How-to Install KTM, HQV Fuel Tank with Fuel Pump

[@lodcomm]

Yet again, slavens has a video of exactly what I was looking for! - thanks again guys

[@Sturlington48]

I recently replaced the fuel pump in my 17 KTM 450 EXC and I wish it went as smoothly for me as it did for Jeff. I had the same idea to use safety wire as well, but for some reason my tank was so narrow on the fuel pump side it would pull the wire loose trying to get it down to the holes. I ended up using nylon string and a really long screwdriver to get the pump to slip in between that narrow portion of the tank and down to the two holes. I cussed and wrestled with that SOB for almost two hours. Now I’m watching this video a month later after doing mine and Jeff makes it looks as easy as falling off a log😂

[@DMobley232]

Can you explain more about how you used the screw driver? Did you use the screw driver to slightly pry to make it a tad bit wider in the tank? I'm damn near to the point of lubing the damn thing of with some KY Jelly and see if that does the trick.

[@lonsomecrow]

Same here . Jeff makes it look it easy but getting it in there is next to impossible. I’m still struggling on my ktm 500 :(

[@DMobley232]

@@lonsomecrow What helped me was I could get the larger end started. Then I used a flat tip screw driver pried it through and while still holding the flat head I was able to get the end started on the threads.

[@lonsomecrow]

Dustin Mobley you mean you inserted screw driver from gas cap and pushed it down while pulling the wire from other end? I have used Acerbis tank and it was easy but somehow Stock tank is PIA

[@DMobley232]

Girish Sharma no. I was able to get both ends of fuel pump started just a bit in the holes. I was able to then use a small screw driver at the bottom of the threads on larger one a pry out enough to screw on connector.

[@danpluso]

Torque specs are 15Nm (11.1 lb ft) for the two 17mm and 2.3Nm (1.7 lb ft, snug) for the four 6mm on a stock XC/EXC tank.

[@johndavis1217]

Lots of talk about Acerbis vs IMS on the forums. Some guys love the IMS with the brass inserts. Some claim the Acerbis leaks. I've had good luck with brands in the past. I'm leaning towards the Acerbis.

[@claytonhertz251]

John Davis I’m curious too. I’m not Sure what the difference would be.

[@lonsomecrow]

Don’t buy Acerbis. Their wood screws are shitty ...mine are messed up and now I have to buy new tank! Why don’t they use metal inserts??

[@DMobley232]

Have you done this on a '17 KTM 250 SX-F stock fuel tank? I am struggling to get the pump back in the tank and lined up. Going on 2 weeks now. At this point thinking of just buying new OEM tank or may upgrade to the Acerbis 3.1 and maybe will be easier to get back in with a bigger tank.

[@slaverace1]

Yes, I have installed them in the small tank and the procedure is the same. You can call me and I'll try to help over the phone. [phone] Mon-Fri.

[@DMobley232]

@@slaverace1 Thanks. I'm getting closer. I can get the small end with the wire around it about 1/2 to 3/4 through the hole, but can barely get the larger end started in the hole, just a bit more and I can probably get the screw on it. May need to get a 2nd set of hands.

[@crs2crs2]

I wish I knew this before I bought a torque screwdriver and tried to torque those bolts to the value indicated in the manual.... those threads stripped instantly... So follow the instructions in this video, do not try to torque these bolts.

[@johnathonsilva5279]

How did you fix it? I stripped one of mine

[@crs2crs2]

@@johnathonsilva5279 fortunately the screw could still bite enough to hold the plate securely. I've been using it for 2 years no problems. Next time I change the fuel filter in the pump I might fit metal threaded inserts for plastic. If those won't hold I'll have no option but to get a new tank.