KTM & Husky Fuel Pressure Measurement 

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!

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.

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

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

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.

EXCELLENT video!

Great video as usual, super professional. Nice.

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.

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

Thank you for the video, is very helpful.

great info!

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

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

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

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

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.

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?

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.

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

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..

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

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

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.

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

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

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

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.

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!!

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

hm its a 4stroke