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Old 08-18-2010, 10:52 PM   #1
MY ADV OP
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Dont replace your fuel pump- FIX IT.

This was going to be my 4th fuel pump replacement and I didn’t want to buy a new one for $155.00 or go down the Facet pump fix. So I did some research and thanks to some fellow inmates I found a set of replacement contacts for the OEM fuel pump. It took me less than 1/2 of an hour to replace them and it only cost me $50.00.

You can order the contacts at http://www.moto-services.net/search.php Part number 18-4615

Shakin_Jake found them here for $43.00
http://www.wemoto.com/bikes/KTM/950_..._Point_Switch/




And here is a link to a how to. http://www.cbrforum.com/forum/showthread.php?t=102151

Here are a few other tips to help you get it done.

1. Remove the old contacts by removing the two screws and desolder the black pump motor lead.



2: When istalling the new contacts be sure to get the top pivot plate into the grove on the pump shaft.







3: Secure the screws and resolder the pump motor lead.

4: Before you replace the cap be sure that the cable stop (black rubber grommet) is seated all the way into the cap. I used some silicone spray to get it seated.



5: Silicone the cap and the screw. WATER TIGHT!


6: The right side is the inlet. You may want to connect the pump wire and turn your key on to make sure it works before hooking up the fuel lines.



And it's that simple.
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Old 08-19-2010, 01:23 PM   #2
dezracer
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What year is your bike? Will that work on internal pump on 07?
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Old 08-19-2010, 06:54 PM   #3
nomad guy
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just out of curiosity , why not go with the facet when its $58 ? and probably will last much longer..

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Old 08-19-2010, 07:33 PM   #4
MY ADV OP
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Why not the Facet?

Quote:
Originally Posted by nomad guy
just out of curiosity , why not go with the facet when its $58 ? and probably will last much longer..

cheers
guy
Less trouble trying to get all the parts and bits and best of all, there are no modifications needed to the fuel system. The OEM pump is what the bike was designed with and has the proper pressures and all of that. My pumps on average have lasted a bit longer than the water pump shaft and seals. So I would recommend replacing the pump contacts and the water pump shaft and seals at the same interval.
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Old 08-19-2010, 07:43 PM   #5
MY ADV OP
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Quote:
Originally Posted by dezracer
What year is your bike? Will that work on internal pump on 07?
I don’t think so DEZRACER. The 990 pumps are completely different. These pumps are for the carbureted models. I know, one day I’ll stand upright and stop dragging my knuckles and get the 990.
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2012 KTM 990R ADV (20.0K Miles and growing)
2005.5 KTM 950A ADV (106K Miles to its death by way of truck)
2005 KTM 450 EX-G (Plate)
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Old 08-20-2010, 12:00 AM   #6
shakin_jake
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Nice write up!, and thanks for the link to the CBR forum which shows a little more detail. I have this same job up and coming and your tutorial will help a simple man like me quite a bit=:-)

BTW, I bought the exact same point kit a week or so ago from a UK parts reseller here-

http://www.wemoto.com/bikes/KTM/950_..._Point_Switch/

Price was $43 delivered to my door, including overnight international shipping (Fed-Ex) to boot. wemoto rocks hard!

I agree with the premise of rebuilding the OEM fuel pump. With a good point set, the original equipment pump works well. I'll be rebuilding my water pump soon and will do this fuel pump rebuild at the same time. Since the water pump needs a regular rebuild, it only makes sense to fit new points to the fuel pump at the same time. FWIW there is currently 14 K miles on my 05.5' KTM ADV, still on the original fuel and water pump. I'm 3rd owner of this bike


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Old 08-20-2010, 12:04 AM   #7
David P.
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Quote:
Originally Posted by MY ADV
The OEM pump is what the bike was designed with and has the proper pressures and all of that.
Yes and no. It was probably the cheapest they could get since they raided the Honda factory´s trash bin and found the only reliability flaw of the AfricaTwin; the fuel pump. And they didn't care that fuel pressure was way too high and that you can't use it for serious trail riding and that they burn out like candles...

Get yourself a vacuum pump and stop worrying!
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Old 08-20-2010, 01:44 AM   #8
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QUOTE DavidP: you can't use it for serious trail riding and that they burn out like candles...


Show me a candle that lasts 18,000miles of serious trail riding...(1st set of points last month!)
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Old 08-20-2010, 06:09 AM   #9
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Quote:
Originally Posted by David P.
Get yourself a vacuum pump and stop worrying!
+1
$50 you can get 2 new vacuum one's as well. or a pump & a couple of rebuild kits.
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Old 08-20-2010, 09:05 AM   #10
BronsonRacing
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Quote:
Originally Posted by David P.
Yes and no. It was probably the cheapest they could get since they raided the Honda factory´s trash bin and found the only reliability flaw of the AfricaTwin; the fuel pump. And they didn't care that fuel pressure was way too high and that you can't use it for serious trail riding and that they burn out like candles...

Get yourself a vacuum pump and stop worrying!
Is it the very same pump thats on the Africa Twin? If so i've a spare one kicking around somewhere cos i went the facet route on my old AT. And from what i understood it was only the pumps on the early Twins that gave trouble?
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Old 08-20-2010, 09:35 AM   #11
kelly duke 2000
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Thanks for the write up and photos myadv. My points arrived from wemoto yesterday and I'll be putting them on today.

The stock ones lasted 35,000 miles, I don't think thats too bad.
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Old 08-21-2010, 01:39 AM   #12
KTBen
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Quote:
Originally Posted by veetwo _tls
+1
$50 you can get 2 new vacuum one's as well. or a pump & a couple of rebuild kits.
anyone got a link to where I can get a vac pump... I think mine just died
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Old 08-21-2010, 02:26 AM   #13
veetwo _tls
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Quote:
Originally Posted by KTBen
anyone got a link to where I can get a vac pump... I think mine just died
PM sent of the ebay links:

i got both mine (round & square) vacuum pumps from ebay. new & CHEAP & 2 x rebuild kits for each
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Old 08-21-2010, 02:33 AM   #14
mookymoo
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These pumps have 2 modes of failure:

1) The points erode.
2) The piston corrodes/seizes. Ive seen 2 of these.

The facet or vacuum pump fixes both issues. Replacing the points only fixes one.
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Old 08-21-2010, 08:59 AM   #15
ridewestKTM
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Failures

Quote:
Originally Posted by mookymoo
These pumps have 2 modes of failure:

1) The points erode.
2) The piston corrodes/seizes. Ive seen 2 of these.

The facet or vacuum pump fixes both issues. Replacing the points only fixes one.
Saw the corrosion once. But in this case I think it was toast by over heat due to stuck points first - but then again it could have been stuck first -oh well. That pump actually caught fire. If the pump corrodes it must be getting wet internally. The points can handle wet - just not very long.
As I stated before I think the mit'zu pump is junk but the FET triggered by the points makes it near perfect. I'm STILL running the timer circuit. I've got a box of them so I'm good for 30yrs worst case! The vacuum pump is interesting but it's just wrong (philosophically-I know it works tho) to put it on the intake suction and the crank-case vacuum pulses (very astute) are subject to case vent changes and either way some find pressure to be excessive.
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