Broken down and NO spare! FUEL PUMP FAIL 2 | KTM 500 Madigan Track Desert Crossing Part 5

Our trip home, 5 days through western Queensland, Haddon Corner, Innamincka, Broken Hill, and the Murray River forests.
Part 5 of a two-week, six thousand kilometer ride aboard the KTM 500 EXC.
Full series -
Part 1, Saved by a Stranger: • SAVED by a stranger! |...
Part 2, What Else Can Go Wrong: • What ELSE can go wrong...
Part 3, Followed by a Dingo: • Followed by a DINGO! ...
Part 4, Are we CRAZY? • Are we CRAZY? This tra...
Part 5, Broken down and NO spare! • Broken down and NO spa...
Part 6, The Wrap-up: • Is this bike ACTUALLY ...
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[@davidfindlay5432]

Hint. Stop running the bike out of fuel. No fuel pump likes that🤔

[@KaneTerry]

was thinking the same thing

[@mattw1393]

100%. Electric fuel pumps need fuel flow to cool.

[@chris_mastro]

Was thinking the same thing as well. Were I to go on a long trip with a 500 id bring a spare, but I'd also try my hardest to not run the pump dry

[@cliftonsr]

As an auto mechanic for over 45 years I had the most problems with fuel pump failures from vehicles that ran the fuel level too low to running out of fuel and some even had burnt contacts of connections. Rule number one have plenty of gas will travel!

[@dan950se9]

If It's a KTM, dont leave home without a fuel pump. It's almost guaranteed it will fail on a long ride. You have to take the good with the bad if you want 1 of the best performing bikes. Just expect that the known problems will happen for them. The simpson is a breeze on an exc. It's just the remoteness and distance that can make it challenging. My 950 had to get topped off every 20kms 1 day to get enough fuel pressure to keep running until I grafted a car pump into it to continue the ride.

[@1BayGolden]

Great series thanks for sharing! I was a bit surprised when I saw you guys running your bikes out of fuel when you had some in the bladders. This is a known cause of pump failure. The only time I have ever run mine out resulted in a big dump of very fine black crap (presumably worn material from the pump brushes) into the zipty external filter. The pump also became a bit noisy after that so I swapped it out. I had already been advised to avoid running dry and this confirmed the validity of this advice.

[@thesuperfunkomatic]

What a great series. A serious accomplishment to cover that difficult territory. Bummer about the fuel pumps - can't count how many rides I've heard of KTMs having a fuel pump pack it in. Glad you made it home!

[@MLS_Adventure]

Thanks Keith! Great coverage.

[@davidphillips4014]

Love it. Thanks for capturing your ride on film. We rode your exact Madigan and Hay tracks in July on 690s. Used 38litres for 760klm. The last corrugations will take some beating 😊

[@robertchester1596]

Great series. Change your fuel filter as part of servicing and don't run it dry. I've done 30,000 ks on a 701 and change the filter at 10,000ks

[@Jolly-Josh]

It’s a KTM, never go anywhere without a spare fuel pump. Even I know that and I don’t own a KTM!

[@HoagesMoto]

Yep... pretty much any euro enduro bike or tbh any injected bike it's common sense going that remote to carry a spare pump and/or filter pre-filter your fuel. Especially on KTM 690/500's where its is a very, very, well known issue, but for the price and weight of a pump it's easy enough to carry one for just about any injected bike and pretty insane not to unless you're willing to be stranded somewhere. Bloke is lucky it happened when it did, running the poor thing hot/dry wouldn't have helped either... lol

[@dwlee67]

Awesome series mate. Really enjoying it.

[@CaravaningaroundAustralia]

Awesome series, loved it. Good work on the filming, editing and narrating 👍

[@ThisTall]

Great adventure! Thanks for sharing it.

[@keithjob]

Glad you enjoyed it!

[@davidricketts6985]

Thanks Keith.. and to Pete. Really good quality stuff here! So much work you've put in to sharing your adventure!.. Really appreciated.

[@michaelcorker7168]

Really enjoyed this series - great content.

[@NotShookADV]

What a great trip Keith. You did well to make the ride home interesting with some great tracks. Bit of a limp home at the end, makes for a great story. Looking forward to your wrap up video.

[@keithjob]

Glad you enjoyed it

[@johnbradley1599]

thanks Keith, well done.

[@radadventure2606]

Great Trip! Thank you!

[@glennaltschwager5234]

Awesome series and ride mate. I've just got back from my first unsupported Simpson Crossing and I am addicted to this type of riding, Look forward to the final wrap up video. Thanks for sharing

[@brucekendall52]

Amzing ride,thanks.

[@theruffiankj4164]

Love your work on this channel - from one who has ridden for 50 years across the deserts and rimlands of Southern Africa, camping… Rotating my DR 650 with a gen 1 KLR. Really appreciate your footage and technical commentary!

[@broncoridesagain3176]

Brilliant series - glad you came back to make more vids. More and more rid vids Keith as well as any 500 insights. Been my go to channel for 500 gems for a while now.

