KTM can you fix this?

I've replaced the filter on my bike twice now, so that's the original filter, a replacement at 40 hours and a replacement at 70 hours. On my third filter and I'm wondering if I can trust this bike. KTM, it sure would be nice if you came up with a solution like a slightly more open filter so it isn't screening down to whatever low microns and clogging up. I'd rather replace inline filters more frequently. Alternatively deeply discount the fuel pump filter if they have to be changed out every 30-40 hours because $66.77+ tax is ridiculous. Dealership cost is half that and the part itself is a $10 part.
My disappointments with KTM are few and I admit I'm an orange koolaid consumer. (Currently own three) and while I could to stamp my feet, throw SB in the corner and have a big tantrum and try another brand of bike I've also seen every brand of bike fail on the trail or in a race. KTM makes good products and this seems like an easy fix to keep a consumer like me coming back.
My working theory is the carbon coming off the fuel pump brushes eventually clogs the fine gauze/felt inside the filter and that prevents fuel from flowing at full throttle. If left this will eventually prevent the bike from running. I see a huge liability for KTM if someone goes to hit a big jump and the bike bogs out and they crash because of a manufacture defect. Do better KTM.

[@mikebarger3563]

I've replaced my second one of these on my 23' 300 XC. First one at somewhere around 60-70 hour mark. My bike now has 125 plus hours and it started doing this exact same thing again. I bought a new pump and filter assembly this time. Bike has been running good since I replaced it but time will tell.

[@TeamStruggleBunny]

I've been told that washing the tank out with soap and water has helped. Haven't tried that myself. I think the carbon coming off the pump's brushes is contaminating the filter. I see there is a new part number for the pump so so maybe something there, no idea.

[@davewatt5215]

Do you have an in tank screen/filter at the filler neck(A48007918000)? I put the KTM part in from the get-go and have just over 60hrs with no issues. Ive changed out the small inline filter twice.

[@TeamStruggleBunny]

Yes I do. Put it in after my first filter failed and it's been there ever since. That said the fuel jug I use is new, the fuel comes from the same station where all my fuel comes from for the bikes, truck, and tools. It seems unlikely it is contaminate getting in from the outside and looking at the filter it looks like carbon from the fuel pump brushes. I think the filter screens to a very low micron. When you changed your inline filters were they dirty or did you change just as preventative maintenance.

[@BabineauMoto]

That's super annoying! I wonder if the same would happen with aftermarket fuel filters.

[@TeamStruggleBunny]

No idea. Haven't found an aftermarket version and I'm sure the filter is doing what it was designed to do so a couple of ideas, the tank mould release agent is leaching from the plastic fuel tank, the pump is working to hard and carbon off the brush contaminates the filter and the filter screens to a to fine micron level. Other thoughts, something in our fuel or the 2T oil.

[@Tacoexplorer]

That's odd. Did you have a bad batch of fuel or something that clogged the filter? I have a 2024 KTM 250 XCW.

[@TeamStruggleBunny]

Nope don't think it was fuel. My working theory is: 1. The filter strains down to a very low micron 2. The carbon from the fuel pump brushes contaminates the filter.

[@Tacoexplorer]

@@TeamStruggleBunnyare you sure it's brushed motor and not brushless?

[@TeamStruggleBunny]

@@Tacoexplorer Pretty sure. Here's Taco Moto talking about the pumps. kzbin.info/www/bejne/Y2eui6KppqqgsKc

[@TeamStruggleBunny]

@@Tacoexplorer Pretty sure they have brushes. Here's TacoMoto's dissection of the old and new pump. Seems to think the new pump had less failure points. kzbin.info/www/bejne/Y2eui6KppqqgsKc

[@ryanstewart1521]

Went for a ride the other day on my 2024 300 xc-w and gas light came on at 1/3 tank left, another issue Ktm needs to fix, the ccps sensor is a bad design and leaks causing fouling or poor running, the mapping is to rich in the lows and to lean in the higher revs also causing fouling, the tps needs to be reset frequently as it’s crazy sensitive, the rebound clickers on the bottom of the fork are plastic so they break off, the oil fill tube where it connects to the reservoir can leak if it’s bumped and knocks the little o-ring, the start stop switch is just stupid hard to press and make work and it’s on the same frikin side so it’s easy to confuse, and their new headlight bolt on setup just sucks. Besides that they are a great bike.

