How To Replace the Fuel Pump on a KTM 690 & Husqvarna 701

[@peterwatkins5630]

Great to see a video without time-wasting crap that has very sensible and useable content with important tips. Thank you

[@djdarrenrv]

great video! im about to go fix this bike (2015 duke690) with this problem. gonna replace with new whole pump assembly since it's cheap at under $150. thats crazy that the whole rear section is a gas tank!

[@craighoffman6876]

Nice detailed video that shows how ridiculous this design is. Be that as it may, KTM excels in other areas and addressing some of their flaws is worth it to me as they make bikes that the Japanese simply refuse to make, like that burly and very cool 701. No way I am riding a DR650 or KLR, life is too short for that at this stage in the game. I have a '10 "70 Degree" Husaberg FE 450 that I bought new back then, it is essentially a confused KTM and the first of their dirt bikes to come with fuel injection. Naturally the FE had widespread fuel pump issues, and the collective online brain trust learned how to deal with them. The layout and even the Mahle KL97 in tank filter shown in the video are all the same as my '10 'Berg. That makes me wonder if KTM has learned anything about their fuel injection pump issues over the last 13 years. On the plus side, at least I know how to make it reliable 😆 I replaced the failed OEM pump on my 'Berg with a Cycleworks unit back in 2011 and it (and the bike in general) has been flawless ever since. While in there, I also deleted the retarded in tank Mahle filter and instead run an external Wix/Napa part number 3100 11 micron metal canister filter located where the quick connect used to be. Everything is secured with Oetiker clamps. I replace the external filter, which is a simple 10 minute job, each riding season. Another advantage of the external filter setup is you don't have to keep removing and reinstalling the self tapping screws from the plastic tank over and over, which is a potential fuel leak and strip job if there ever was one. Why no metal inserts in the tank for the fasteners there? Things that make ya go hmm... Much of that black "dirt" in the in tank filter is from the KTM fuel pump itself. Ya don't see that kind of accumulation with the Cycleworks pump. I dunno if I would trust that no name All Balls pump, because if the pump quits the bike is dead - it is a critical part. Speaking of the filter, the Mahle "97" in tank filter is 30 micron, which is inadequate to protect the injector. KTM added the tiny "cone" filter shown in the video. The 10 micron cone filters were/are notorious for clogging as they are so tiny. At least for awhile there, KTM went to a 20 micron cone filter, which is marginal for protecting the injector. I recently bought a '23 Husky 701 and plan to remove the cone filter and run the Wix/Napa 11 micron canister external filter. Will delete the internal filter after a riding season and set it up just like my old 450. I just hope the pump itself is better than the days of old. One handy tip for any injected bike - don't run the fuel super low if you can help it, as it will get hotter, and hot fuel is hard on the pump, potentially causing the impeller to partially or completely stick, which burns out the pump motor.

[@donkeizluv]

thanks. Some awesome info here

[@themosaito]

This is an excellent video. Thank you very much!

[@greatfallskam]

What kind of zip ties do you use for inside fuel ( in tank )? Someone told me to look for PA66 type.

[@terramoto215]

Apparently most zip-ties are nylon which is ideal in fuel. Seems the PA66 is a nylon type too

[@docwyte]

So at least on my '17 690 I didn't have a flap to remove covering the fuel pump and I also didn't have to remove the side plastics. Removing the muffler helped a bunch and I did have two lower tank bolts...

[@andreisimion373]

Hey, thank you for the video. Just replaced my burnt out fuel pump one my 2010 Duke 690 with the one from AllBalls you show in the video. Why do you think this new pump failed after less than 50km of using it? Could it be a bad pump or could it be something else and the pump is just a symptom for the actual problem?

[@billslicer3203]

Thank you

[@alexandrdolgy]

Это было полезно.

[@dougiequick1]

IMHO this is a VERY poor design I believe there is just no good reason that this is not a complete unit where there is no need to do all these steps to preserve a bunch of cheaply made parts...the ONLY reason I would be in favor of the rebuild kit would be so a new pump could be more easily carried on a true outing adventure where every ounce of weight matters and where space is precious. I just see no reason now that most motorcycles are fuel injected that fuel pumps are not more universal and of more simple design ....But I watched a video on tearing down the 60 motor and came away in wonderment how complex KTM makes things compared to Japanese motorcycles....well to be fair older Japanese motorcycles as I honestly have little experience with real recent stuff

[@GrahamSmith1523]

This music fading in and out is pretty painful. I expect better from you guys.

[@The-Host]

Trade it in for something not built in china by ktm. Done.

[@noahlhefner7150]

husky isnt even a chinese brand

[@The-Host]

@@noahlhefner7150 ktm owns husky. Ktm now builds their bikes in china. Look it up fan boy.

[@noahlhefner7150]

@@The-Host No? They are quite literally built in Austria. No bike built in China would be 9000 and up

[@The-Host]

@@noahlhefner7150 go do some research bud. They are most certainly built in china now. I was just reading dirt riders article a few months back. The fact that they are close to 13k should infuriate you. But fan boys gonna fan boy. I bought a brand new Rieju Ec300 for 9500. Built in Spain. Comes with all the bells and whistles even off the show room floor. Keep simping for your Chinese built bikes. Quality was garbage before they went to china. I guarantee it ain't about to get any better hahahahaha.

[@The-Host]

@@noahlhefner7150 advrider.com/certain-ktm-models-will-be-made-in-china/ You won't look it up yourself. So here ya go. ;) Enjoy those orange china bikes my dude.