bought the bike @8000 miles after watching this video) :) and plan to rebuild next weekend. Thx Mario, I'll report back.

[tmarkcc]

Great post Mario. As an aside, Guglatech has some oversized (internal) and optional external fuel filter choices as well in addition to the neck (pre) filter that you mentioned in your video.

[davidwilley]

Guglatech is the tank filter sock. I always appreciate your videos.Im going to attempt this fuel pump swap.

[salvadorpartolan]

I know this is late but I'm glad you did a video on this. Mine is going out and got the failure code while riding. Going to do the aftermarket pump for sure! Thanks for the advice and video. I also have a 2016 1290 SA! Great bike!!

[fish]

My 2 cents. I went with the entire assembly, as opposed to the rebuild, for one and only one reason. I want a backup now. For $189 you get the "Full Monty". Oh by the way I was 500 miles from home last week finishing a 6k mile ride on my 1190R when I started to have some "revving" problems. Intermittent hesitation at 5-6k RPM, I figured right away it was probably fuel delivery. Bike had no issues until you hammered on it hard. Now, fortunately minutes after the first time, I had a quick pit-stop to use the restroom. Low and behold when I get back on the bike for the next 50 miles or so, no issues. As I was running low on fuel as I continued on, it started doing it again. Topped off and it didn't do it again for another 50-100 miles. 2 more times and same scenario, I'd stop, it would reset or whatever was happening. However, I made it home. By then, I knew it's fuel filters or pump itself. So, now I will have an entire new assembly and will run a Twin Air gas tank filter "sock", for some extra protection along with a new pump and filters. I bet I won't have the problem again. However, I will rebuild the entire original assembly for $100 bucks and keep it in my saddlebag. Now if I can get the damn thing pulled out without loosening up the tank. I have Rumbux upper and lowers and they seem to not quite allow the pump to slide out, I am going to indent the bar about 1/4" to allow for ease of removal for now and future. I would rather not have to loosen up the tank on the shoulder of I-5 or in the middle of TimBukTu. And, I don't need to pull my tank for anything but this repair on this go around. Valves have been checked/adjusted, plugs done and I just serviced the Rottweiler velocity stacks, filters and pre-filters, 10k miles ago.

Great job with your channel and content! Keep it up, we appreciate it!

[gilvietor]

Dude, thank you so much for this video, I did it (1090 Adv R, 2018). I bought this used from a guy, thought I had done a horrible thing buying it, turns out the gas I got in Black Hills on a pass (I live in Gillette) was bad, really bad. It had dirt and some weird fluid I couldn't figure out, maybe rusty water? Anyways, video was a huge help, thanks man, got the Quantum pump, filter kit and it was a breeze.

The o ring on the pump that mates to the tank, a trick for people who might be running into issues. Use some 3M Silicone o-ring lube NOT GLUE and lube it up like Mario says, when you are putting the pump assembly back into the tank, get the o-ring started, get a screw driver and very lightly help the o ring stay in its grove as you push into the tank. I have had a lot of experience with o rings out in the field where you had no options and it works.

[djash]

Dude, much appreciated you sharing this information. Just ordered one and got it delivered the next day! 35k and whilst I was doing 80 on the freeway it just cut out. Was able to baby it all the way home. Any heavy throttle it would just cut out. Could have been the filters or the fuel pump. Changed both with the link in your video and all is well. Thanks again for sharing!

[johndemmink]

Thanks Mario! I now ride with a spare, if I’m riding any distance from home.

[drumsnbass]

New 1290 owner here shouting out thanks!

[adv]

Thanks man! Sitting in the garage and this helped me out

[BigMacOakland]

Great Information, again. I have my fuel tank off and was wondering if it would be more useful to install external fuel filter. I was thinking of visiting a friend in Mexico and was concerned about potential dirty fuel. Any thoughts on that? I have a 2017 KTM Super Adventure R. bought it used with less than 10.000miles in January. Oh, forgot to ask. how often should I replace the internal fuel filter?

[wordword]

2 Wheeled....desperate for info

I had to replace the connector on the fuel pump (gear shift side 3 pole connector w/2 wires) that goes into the fuel pump. I used a water proof connector kit by (Looks like Delphi or Adelphi).
1. Replaced the two pins on male and female connected them directly to a battery (off the bike) to check it before I mounted the tank back completely.
2. The fuel pump comes on hooked directly to a battery and spins like a top.
3. I then checked the voltage coming from the bike going into the connector. When I turn on the ignition the voltage appears to go to 13v then immediately goes beck down (I think that is designed that way to prime the pump). I think I can hear the slight "pop" in the fuel pump when I do this when connected to the bikes power instead of just straight battery.
4. When I connect the fuel pump to the bikes power it wont start (turns over fine and getting electrical to the spark plugs).
5. When I use starter fluid to check if there is something wrong with the engine the bike starts and of course almost immediately dies. It does a few revolutions and runs out of vapor. I wanted to know If something was wrong somewhere else but it appears not.
6. I checked the fuse for the pump at the fuse box and its good.
Any ideas? Perhaps the relay? Keep in mind it was running fine before I removed the fuel tanks to do a valve adjustment (using starter fluid to check to make sure the engine was fine so IMO I dont think anything is wrong with the valve adjustment otherwise it wouldnt do much at all regardless of starter fluid or not). I am already on several forums and have yet to have any answers.
Can anyone direct me to the fuel pump relay and how to test it?? Or do anyone else have any other ideas regarding what it might be?? Thanks!!

[robinsongguitars]

Nice video. How much time is involved in replacing the pump and filters with all the right tools on hand? thx

[PeterWhitney-hupz]

I installed a quantum pump in my 1290SAT northern bike runs until it gets warm then stops like its running out of fuel. Wait a bit then runs again for a few minutes and splutter again. Could the pump be getting hot in the tank i noticed vapour coming from the vent hose near the footbrake lever

[obrianmcc]

Great videos ... a good mix of relevant how to's and ride videos. I myself suffered the dreaded KTM fuel filter issues at 250 miles on my new 1090. 6000 miles later and on a recent trip and luckily only a handful miles from home my 1090 bogged and the Fuel Pump Warning flashed up on my display. I got her home and replaced the pump with the Quantum and a Guglatech filter kit .... bike is running great again and I hope to not have any more filter issues as they advertise. I've tried to be preemptive and run all non-ethanol/treated .... also prefiltering most of the fuel that's ran. I've read that the Fuel Pump Warning is detecting a dead short in the pump, which makes me wonder if the original fuel filter issue over strained the pump?