20+ KTM TESTING FUEL PUMP, FAN AND LIGHTING RELAYS

*CORRECTION*
i mis spoke at the beginning of the video.
The relays are:
LEFT: FAN
CENTER: LIGHTING
RIGHT: ECU / FUEL PUMP
Left of bike=chain side
Right of bike=clutch side
How to test your relays on any year bike with the same style Panasonic style relays.
As with anything electrical, use the repair manual, use the correct tools and equipment, be careful and understand what you’re doing to avoid possible damage to components or systems.
Besides you, nobody loves your bike more than we do.
Let us know if you have any questions about this bike build or anything else on your KTM, Husaberg or Husqvarna dirt bike, and don’t forget to like and subscribe🤘🏽
Oh.....and #gooutandgetsomeadventure
if you need any parts, want us to build you a bike, have any questions, or need help with anything on your machine don't hesitate to call or email us.
702-812-6626
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groups/EXCFE...

[@emreturan-KTM]

Many thanks to you my dear friend. I just fixed my KTM 250 EXCF with your video guide. My fuel pump relay was the problem. I renewed i, and it works just fine 😊🙏

[@Papparratzi]

Really great and practical tip on switching relays according to your need.

[@bretgerding1399]

Just used this method to test power output from the light circuit while my bike was off. Thanks for the tip! Keep these vids coming!

[@100868ful]

Another great lesson. Thank you!

[@seanmacnee3251]

Mike for the win. Trying to figure out how to remove a relay and there's a video of it. You rock.

[@user-lo8ls6ti3g]

Great video! Thanks for posting. This just helped me quickly diagnose a bad fuel pump relay. Easy swap with lighting or cooling fan relay. Back on the trail now!

[@smacnee3278]

Great tips could come in handy in the middle of now where sometime thanks

[@kostapopov384]

Great,helpful video.Thank you brother for sharing your knowledge!

[@gcostanza2115]

I need to check if my fan is working, so this was very useful, thanks for posting.

[@mikeerdman4831]

Excellent video. I needed it 3 years ago. Would’ve save me a lot of money on my 500ecx

[@kobybenyakar4714]

Great video, I learned a lot I’m pretty sure you stated in the beginning that the left relay is the fuel and even stated it’s marked but when you grounded the control you said it was the fan. Bottom line it’s clear the left one (air filter side) is the fan, middle is lights and right one is fuel pump 🙏🏻🙏🏻

[@kostapopov384]

Lights and fan are on same relay on Husky tpi 300 21

[@giacomomicele7886]

@@kostapopov384 i have an husky te 300 (2020). In my case middle relay controls lights AND fan, the right one is fuel pump. Do you know whats the left one for?

[@ADVNevada]

Very cool, thanks!

[@michael397]

really helpful thanks a lot!

[@bradybenson4638]

Rad Bro. Nice Video

[@laosgpsmapmidnitemapper9411]

Great Vid, schooling for when I get a bike with Fan and Lights and injection> Long live the PWK!

[@kevinjoslin6351]

That was 8 minutes of nothing but learning for me. Thank you for sharing your knowledge with us.

[@TheLostAdventuress]

Thank you for education mike

[@kadir5625]

U saved meee, tnx!

[@E.FrankSmith]

Excellent thanks

[@charliemccallum5660]

Thanks for this Mike, another great “pro tip”! Just helped me test the fan which proved its working great 👍🏻

[@DMC-179]

Thank you!

[@johannposch3918]

Good info - thank you!

[@donpizzo8963]

I think most this applies to my 2017 as well

[@vinnieboy66]

Great Video as usual from Mike! I tried to test my fuel pump using this method but unlike how yours fuel pump runs for a while mine starts then sounds like it is bogging out like a starter with a nearly dead battery. Should my 2022 500 excf fuel pump run for a while when testing the relay using this method? I am having some issues and thinking this could be at the root of it. Please advise.

