KTM & Husky Fuel Pressure Measurement

[@motocyclesandmayham]

My 2019 300 TPI with 45 hours would not idle and was difficult to start. I built the fuel pressure test tool described in this video to get an initial reading before making any changes. The initial reading was zero (even when running which I know sounds impossible). I tested the tool on another bike to confirm it was working properly which it was. After changing the filter in the tank (KL 97/1), the pressure readings on the 300 were the same as my test bike and similar to what is shown in the video. A mechanic friend suggested on anything fuel injected, always start with fuel pressure. This video was especially helpful on how to do just that. TokyoOffroad is a fantastic channel for gumbies like me who are trying to learn how to care for their machines. Thanks!

[@human1513]

I just learned on my 2022 KTM 300 XC TPI while checking the torque of the retaining screw for the front drive sprocket while it was in gear (bike on a lift so the rear wheel was free to spin) that when the engine turned over due to my manual torquing the screw that the fuel pump will cycle for approximately 1 second. But not the oil pump as I checked via a stethoscope. The fuel pump would repeatedly run for 1 second every time the engine turned over. An easy & simple way to prime the fuel system I discovered. No jumpers to the fuel pump. No starter usage required.

[@mesbahe]

What an amazing channel keep up the good work and don't forget about the 4T guys.

[@itsthebike6672]

Great video as usual. Thank you. For the newbie KTM riders out there, I always ensure that I have a spare fuel filter and spare fuel filter O rings as well. These two items will ruin your event if you don't have spares.

[@AlexKost-tq6bj]

Great video as usual, super professional. Nice.

[@TokyoOffroad]

Thanks. Pleased to hear that you liked the video

[@NirHason]

As always, detailed informative video! Congrats on the new T-shirts!! :)

[@human1513]

My 2022 KTM 300 XC TPI fuel pressure test produced 48 - 50 psi with the engine off. ~50 psi then it dropped to 48 psi after approx. 5 seconds and stabalized there for a while. Engine running it produced a steady 53 psi at idle and raising the rpm some.

[@SM-98]

Thank you for the video, is very helpful.

[@TokyoOffroad]

Pleased to hear that you found it useful.

[@ThisTall]

I’m going to try to build one of these today. My 2018 exc 500 seems to be draining that black fuel pump housing faster than it can possibly draw it in through the two bottom Inlet pinholes. So it’s draining the entire housing and sucking air in through the top. My theory is that the regulator must be allowing too much bypass without achieving pressure, and the pump is just running too fast?

[@mt1885]

EXCELLENT video!

[@human1513]

Not everyone has the pliars. Just use a dulled pair of side cutters to crimp the clamps. I bought that fuel pressure kit from amazon.

[@stephenking9797]

Classy video as always but one possible snag is that you are measuring the pressure with low fuel flows at idle. If the pump is getting bad then low pressure may only show up at high flows. I think that is why the KTM manual shows a test where fuel is discharged through a nozzle into an external container. You really need to observe the pressure when you are blasting along at full power and there is maximum fuel flow to the engine! Now that should make an interesting video..

[@TokyoOffroad]

I did rev the bike too in the video (5:10~) and the pressure didn't change. Yes, they are not full load measurements, but good enough for my purposes. I wanted some reference baseline measurements which I can easily reproduce if I suspect I have an issue at sometime in the future.

[@09Tedesco]

The KTM manual also states: Select the "Function test of fuel pump control" actuator test. Is there anyway to do this with TuneECU or with the ODBII connector you made to read the diagnostic codes?

[@danielcheng5070]

Thanks for the video, it's very helpful!!

[@redbear1935]

Have same kit it my gage shows 25psi on my supertenere 1200c.c when running on idle. Manual says should be 43.5-56.6

[@user-vo8ij2jj4r]

I got a question regarding the fuel pressure. I tried 2 different pumps, one idles at 3.5 bar one at 3.4bar. Both dont drop while revving the engine but will drop around 0.1-0.2 bar while riding. Os this normal? I got aome misfires on my 2016 501 and cant figure it out...

[@adambatchelder4121]

Yep I made one like that when the efi came out in about 2011

[@lukasilec1987]

I have exc tpi 250 2019 i have 20 hours on it. i noticed inside fuel tank fuel is spraying and i can see somthing like air bubbles so im guessing there is some crack on hose or on pump joint with filter. otherwise bike runs fine at mid-high rev and full tank but when is on fuel reserve it start bogging (i think then it starts to suck air through this crack). Also in 6 gear at low rpm bike also have running issues.

