23' KTM 450 XCF / 24 EXCF, XCFW FUEL PUMP DISSECTION

[@frazzle657]

Taco moto will be a leading motorcross parts provider within my life time, thats pretty cool.

[@johnnymac8179]

Thanks Mike! That was good information. I can’t wait to see the taco Moto pump! I want to be the first one in Montana with a taco pump in my 500!😁👍 Cheers!

[@human1513]

Very usefull video, thank you. I use a length of saftey wire or similar and wrap it around the fuel pump's mounting outlet before I pull out the pump. Then I gently pull the wire out throught the tank on re-installation pulling the pump back in place. Easy Peasy & takes seconds to do.

[@paul.vanhout57]

Very informative and appears KTM finally realized they had a flawed fuel system design. Interesting in the trade off between serviceability and access to fuel in the tank.

[@jawanzabanyard1400]

where was this video 2 months ago when I bought my bike and thought I had fuel putmp problems. drove 3 hrs back to dealership left bike over weekend only to find out that bike was just to low on fuel btw I ride single track mostly

[@DirtRider6512]

This has to be one of the dumbest ideas they have come up with!!!!!!!!!!!! They should offer a fix. Stop following Honda and keep your your customers happy. This is a hot mess.

[@veiga_daveiga7089]

FUEL PUMP DISSECTION. Thanks Mike! That was good information. (BRAZIL)

[@mikeolson7188]

I recently did a fuel pump replacement on a 19 Husky FC-250 And it took a bit of time to get the fittings lined up and in the 2 holes but using a pick and some safety wire were Def key to the install.Bike had 190 hrs on it.Your vids are always very helpful,thanks Mike.

[@TACOMOTOCO]

There’s lots of good tricks out there for sure

[@markbour]

I used safety wire around the threads to pull it through and it was a complete non-issue for installation, at least on my larger aftermarket tank.

[@Dmac1vids]

@@markbour Same here.

[@bwebb3549]

I had to do the Sabe thing 🤙🏼 However, it’s wedges in the pretty tight..did it sit in there and line up for you easy? I’m worried there’s some pressure on the pump. Using stock tank. Thanks

[@juliomoscoso9427]

Hi Mike, great info. In the old system the internal fuel filter would turn black after the first few hours of operation. Not sure why but what I read was that it came from the pump itself, maybe from the brushes. Hopefully this new pump will not generate that type of debris, which in the new system seems like would go straight into the fuel injector. Unless there is good size external filter...

[@TACOMOTOCO]

All pumps generate carbon

[@mark_Hershey]

So you think the 23 and up fuel filter is about a 200 hour filter? I kinda agree. I have a 2023 with a random bog. It’s frustrating but for the last 2 months I’ve dove into everything. There is a good amount of post about the tbi bogging and people/dealers think it’s the pump filter. I have cut one open and you would need muddy gas to completely clog it. I think there is a bug with the tbi’s and a bog thats just inherent for hard running bikes, not weekend trailer bikes. I am curious how much the check valve in the quick disconnect is released when the male portion is inserted. Could the quick disconnect act like a choke point for fuel? These bogs i am talking about are on good running bikes, but every once in a wile you twist the throttle and nothing, then it will be fine for a wile. It aggrevating and in some cases like mine, dangerous as it did it on a jump breaking ribs and getting my spleen. I have been trying to figure this out, ktm diagnostic tool shows no issue, and ktm said it would have to do the bog wile hooked up. Kinda impossible, maybe with a dyno but no dealer around me has one or can invest the time to figure it. Mine is an XC and i will not run on my mx track at anything lower than half tank just to make sure pump doesnt get starved. Thanks for the vid, it helped me with understanding the regulating property of the pump.

[@milossochor5417]

This is a NO GO for us rally riders. We ride terrain but you may have road sections between Times Special Stages. This design actually does not allow to use the last 2 litres of the 9 litre capacity. That is little under 20%. That is too much.

[@angelopetretti9480]

😂😂😂😂 Ktm spend so much time for minimize failur on the end you can't use the complet petrol in the tank. What a COGLIONI!!!!!!!!

[@mbrick]

Very interesting, thanks for sharing!

[@joemak9207]

Excellent video! Thank you. I have a question about the old pump design. The lines that run to and from the filter are attached by hose clamps, but at the other ends they seem to be fixed in place. Can the other ends be removed, and how? Seems impossible to replace just the fuel lines.

