KTM/Husqvarna Fuel Pump Rebuild 

Great video, new kits come with new hard plastic lines, I'd recommend throwing them away and cutting some efi fuel hose as the plastic are difficult to get over the barbs

Thanks for the tips and tricks! Very nice rebuild kit, am surprised it didn't come with a new stem mounting o-ring but not a deal breaker at all.

Some great tips, thanks for posting.

I see options for metal in-tank filters that are washable - maybe a better option than the plastic filters and less prone to splitting? Fuel contamination and dirty filters/strainers seem to be the culprit for fuel pump failures. Great video and will use your trick to attached the safety wire before removal.

Very helpful thank yoi

Awesome video. This kit should also contain the fuel pressure regulator. That failed on my 500 EXCF and left me stranded 45km from home.

Nice video, I have a 2019 300 tpi where the pump pump failed at 5.2hrs, not sure if I just had a bad one or if this is the normal for the tpi 2 strokes !! No support from ktm on the replacement unfortunately !!

Ive just done mine. Only reaching about 40psi and drops pressure immediately when shut off

Great info thanks 👍👍

Merhaba arkadaşlar İst Türkiye benimde KTM 250exc var istop sorunu var yakıt pompası yaparmi biraz yardımcı olsan

Could you provide a link to the kit you used for this rebuild?

How do you make sure that the hose clamps on both sides of the in tank fuel filter are tight enough?

Not sure that pump to filter line you are using is meant for in tank submersion applications

From my experience no matter the type of rubber hose, if it’s submerged, it will degrade.

Watched your video and it got me thinking....what part of the pump is responsible for the pressure. Reason i ask is I have a similar problem, i thought maybe the filter was cracked causing the low pressure in my fuel line. I removed the pump from the tank and confirmed that it is working. i removed the pump housing and kept the pump submerged in a bucket of gas, and put the discharge hose ina seperate container. When i push the start button, i see it priming( pushing out a stream of fuel) but when i buttoned everything back up there's no pressure in the line when i disconnect the quick connect. Is that the fuel regulator failing on me? Just trying to understand what part is failing so i can rebuild it appropriately. Thanks!

Fuel pumps...... Lot split filters on these bikes. Sometimes just the line splits.

What are all those little bag filters for as you didn’t use them? I’m buying a rebuild kit and see the bags come with it but can’t see where they go on my Bike? Thanks

Is this a good kit ?

What AllBals model ?

What rebuild kit is this?

Dang so much easier on my RMX450 keihin fuel pump. Just six bolts and rubber oring, and then pull out from the bottom. No need for guide wires and feeding issues. Why so many leak points on the KTM design?

Think about it,that’s the bike heart,it pumps it’s life’s blood to keep you going,35miles from home,out far from your truck,or worse,60 miles from your home.$12,000 dollars and KTM doesn’t design and manufacture their own fuel pump and filters in house? With rigorous testing,to make they don’t fail? $12,000 dollars.They outsource the bikes HEART to china for the pump,and turkey for the filters.Thats the most IMPORTANT part of the bike,They KNOW those inferior pieces FAIL and can STRAND You,way out there.Yet,they quietly turn a blind eye to the bike main artery.They are a robust,strong,exhilarating street legal masterpiece otherwise.Heres a pro tip..get some roomy,yet tight to the bike luggage..giant loop perhaps..and carefully bag up the tools needed for tank removal and pump removal,out in the field,a couple filters,o rings,an extra pump and one extra fuel regulator.These things will be key.God help You My friend,if You leave out ANY of these vital pieces,on a long distance endeavor.Make sure You have at LEAST two empty fuel bottles in Your equipment as well as a funnel,to have handy when You empty Your tank,on the side of the road,once You have replaced one of the three key components that FAILED You,waaay out there,You’ll be able to pour those bottles back into Your tank,then You can repack all Your SHIT and enjoy the rest of Your ride. Shame on ANY company,that outsources inferior parts,to cut R&D.

Great video, but another reason not to get a ktm. More crap to leave you stranded. LOL. Ride safe my 2 wheel friends.