[@donwalker9767]

Hi cool vid. So by doing this check it says that the relay is also fine and working as it should. Thankyou

[@derrickhokit]

What is the white cable in the center near the ECU? looks like a loop back adapter of some sorts

[@harrisondawes5922]

I found out today that the middle relay for lights also sends power to the fan relay so if either are faulty your fan won't run

[@shaunbean5553]

Any idea where id find the fuel pump relay on my 2019 300 tpi? My fuel pump randomly stopped working yesterday

[@g4voe242]

Is there a similar method for a 2018 300tpi?? I want to test my fan wiring?

[@eloufirjawad]

Thanks man! I have an issue with the fan of my 390 duke (2020). It starts running as usual when the engine heats up, but it doesn't stop. Oddly, the engine doesn't cool down effectively nor does it overheat. Has anyone faced a similar issue after exposure to water? Appreciate any insights or solutions.

[@jarrodbrandin7492]

Hey man, I used this trick to test the fuel pump relay on my 350sxf, when I put the pick into the relay, I got a little spark and didn’t think anything of it, after I replaced the relay, now my starter button is dead, even with the old relay put back in it. Before I tried this trick, it would crank just fine, my fuel pump just wasn’t priming. If I jump the fuel pump straight from the battery with some test leads it works fine, but like I said, after sticking a pick that I grounded to frame into the relay, now I have a dead starter button. Both fuses on my starter relay are good, now I’m stumped.

[@user-pt4wp3zs5r]

Hello, good video. My ktm exs-f 350, 2020 is not working. When I do a test like your video, the pump works normally loud. When I press the button to start, the pump can hardly be heard? What's wrong (if you are familiar with the idea?)

[@blackboy-io9lx]

How you doing I'm having a big problem could you please help me I have a 2005 Suzuki burgman I'm trying to see where is the fan relay located

[@user-pt4wp3zs5r]

At 3:56 seconds there is a test ground (white/black) wire. what is wrong if this mass is not good? What is wrong if a maximum of 10 volts comes to the gas pump (good/full battery)?

[@zangarag7762]

Hi I found my 2022 Husqvarna fe350 submerged in water. I want to ask how to turn it on. Is there a key to this?

[@recepyuksel9388]

I have a KTM lc4 640 now and unfortunately, the electrical connections have been wrecked because of our uninformed masters. I need a master like you in Turkey. They have exhausted my love of engines.

[@chandrairawan8546]

I have a problem with the 2016 KTM 250 motor, the electricity won't turn off after 10 seconds the engine dies

[@aurimaslasas4015]

sorry what is code for pump relay

[@stephenscott4019]

Correction accepted. Was puzzled about how the fuel pump relay turned into the fan relay @ 1st half a video. & vice verse..

[@TACOMOTOCO]

We mis spoke in the first few min

[@sumporfuk]

So, how do you recycle the ECU if you have eliminated the key switch by installing the Sicass module that enables the use of the start button only?

[@TACOMOTOCO]

Press the start button for one second

[@jMc.55]

Great video, I need help. Installed a Tidy tail and wiring harness on my 2021 XCF-W 500. When I jumped the relay to test the lights I accidentally hit the 12v side and blew the starter fuse. I changed the fuse, the bike turns over but won’t start. I have tested all the fuses, relays, and changed out the ECU. The fuel pump doesn’t cycle when you hit the starter. I can get it to cycle by jumping the wires. Any suggestions

[@Evil_Morty2000]

Hi were you able to figure it out ? I'm having similar issues,bike will crank but no start.Intermittently,sometimes it does start just fine

[@carlhansen8668]

Hi I have got a ktm 350 exc 2017. The fuel pump relay only gets ground from the ecu when you push the starter button and turns the fuel pump on but drops as soon as you release the starter button (will not stay on for 3 seconds ) the bike will not run start. I can run a jump wire to the fuel pump relay earth fuel pump come on still no will not start any ideas please? I think the ecu may be shot !

[@dirtrider9268]

How did you resolve it Carl?

[@carlhansen8668]

@@dirtrider9268 spark plug and new relay fixed it from memory. Mate of mine also had a no crank on a 701 spark plug was fecked. I guess the ECU can see no resistance from the spark plug then creates a fault??

[@jr.6199]

@@carlhansen8668 thanks, post the error code if you have it.