[@bradsadventures4558]

Great footage mate. Very enjoyable.

[@Zobby447]

Great work as usual Awsome trip

[@walles1]

Really enjoying the series and you channel. Greetings from Scotland.

[@MichaelDiSimone-rd6zr]

Hey Keith, That looks like a great ride to me , driven those roads in a car before but look forward to doing it on my 500 soon!! Thanks for all the advice and keep putting out those great videos. Mick

[@Gazza13]

Suggest you look at the Tacomoto 3k fuel pump - will not fail and last the life of the bike - check out their videos on fuel pumps.

[@zmoke10]

Their pump is aftermarket pump like other aftermarket pumps. They tell nothing from their pump which would make it any different than others. So 3k is sales speech.

[@glennwr450]

@@zmoke10didn’t I see a vid put out my taco regarding oem pump and what they did different, 3k hours no questions replacement warranty- that’s got me interested

[@Gazza13]

@@zmoke10 Its pretty obvious from your comment that you have not looked at the details of the construction and materials used and the rigorous testing criteria nor have you tried one or spoken to anybody who has installed one like myself. LOL.

[@JimJamJammer]

Nice to see you made it back. My dream country to ride in is Australia and God willing it'll happen. Excellent content and well done.

[@howardbarker7768]

Don’t know many fuel pumps that like running out of fuel as the fuel keeps the pump cool. Great KZbin thanks for sharing your journey cheers

[@MotoPassport]

Man that was right down to the wire getting home, well done on so many levels

[@keithjob]

Thanks!

[@YnotadvOz]

Another great video series, thanks for sharing and looking forwards to the wrap up video. Yep, that style of fuel pump (common on many bike brands) are known to fail and don’t like to be run dry - they use the fuel for cooling and lubrication so best to try to keep them submerged. Do you run thread-locker on the bikes bolts?

[@philj3955]

DR650 fuel pump wouldn't have failed!!!

[@maccas44]

Fantastic Keith really enjoyed it.....wish KTM would iron out those small faults that damage the brand

[@AusMoto]

Talk about good timing for the fuel pump it to pack it in haha!

[@StuTheFarmer]

Good coffee shop at Pooncarrie. If it’s still open

[@davidtrappel]

I doubt it's a fuel pump problem. To test, disconnect your fuel line and start the pump while holding the fuel line with your fingers. If the fuel line builds pressure and swells it's your zipty style filter that's blocked. From my experience once Zipty filters block they continue to block more frequently regardless of how well you clean it or how clean you tanks is or how new your internal fuel filter is or how new your pump is. I ditched zipty and went back to the standard tiny inline filter which is cheap and easy to replace at regular intervals.

[@massdrivemoto]

Seems to happen to often with KTM....

[@wazza33racer]

The RAAF for some time had the carbie DRZ-400 and then they decided to buy fuel injected bikes. The bikes dont get ridden much, but still get serviced every 6 months regardless. RAAF mechanics I know say that the fuel injectors are often dead from lack of use. Similar problem with buying fuel injectors for cars, if they have been sitting in boxes too long in a warehouse, they are DOA when you buy them.

[@brendenvosper7772]

I am supposing your next video will cover this. Going on it being the fuel pump. The internal filter is tiny, too. I have a 17 500 and change it every 3000km or so (well we have three bikes with sugar filters and the you bloke and I just get into it and do them if they need it or not). Your fancy strainer outside only protects the injector. Running out of fuel consistently won’t do it any favors as it needs the flow to cool it. I have an ims tank like yours and considered installing a balance pipe. A quick connect between two tank flanges. While at it, consider a T to enable a drain point for the odd time you top up a mate or are draining for maintenance. I do carry a fuel pump, filter and injector on my 701. Sounds like it’s wise on the 500 too. Easy to change on my 701 with the fuel pump in the side tank. The 500 is tricky, but certainly doable in the field provided you manage the fuel into a bladder. Thanks Keith. Look forward to the next video.

[@franckbrunie4759]

Clogged tiny filter within the fuel line connector of the tank. Typical symptoms of a KTM EXC 500 that would restart after a while. There is also a larger filter within the tank. So was the fuel pump damaged? Yes starving the bike and having clogged fuel filters may have damaged it. Changing the tiny filter regularly is part of standard maintenance. And you were in dusty conditions, even more when riding in a group, so bringing a spare filter is necessary. Very easy to change.

[@miro_s]

in the end it brought you home… didn’t let you down…

[@ericdawson3425]

Try silicone on bolts and on out side so you don’t lose bolt

[@knuckles-3386]

I rode thousands of miles on bmw and Honda never had a fuel pump problem oh that’s right neither bike had a fuel pump some times new isn’t better

[@jw8556]

What else do you have to carry just ride a bike with a carby and a Kickstarter if possible the desert is a lonely place without a camel/bike l had a 2011 KTM 690 and that is just one reason why l did 4000 ks on and sold it all good when your not for from the trailer or shop but a nightmare in central Australia

[@FloridaDualSport]

Question for the 500 expert: if I tapped my tank and installed a petcock, could the gravity flow be used to get back to the ranch if the fuel pump quit. Just switch the fuel line. I know the performance would suffer, but would it work? Thx!