[@bdb3011]

In my world (my 500's are for dual sport and snowbiking), this new fuel configuration has me running, not walking, from my 10 year relationship with KTM. It has proven to be an absolute deal breaker on the snow. Super sad to see. Hopefully someone comes up with an aftermarket lower pickup soon, or it's off to another manufacturer for me. :(

[@Zt3v3]

I think a larger fuel filter could solve the problem, one that runs over the left side "well" of the tank. I'm sure someone will come up with a solution.

[@standjos25]

I use gas cap vent hose to pull the older style pump through the tank. It fits tight enough over the threads to give you something to pull on.

[@barnescycle]

Thank you so much for all your detailed videos, I have some how got alot of mud in my tank and have clogged my filter. Some debris have made it as far as my inline filter creating a random bog while riding. I'm about to replace the sock on the bottom but know I'm more knowledgeable about the whole system, big thumbs up 👍 and subscription

[@barnescycle]

Also I only have 10 hours on my bike, I'm still trying to figure out how I got this level of contamination in my tank.

[@jaykanor9613]

Mike, what's stopping ktm or a road/ dual sport guy from putting an extension hose between the pump and the fuel sock and throwing the sock down in the tank wing to draw from the bottom?

[@TACOMOTOCO]

Looking into that as a solution

[@mattbillenstein]

Wouldn't this possibly lose prime between the sock and the pump? Like potentially you need a check valve at the bottom then as well? I'm not sure how this splash fueling method could be good on the exc - like if you do a flat highway section, you're just going to run out of fuel before running out of fuel no?

[@TACOMOTOCO]

Keeping fuel in the pump cavity is key

[@gasgasman230]

IMS already has this figured out. kzbin.info/www/bejne/gXvNpnWsiNeEmrM

[@stevegeorgepeters]

That's a very very good question

[@scottyd980]

Sir Isaac Newton is scratching his head.

[@stevegeorgepeters]

😂😂😂😂

[@TeamStruggleBunny]

A few people I know, myself included have had issues with the new system in that the sock filter seems to get plugged up. My friend's bike died at 4 hours, attributed to the plugged filter. At 89 hours he has the same issue with the filter being plugged (pump is still good). Mine plugged at 55 hours. The bike won't start with a plugged filter as the bike reads low fuel pressure. I know of a third and possible fourth bike in our extended riding group with this issue. One being another sub 5 hour old bike. The current theory is the filter is screening down to a very fine micron. Alternatively we're wondering if it is a regional issue with dirty fuel from the gas stations or additives for the market (east coast Canada).

[@HoneyBadgerRy]

I've noticed problems too. I added the KTM fuel fill filter and didn't notice any improvements. The amount of filters I've gone through in 25 hours is pretty wild though. Idk if I either have really dirty gas, or maybe Yamalube clogs filters. 🤷🏼 I've also found that my fuel pump will not self prime. I have to take the quick connect off and suck prime it after removing it from the tank.

[@TeamStruggleBunny]

@@HoneyBadgerRy That's not ideal by any stretch. Dealer is telling me that I with the fuel sock added I shouldn't have any more problems. I mix with KTM 2T oils and have stayed at the recommended 60:1. I haven't put on many hours since I had an issue, maybe 10-15 hours because it is winter here. Seems the sponge filter is really sensitive. Have you pressure tested you fuel system? Wonder if your pump is failing after working so hard with plugged filters?

[@HoneyBadgerRy]

@@TeamStruggleBunny I did order a taco moto fuel pressure tester a couple days ago, but it hasn't came in yet. I'm not expecting anything to come from having it though, I only experience problems loaded on a MX track, that seem to be more common with dirty filters. I really don't know if it's a filter or pickup or pump issue. I did change my inline filter from the traditional type to the aftermarket type, maybe it will make a difference.

[@609enduro]

Wind a piece of safety wire on the threads before u pull the old pump from tank. Then re wind the wire on new assembly. Ez peazy lemon squezzy

[@tjsskier]

Riding and racing in Baja, I need at least a 3.2 gallon bigger tank for my riding, it will be interesting to see how well the aftermarket tank companies get fuel splashed up from being carried farther down in the larger capacity 3.2 and 4.2 gallon tanks.....or will there be an attempt to carry the fuel higher raising the center of gravity of 1-2 more gallons of fuel? I haven't seen any yet.

[@TechEnduro]

Great video Mike! Keep ‘em coming with the changes/new parts. I have a 23 300xc coming so a bunch will be the same. Curious about a few thing that I’ll need for my XC. shark fin rear? I guess a new design with the axel different? Skid plate. Looks like some great new mounting points, also looks like current gen won’t work. Single seat bolt, wonder if a hand turn attachment could be used like on the Sherco to make it a zero tool removal. Is the subframe Grab handle actually usable?

