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Old 09-10-2013, 09:16 AM   #1
tanker253 OP
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Pin hole in fuel line

My three month old KTM 990 adventure sprung a pin hole leak in the main fuel line leading from the tank to the engine. Sprays a fine mist of fuel all over the running engine and my pant leg and boot. I was probably a minute away from a really bad fire. Luckily I stopped at a red light and nearly fell over because my foot was soaking wet and slippery with fuel. Worst part is now I'm stranded in Winnipeg with no dealer for hundreds of miles.. Anybody ever hear about defective fuel lines?
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Old 09-10-2013, 10:24 AM   #2
renogeorge
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Standard fuel line from an auto parts store works fine. The line for fuel injection would be best if they have it.

Are you sure it's not the quick connect?
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Old 09-10-2013, 01:01 PM   #3
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Definitely a pin hole. I can put my finger on it when I turn on the ignition and feel the pressurized fuel squirting out when the fuel pump turns on. I think I have an idea for a "patch" so I can ride it to get fixed.
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Old 09-10-2013, 02:37 PM   #4
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You probably thought of this. But a barbed 5/16 or 1/4" connector would get you home. Cut the hose at the hole, insert barbed ends into hose ends and ride on....

Good luck
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Old 09-10-2013, 11:32 PM   #5
Katoom72
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This is why i have cable tie around my fuel lines
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Old 09-11-2013, 11:08 AM   #6
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That's exactly what I did. It will keep my going till it gets fixed properly.
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Old 09-11-2013, 12:37 PM   #7
rtadlock
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Just FYI, my 2013 500 XCW sprung a pin hole twice in a week when I first go it. Here's a picture:

Somehow I got a small hole in my high pressure fuel line

Turns out there was a bad run of fuel lines and KTM recalled the part. I had already fixed it with a high pressure line, but like you, I was covered in fuel twice before I fixed it and got recall letter from KTM.
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Old 10-04-2013, 10:16 AM   #8
tacosupreme
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Mine just did this this morning. Almost aced it, tried to pass a car and got a little sideways. Good times. What size is the fuel line? Is it metric?
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Old 10-04-2013, 11:27 AM   #9
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Quote:
Originally Posted by tacosupreme View Post
What size is the fuel line? Is it metric?
Yep. 8mm internal diameter.
It's a good thing to protect the fuel line from rubbing to the frame, just above the connector.
A picture is better than my english
It's where the grey duct tape is.

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Old 10-04-2013, 11:31 AM   #10
Sporting Wood
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Most auto parts stores have 5/16 fuel injection line by the foot. Just be sure not to let them give you carburator line! I just replaced some on a BMW in the shop that was doing the same thing. BMW wanted over $100 for the two lines...cost me $5.
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Old 10-04-2013, 06:49 PM   #11
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My local NAPA only had 1/4" line, and being stranded I tried it. It fit, but it was tight. Interestingly, I got an FI fault and the bike won't start. You can hear the fuel pump run when you turn the key on, and it briefly started at first but it sounded like it ran out of fuel and died. Quick disconnect is attached properly along with all wires and vent lines etc. Do you need to purge the EFI or something? Second time in 3000 miles I've been stranded. Almost as reliable as a harley.
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Old 10-04-2013, 07:04 PM   #12
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I have had the quick disconnect cut off fuel even when properly connected. Might want to disconnect it and push something into the connector to open it.

Good luck
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Old 10-04-2013, 08:54 PM   #13
Sporting Wood
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Those quick connects can be a pain. I bet George is right?
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Old 10-04-2013, 11:49 PM   #14
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Quote:
Originally Posted by tacosupreme View Post
You can hear the fuel pump run when you turn the key on
Actually the sound you hear could likely come from the secondary butterflies (much more noisy then the pump).
Keep a finger on the pump while you're turning the key on to be sure it's priming the circuit.
Sometimes the electrical connector pins slip out.
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Old 10-05-2013, 02:06 PM   #15
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Quote:
Originally Posted by Sporting Wood View Post
Those quick connects can be a pain. I bet George is right?
Turns out it was a kink in the fuel line. The factory line has a 90* elbow where it goes into the air box. I replaced it with straight line and it was a little too long, and it kinked when I put the tank back on. Lesson learned, don't hurry maintenance just because you are "stuck" somewhere.

That said, the factory fuel line is very soft. I have had to run a few tanks of crap gas through it, I wonder if the ethanol ate it?
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