[@TeamStruggleBunny]

Lol, there looks to be an easy way to adjust the sensitivity of the low fuel, look at tacomoto video where he talks about the new and old style fuel pump set up. The newer CCPS set up is better protected than the old one but I've never really had an issue on my '19 or my '23...wait I think I did replace the CCPS on the '19 once. I've never messed with the TPS but have been tempted as I did a mild increase in volts on my '15 500exc and that woke the bike up significantly. Are you running the most current map? Strange to be fouling plugs on the xcw, I've heard of this on the xc but not so much on the xcw. I've never fouled a plug, save one time on a te250 I owned and it was totally my fault. Also no issues with the oil reservoir or start stop switch, though I totally get you on that as I sometime get a bit confused moving between bikes. Hope you can get those annoyances sorted out, because I think these are great bikes.

[@ryanstewart1521]

@@TeamStruggleBunny I meant the start stop switch on the handlebars, yes I’m running the current oem map. It started fouling plugs a little after 30 hrs.

[@TeamStruggleBunny]

@@ryanstewart1521 Yeah I don't mind the start stop, have mine set up so when my hand hits the bar (dead engine race starts, hands on helmet) my thumb falls to the go button. When I jump on my '19 xcw I sometimes get messed up looking for the kill switch. Have you had any map updates since getting the bike or have you adjusted the air screw any?

[@ryanstewart1521]

@@TeamStruggleBunny no map updates yet, not sure where the air screw is at on a tbi bike. lol.

[@TeamStruggleBunny]

@@ryanstewart1521 Lol, right forgot ...tbi. There's some good videos, tacomoto again that walk through TPS setting and how turning the red idle screw and, what I didn't know, turning the yellow high speed idle can throw things off for the TPS and how rich it might run at low rpm.

[@mark_Hershey]

Bike doing the same thing. 2023 300xc

[@TeamStruggleBunny]

I'm told that rinsing the fuel tank out with soap and water helps before replacing the fuel filter. I'll try that next time. Taco Moto snorkel goes back to the old style fuel filter which I think is more durable. Idk... I'll try a the rinse, maybe a new fuel jug and go from there.

[@mark_Hershey]

Well, I wasn’t able to pull my pump out tonight, fuel to high. Rode a little but hot. I’ll check it out tomorrow. If washing is good then buy one, washing old one, and keep swapping. My issue with the filter being clogged is after I do stuff or fill it up it goes away. It seems it only happens when fuel level is low, but not low enough for the light to come on. Looking at pump maybe will tell if I got a loose filter maybe? But my bike is doing exactly what yours is doing, sometimes….

[@mark_Hershey]

Hey, I just changed mine. I have been trying to find out why my bike loses power, last night it about hurt me on my big double. Took everything apart, traced wire harness, nothing. Got a pump filter because of your vid but decided the filter was fine. Today I changed it. As I was messing with the pump a wire sheath fell off, it’s in bad shape. Kinda dissolving. Could that be why my old filter is black? Here’s a short vid.. kzbin.info22lRp0ofM04?si=eNktoEeDeeegW5Fd

[@TeamStruggleBunny]

That's a solid lead for a possible cause. Is it the wire loom that goes over the wiring that fell apart? I noticed there is a new part number for the fuel pump so I ordered it and can compare the two. Super curious about that stealth.

[@mark_Hershey]

It was just around the wires, honestly I wasn’t paying attention to it until it fell off wile fiddling with putting new filter on.

[@TeamStruggleBunny]

@@mark_Hershey Definitely going to pump my pump and look at that as a possible source for contaminate in the filter. I was thinking fuel pump brushes but this is an interesting possibility too.

[@TeamStruggleBunny]

@@mark_Hershey I'm guessing it was covering the blue and white wires. Also was just looking for info on heat shrink and wire wraps and they may be susceptible to breaking down with alcohol so fuel with ethanol might be why yours came apart maybe.