[@Shecki603]

I have a 23 350 XC-F and Bulletproof Designs is just giving you a 22mm chamfered insert for the disc guard so that their current guards fit the new bike. Mine fit like a glove. There is no change with the front. Just need the insert for the rear. Also, the 17-22 rad guards fit the new chassis as well.

[@TechEnduro]

@@Shecki603 great news! Thanks. I guess the OEM fan will fit since the rad guard do too?

[@Shecki603]

@@TechEnduro ...I'm not 100% sure on the rad fan....because the shroud is so close to the back side of the rad. It's possible it could work though....I just don't know for sure. I don't have one mounted.

[@joeb10p69]

@@Shecki603 the rad fan from the 19-22 won't work but the 16-18 model year fan does fit though, that's what I put on mine and it's perfect.

[@dirtbkr100]

Mike, is there a reason the pump doesn't just have a hose extension that reaches down to the lowest wing? My gas light came on the other day, and I tried to get back to my truck via dirt roads...and the bike died a dozen times on the way back - despite having plenty of fuel in the wings. So frustrating!

[@Zt3v3]

A larger fuel filter for the new design could be a solution. A filter than wraps over the left side down into that lower well. I suspect it could wick enough fuel that way.

[@jeffreyburck6968]

Mike, is the new style pump in the 2023 XCF-W?

[@grapemustard881]

no, old frame, old tank, old pump

[@frazzle657]

I believe my pump failed, fouling the filter and in turn clogging the pressure regulator open? Or maybe the regulator just failed as well. Anyway, its got a new fuel filter and pump but the psi only increased by 5 to 40 and doesnt hold pressure so i backed the regulator out. Started it and it was just pissing out from the word go

[@bengtphorks4756]

How I would solve the fuel pump issue on the 2024 bikes. Put a hose adapter on the inlet of the fuel pump and run the hose to the bottom of the tank on the side of the tank that is the lowest. An inline filter could be installed on the hose and the hose end could have a fitting that allows fuel to flow into the hose and a threaded stud that fits through a hole that is drilled in the bottom of the tank similar to the earlier versions of the KTM fuel tanks. The parts could be 3D printed.

[@HoneyBadgerRy]

Is the fuel pressure regulator adjustable? With a brand new OEM (in tank) filter with the bike running I have 47 psi fuel pressure (1 psi below the 48-52 spec) and experience an issue that feels like random loss of fuel pressure only on the track.

[@donpizzo8963]

Hoping the new pump is on the 300XC I have on order. Thanks for the video info😊

[@TACOMOTOCO]

That bike gets this chassis in 24

[@nascarco]

It would be great if you could show pulling it out and putting into the tank! Thanks, otherwise great information and video.

[@danarussell4246]

I’m still a little confused. Did the 2023 KTM 350 & 500 EXC-F get the new style fuel pump?

[@MrShawnaandgreg]

Hey Mike, As I see you commenting on a positive upgrade to in-tank filter maintenance. I had a question I think a knowledgeable mechanic like you might be able to answer, is there a reason that one wouldn't put a rally replica oil cap on a 500, ( same year ) with a cooler adding oil to a total of 2.5 liters for example to get much longer intervals? I assume that you might be currently do this for baha racing. KTM owners could use this for the application of longer term dual sport rides. Thanks in advance for your reply.

[@paulthrelkeld3341]

That smaller size compared to the older unit definitely displaces less fuel in the tank as well.

[@jawanzabanyard1400]

facts

[@jonteten1211]

Do you foresee a larger aftermarket tank for this new XC-F platform? With the new fuel pump mounting position. Would deeper cavities cause more fuel that couldn’t be picked up.

[@TACOMOTOCO]

Yes and yes but just shake to the side or pop a wheelie to get it

[@jonteten1211]

More likely to crash😆

[@AdrianDelaTorre-f4e]

on my 24 exc500 have yall found a fix for relocating the pick up tube on.tank ? the pick up is too high and alot of fuel is left un unused

[@TheCorbin155]

What is the Allen key slot for in the regulator on the new style pumps. Is that for serviceability or can you adjust the regulator pressure with that?