[@TokyoOffroad]

Possibly the fuel filter is cracked and needs replacing

[@98NSX]

I had low fuel pressure on a 2017 FE350, after swapping the pump, filter & regulator I carried out the pressure test, with the engine running the pressure reads a steady 50psi. However when when I turn off the engine the pressure drops quickly (about a min or two) to zero... is this normal or should it hold pressure?

[@rotor676]

Love your repair vids.. Any chance you could do a review on upper body armor. Thank

[@maxkapo1]

I carried out the pressure test, with the engine running the pressure varies from 46/48 psi. when I turn off the engine the pressure drops quickly to zero... is this normal?

[@willyfromthehillies]

great info!

[@09Tedesco]

Do you recall any details about the after market metal connector fuel pump?

[@TokyoOffroad]

The full metal quick disconnect inline fuel line connectors which I know of are CPC LCD22005 and CPC17005. Please note that I have no experience of using these parts, but others on KTM Talk web forum have used and like them.

[@Bimmere]

I did this same exact thing when troubleshooting my buddy’s 16 ktm 500exc.. he told me he was riding his bike to work and all of a sudden it bogged, died and couldn’t restart.. I tried various things and couldn’t figure it out.. I told him let me look at it.. sure enough I hooked up a fuel psi gauge and psi would crash, and ended up being a split fuel filter inside the tank. (Dumping psi back into the tank).. replaced filter in the tank, and it fired right up!!! Took me about 30 minutes to find the issue, I can imagine how much the dealer would have raped him on that!!

[@Bimmere]

Sorry “he tried various things”

[@scotttaggart]

I have a '17 fe501 and various buddies have KTMs, etc. Virtually every one of us has experienced the "split" fuel filter in the tank problem (mine happened once in Moab and then a few months later in the middle of nowhere in Nevada). Many people think their fuel pumps have failed and the dealer, either none the wiser or looking for a better boat payment replace both the pump and filter. The problem is the the stock plastic fuel filter is junk and just as likely to fail again after replacement. I and friends have gone to a metal replacement (same in all dimensions as the OEM filter). P/N is Purolator F29160 or equivalent. A few bucks online. I am now replacing these proactively when I get a new bike from Austria.

[@andycapp8843]

@@Bimmere .....Sir...yes! You are indeed an apology. Is there really nothing going on in your life?

[@Bimmere]

@@andycapp8843 uhhh what do you mean? I’m confused by your post

[@lisandrograciano3916]

What it does the bike dont loose pressure when is off?

[@frazzle657]

I need to find where mine is pissing the pressure out from

[@TokyoOffroad]

Sorry to hear about the problem. Unless you can see a leak somewhere the most likely cause is the in-tank filter/pump assembly. If the filter is old it's a good idea to replace it (worse case the filter body can split) and check the the fuel pump runs OK.

[@Dobemandan]

Nice shirts! Wish the international shipping was less expensive... You should ship from China... International costs almost nothing.

[@TokyoOffroad]

Yes, unfortunately international shipping isn't cheap. One way to minimize the shipping cost is to do a group buy with some friends.

[@09Tedesco]

Hi, I am attempting to build a similar fuel pressure measurement gauge. I have seen similar fuel pressure kits as the one you have purchased however, there is one distinct difference. The 'T join' starts out at the same thickness and then gets longer and thinner. My concern and question is, do you think this will impact the fuel pressure measurement. Happy to PM you the kit I'm looking at. Thanks

[@TokyoOffroad]

Whiskey Throttle Enduro - The length and thickness of the pressure gauge tube isn’t critical and won’t affect the accuracy of the measurement so long as they pressure reaches steady state during the test period.

[@09Tedesco]

Tokyo Offroad Thanks

[@motokamura]

I built same system however I got a reading of 58 psi on both of my bikes(2020 300 and 2021 500). I’m thinking my guage I bought on Amazon is a little off. Looks like the same kit as you show on your video.

[@mattiassjogren2840]

Awesome video as usual! Where can I find the fuel line hose? Is there any part number for it? Thanks a lot.

[@TokyoOffroad]

KTM Part Number of the hose I used is 60007316260. This is a 260mm long length.