[@atlas_au]

Time to rade in the exc for the latest model camel😅

[@margarita8442]

interesting, where did u make a loggy ?

[@uncletom1971]

.. some threadlock then.

[@robsonenduro3316]

Could be the reason you allow fuel go too low and pump picked up some dirt. Anyway with KTM better carry a pare fuel pum for sure.

[@C_R_O_M________]

Could it be fuel filter issues. I've had lots with my KTM 990 in the past. Never with my 2012 500EXC. Never run out of fuel though. That may be it.

[@robpinter5431]

Hi mum, its Keith, is dad there.....yes...have you broken down again?

[@zmoke10]

Will you open the pump to see why it failed?

[@keithjob]

I've given it to the vortex guys who are going to take a look at it.

[@ericdawson3425]

Did you carry a spear fuel pump on your trips

[@MrEtnorb]

All 500/690 owners should carry a spare fuel pump and know what’s involved to change it. Have a look at the recent Taco Moto vid on fuel pumps. The best info I’ve ever seen about these pumps. He has just released a 3000 hr pump after much research. At least 3 pumps for sale are exactly the same and it’s often the case that some fail early and if they don’t they will go hundreds of hours. The comment re running out of fuel is correct, no fuel =no cooling to the pump.

[@justgjt]

Are the bladders absolutely 100% leak proof ?

[@keithjob]

So far, yes

[@colinsweir]

Hey Keith, how many kms did you get out of your fuel pump? Cheers

[@keithjob]

21,000 km, 315 hrs

[@colinsweir]

Thank you mate.

[@richardconnoly]

Unless there is a fire, a closed road out in the middle of nowhere is more of a guideline on DS and ADV bikes. :) Is there a legal issue or concern on OZ if someone just drove around a gate and carried on?

[@andrewlovell9930]

Heavy fines if caught. Up to $5000

[@richardconnoly]

@@andrewlovell9930 And this is why you ride with your brother's plate on your bike!! :)

[@andrewlovell9930]

@@richardconnoly 😂

[@BMXaster]

Nice series, but I've gotta be honest. How can it even be that y'all are loosing bolts left and right? Is it so uncommon in the dirtbike / adventure world to glue in your bolts, ALL BOLTS, with loctite for example? Never had a dirtbike but am quite a sophisticated 4x4 guy and when my truck is ready, the last thing I do is glue in ALL the bolts, which have been loosened since the last time they were glued. I never ever lost a bolt which wasn't me just loosing it repairing some stuff in the wild.

[@wazza33racer]

I watched a video of two Brits that went from the Uk to Russia to China on KTM's........both had repeated fuel pump failures. From factory the KTM's had no fuel filter between the tank and pump. Dirt got in the pumps and killed them......well DUH. Every fuel injected car ever made, has a filter between the tank and the pump. Every time a road tanker discharges into a fuel tank at the servo, some dirt finds its way in, and it accumulates in the bottom of the tank. That discharge, also stirs up the fine silt in the tank along with any water. If you see a road tanker discharging fuel at your servo.....dont get fuel, especially for the common rail diesel owners.

[@franckbrunie4759]

On an KTM EXC 500, there is a larger fuel filter inside the tank and à small filter in the fuel line connection. The latter probably got clogged here

[@andrewsoldan6050]

are you sure it was pump? maybe it was clogged injector?

[@keithjob]

Definitely the pump.

[@graemesydney38]

Now if you only had a dumb arse, low tech, gravity feed carby............ 😁

[@PissTakeProduction]

Shhh the secret word is Suzuki 😂

[@MegaRich7]

The number of worldwide videos I've watched on adventure motorcycle riding seems to suggest that you probably shouldn't rely too much on KTM. It's well recorded on how unreliable these bikes are.

[@Thumpermad]

Why you guys would do that sort of a ride on an Enduro bike when the engine and transmission is better suited to riding single track and then say it's the perfect bike for that sort of a trip? Sand riding is a given but in my opinion Horses for Courses there's probably a dozen or more bikes better suited to riding long stretches of boring dirt roads or savoring the experience by trailoring the bikes to a closer location . Good onya for getting it done it's definitely an epic journey on all accounts especially on 1 of those types of Dirtbikes they were probably only suitable for 10-15% of the trip. I relished my KTM 520 EXC in the bush because of the lower ratio gearbox and found even my CRF450R had higher ratios perhaps I noticed it more because I could draw a better comparison after riding the 2 back to back and understand why the CRF had a higher ratio for fast MX tracks. Low ratio gearboxes are epic for slow single track. I'm not a hater just can't imagine the hassle

[@occyman]

Good job Keith and lucky you were close to help. Bloody KTM …unreliable POS

[@coobye]

I admire KTM riders who travel in remote areas knowing that sooner or later they're going to break down😂. Seriously though, why do KTM still have fuel pump troubles ( and lately battery troubles ). My 950 Adventure ( sold, I just couldn't trust it ) had the same issue.