[@TACOMOTOCO]

Yes and yes

[@TheCorbin155]

@@TACOMOTOCO that's actually extremally cool hahah

[@Danger_mouse]

I'm struggling to get excited... KTM finally came into the 2000s with a unitary fuel pump assembly 🤔 What many other companies do with in tank pumps is use the return fuel to pull a vacuum in a venturi hose and suck the fuel out of the places the pump is physically too large to sit in... I guess that's a bit too technical for the Austrians

[@mikegro8502]

But dont the japanese bikes have a completely different frame and tank design without these low wings on the tank? So the pump sits at the lowest position in the tank anyway? Just by looking I would take the old fuel pump and tank design from KTM. A bit annoying that you are not able to get the tank empty that easy.

[@joeyjojo6699]

Please make a replacement pump! I have gone through 2 OE KTM (Bitron) pumps on my 23 300xc resulting in DNF's each time. I wish I could get "200 hours"! First one lasted 37 hours and the 2nd lasted only 5. Please make it better and I will gladly give you my $

[@rebelliontotyrantsisobedie5602]

Did the new system makes it way on the 2023 XC & XCW line of 2 strokes?

[@DirtRider6512]

Yes, it did and it is a problem no matter how you slice it. The video says it very nicely and is being very kind to KTM but the real true is it sucks. Most peopel are saying just get some good car pad and wick it up to the pump. I guess they use it all the time on the track for race cars. Works great from what some forums are saying but I have not seen or heard if it exists for KTM and others.

[@24mwsmith]

Where can I get the adapter for the external tank?

[@pattimullen239]

Will this pump and tank Assembly fit a 2019 FC450 Husky?

[@TACOMOTOCO]

This pump is only compatible w the new gen bikes and tanks If your tank has an outlet port on the bottom left wing - no

[@taylorc4476]

Me- There's no way a fuel pump video can hold my interest. Taco Moto- Deep dive on fuel pumps. Me- Spouting fuel pump intricacies to my moto bros.

[@TACOMOTOCO]

I’ll take that as a compliment 😎🤘🏽

[@jimzigouris]

any solution yet for pump 2024?

[@Soto_eightyfive]

Nope

[@eriknash8783]

Dramatic improvement is a bit overstated. I understand you think the pump/pick up assembly is greatly improved, but the tank and pump placement is a step backward, regardless of what Honda or others manufacturers do. I've never heard a Honda owner complain about a bunch of unused fuel being left over in there tank when the pump starts to starve, but lots of complaints online and in person about the drastic range reduction on their KTM/Husky when a bunch of inaccessible fuel is sitting in the "wing". I love my Husky and my KTM, but KTM doesn't seem to give a shit when things are not right, because the bikes perform so well that people will continue to buy them. But for riders like me who ride their plated bikes in the desert and need long range capability, this is horrible. You must think the same since you've worked with someone to design your "dip tube" modification. But since that is not self priming, I have be "out" on these newer bikes.

[@kristbjornbjarnason2771]

Hi this is a terrible way for KTM to go. Now it is not as easy to have the tank with the fuel siting lower on the bike. They should have had a fuel pump in the bottom of the tank. The designers are going the easy way. One part of my interest in going from Honda CRF450L to the KTM was the aftermarket larger fuel tanks for KTM cary most og the fuel lower in the frame.

[@TACOMOTOCO]

Taco moto has solutions and options for this coming soon 🤜🏽🤛🏽

[@kristbjornbjarnason2771]

@@TACOMOTOCO Ok that is good. But most likely the aftermarket gas tank manufacturers will build the tanks more upwards than downward. make the bike more top heavy

[@TACOMOTOCO]

Incorrect

[@hsistelo]

​@@TACOMOTOCOyou have already the solution for the new pump?

[@deep4soul]

The designers at KTM clearly dont ride terrain anything like mine. Typical ride for me can end with a road section back to the truck, so after 50 mile ride, the bike most certain to die on the last leg back to vehicle. DUMDUM design!

[@scottyd980]

Gravity is over-rated, I myself, don't use it. KTM doesn't need it.

[@IANDOUGLAS-x6i]

You must surely be joking us to say that because Honda have been using a stupid idea for a long time, then it's ok for KTM to do the same. After 2 hours of pushing and nearing heat exhaustion, with plenty of fuel still in the tank, I finally made it to the top of the last hill and was able to roll down to the gas station. When someone dies because of this, their surviving family will have a very strong case against KTM group. I'm selling my almost new 500 tomorrow. Never another bike from KTM, period.

[@TACOMOTOCO]

That’s very unfortunate you had such a bad experience Happily our taco snorkel solves the problem. Would you like to try it before giving up and selling?

[@joeb10p69]

Funny not so funny story... I had my tank off installing a rad fan on my 23 250 xcf and it fell off the table and broke the nozzle where the hose is attached. Had to buy a new pump for a bike I hadn't even ridden. 🥲