[@mattiassjogren2840]

Tokyo Offroad Thank you!

[@陳民勝-z5z]

Is there any special benefit to living in Japan for a dirt bike rider?

[@TokyoOffroad]

Over 70% of the land area in Japan is mountainous so there's no shortage of places to ride. Also off-road riding is not that popular so you can often ride all day without seeing any other riders. I know many other countries are very restrictive regarding where you can ride so Japan is pretty cool. so long as you respect others and don't abuse things you can have a good time riding here.

[@ollie6512]

Hey! I have a 2019 KTM 250. I seem to have a hanging idle!! Could it be the pump / filter causing this? It feels like a lean condition from my carbed bike experience

[@TokyoOffroad]

Sorry to hear about the problem. Has it always had the hanging idle, or changed recently? Yes, hanging idle is a lean condition. Either there is a fueling problem (fuel pressure too low, blocked fuel filter, or injector) or an air leak (check throttle body outlet hose clamp, reed valve, crankshaft seals). Did you do the idle screw mod? If so try closing the throttle body air screw more (and then adjust idle speed with the throttle stop) and see how it responds.

[@ollie6512]

@@TokyoOffroad thanks for the speedy response! I have only just purchased the bike (it's on 70 hours). I have pulled the fuel pump and the filter was very black so will be changing this. The idle mod has already been done by the previous owner. The throttle body air screw was out 1.5 turns which I have moved to 0.5 turns out. It seems to run just fine under load but when accelerating hard and then pulling in the clutch it then hangs. I will link a video I have uploaded if it's ok to have a listen to that would be greatly appreciated!! Thanks again

[@josex360x]

Man. You seem to be familiar with KTMs and Huskys. Have you experiened frame-rust on your bikes? I have a friend with a 2017 Husky Tc125 and it is rusting fast and I know my friend takes good care of the bike. I want to buy a 2019 250exc but I don´t want the same issue.

[@Bimmere]

josex360x I have not seen any ktm/husky/Husaberg having rust issues... not sure why his is...

[@josex360x]

Do you have newer bike? @@Bimmere I have a 2013 Husky (italian husqvarna with a black coated steel frame). On my bike's frame, there are spots where the paint i almost done, but the bare steel/frame looks shiny. My friend's frame starts to rust a soon as it looses it's paint. All over the bike.

[@Bimmere]

josex360x my personal bike is a 2019 model, but I know a bunch of people with older models anywhere from early 2000’s to present year, and none of them have rust... unless say a rock hits part of the frame and chips sone of the paint on the frame and expose the bare metal elements, then I can see some rust... but that’s why you should have touch up paint on hand Incase you chip the paint..

[@TokyoOffroad]

No I haven't seen any rust issues. I have a 2017 KTM 250 EXC and the 2019 KTM 250 EXC TPI shown in this video. Before these bikes I had a 2013 KTM 500 EXC and that didn't have rust either. I keep my bikes in a garage out of the weather.

[@scotttaggart]

Is s/he riding in a salty area or a desert soil with high alkali? Both will corrode almost anything.

[@chrismarshall4814]

Off topic but can you help with jetting for a friends bike back home is sunny England. 2016 250exc. It has never run right. He has the Suzuki needle in. Any advice be appreciated.

[@TokyoOffroad]

Those come stock with a Keihin PWK 36mm Air Striker. Should run well with the right jetting. What are the symptoms?

[@chrismarshall4814]

Tokyo Offroad it just runs terrible unless it’s wide open. You can’t blip the throttle to clear an obstacle as it just has zero punch. And is also gutless unless it’s full throttle. My 17 250 feels electric response compared to his.

[@andy205wrc]

what jets is he using in the carb Chris? pilot, main, float level height? needle position? The suzuki needle you mention the NECJ??

[@chrismarshall4814]

Andy Baker yes bud that needle. Float height has been checked to spec. 40 pilot 170 main and tried needle on clip 2 and 3. The bikes never ran right. He is very frustrated.

[@chrismarshall4814]

Andy Baker any thoughts?

[@MrPartyplopper]

hm its a 4stroke

[@TokyoOffroad]

No, it’s my 2019 KTM 250 Transfer Port Injected two stroke. They have fuel pumps just like 4-stokes, but the similarity ends there ;-)

[@MrPartyplopper]

@@TokyoOffroad ooo okay thats something you dont see or hear about often :p my mistake, very nice bike!