[@lilmac3434]

My 2017 KTM 500 wont start. the fuel pump doesn't prime, so i grounded out the relay like you did in this video and i can hear the relay click but the fuel pump doesn't cycle. Is it safe to say my fuel pump is bad? i would like to get some opinions before i shell out $$$ for a new one. Thank you

[@TACOMOTOCO]

You can test it with this tacomoto.co/products/fuel-pump-tester-and-transfer-kit-by-taco-moto-co?ToPasteboard

[@jjchopper02]

My 13 exc 500, all of a sudden won’t start. I hear the fuel pump running. If I disconnect the quick disconnect in the fuel line after trying to start it, it has major pressure built up. HELPPPPPPPPPPP !

[@TACOMOTOCO]

Do you have spark? Will it fire on a quick shot of carb spray?

[@jjchopper02]

It has spark. It is fuel injected.

[@kamyksz]

​@@jjchopper02 Fuel injected or not, You can still use carb spray. If it works this way, means engine has spark, but has problem with fuel delivery.

[@lodcomm]

am I understanding this correctly - the leftmost relay (air filter side) is marked fuel relay, but in reality is the fan relay?

[@TACOMOTOCO]

I made an error and one time said it backwards Left side is fan Center is lighting Right side is ecu / fuel pump

[@JAYZRIDEZ]

You end up saying that the fan relay is on the right side but then 2mins later say its on the left side 😅

[@Nicky_Pin_It]

So my headlight is not working, but if I ground the relay like you said it will come on. What's the next troubleshooting step?

[@jasondavies1701]

I got same issue, been racking my brain. Changed really still no joy 😔

[@jesse2413]

I have the same issue. Did you guys figure it out?

[@Nicky_Pin_It]

@@jesse2413 I had the dealership scan the ECU and do the latest update, for whatever reason it came out of it after that.

[@omkarkaralkar]

Hello Does every Fuel pump have relay? What are sign of bad relay? Ive Aprilia SR 160 and the vehicle don't start after a short ride. Initially SC replaced fuel pump and now they're claiming that this maybe because of faulty wiring. I feel that this is a sign of faulty relay.

[@TACOMOTOCO]

Do you have a wiring diagram for that bike? You can trace the circuit and make checks to see what component is giving you the trouble

[@omkarkaralkar]

@@TACOMOTOCO I don’t have the diagram, How do I locate the relay? I thought the problem was with fuel pump so replaced it. But the issue isn’t resolved. What other bad components can cause the fuel pump not to work ?

[@hophophopa2030]

Great video! Thanks! I have an issue with the pump being activated by start button or kick start. I tested the way you show here and work (which I understand the relays are good) but if I hit the start button the pomp is not working. Any help is more the welcome! Thanks!

[@isaaclenon9901]

I have same problem have you fixed you problem ? Cheers

[@sauceracing]

any resolution to this? currently having the same problem on a friends bike

[@hophophopa2030]

@@sauceracing I had a cable somewhere pinched on the right side of handle bars. Just fixed that and was working again

[@ariantopanica3914]

@@hophophopa2030 do you tell me what a calbe i have same isus my exc 500 sommtime when i start pump not activeted

[@dirtrider9268]

This is peculiar. The ignition wire loom is tied to the main harness running on right side top tube, under the tank i recall. Check the related connectors behind mask, unplugging lubing w dielectric grease and replugging. Check that each pin is seated fully in each connector, especially the connector that goes through the hard plastic bracket attached to the top triple/stem. The tanks outside connector is sealed well but those on the pump inside can be a little loose I hear. Squeeze those blade connectors with pliers slightly. Save yourself a lot of $$ by doing it yourself! Mike's vids are a good start.

[@namdarbolour9890]

I'm not an expert mc mechanic, but I think you should warn not to ground out the wrong (ie, hot) coil terminal because that would cause a short to ground! Hopefully a fuse will blow, else you will melt some wires! Is that right?

[@Fordahord1]

I just fried my 2012 ktm duke 690 ECU… just ordered a used one 🙃

[@youtubeuniversity4098]

Xcf only has 1 circuit

[@bethslocum9682]

Everybody's tabs in 10 years are gonna be snapped when the plastic gets brittle hahaha. There will just be zip ties holding these guys on.