I have just about given up, this is a plea for help.

I have a 2009 FE450. When the bike runs it runs great. Unfortunately, it is not running. It starts and runs for about 5 seconds then shuts down. It seems the computer cuts the power. Valves are within spec, engine has 105 hours on it.

Here is what I have done to help diagnose/fix the problem
-   Installed new battery
-   Bypassed the roll over sensor
-   New spark plug
-   Ripped the entire wiring harness apart looking for breaks/shorts
-   Tested every sensor per the repair manual, all are well within spec for voltage/resistance/continuity
-   Checked fuel pump pressure, it‘s +40PSI, FUEL PUMP IS WORKING, all filters are clean
-   No error codes are being thrown

I had other issues. Previously, bike would run great for about 1.5hrs, then start bogging, stall and finally not start again. It has left me stranded a few times this way. I thought I had the problem fixed, but happened again last weekend. The Berg fairies didn’t fix it this time, which in a way is good, because when I fix the problem this time, it should be fixed.

I am at the point where I don’t know what to do next. Everything simply tests fine but bike won’t run.

Any ideas? I need this fixed, I have missed a couple races already this season. My dream bike is turning into a nightmare.

An issue with the FI mapping perhaps?
This is about the time I take it to the nearest Husaberg mechanic!

husky34, on 06 July 2012 - 11:31 AM, said:

Bike was runinng great. Since our local dealer closed up, the nearest one is 5 hours away. I am going to put my ECU on a good bike, see if it has the same problem.

If it were me....I would look at replacing the fuel pump with the CA cycle works pump....especially given that it used to run for 1.5 hrs and then fail on you.

http://www.ktm-parts.com/FP-HUS.html

Also....did you check to make sure the fuel injector is actually working....i.e. pull it out and when you try to start/run it ...make sure it is spitting out fuel.

beyond that I am out of ideas.

BryanK, on 06 July 2012 - 07:16 AM, said:

ALWAYS check all pertinent fuses and relays. If those front-line diagnostics check out OK then follow this:

If the fuel pump does not prime every time the key or kill button is set to RUN, and the fuel pump sometimes sounds weak and strained, THEN replace the fuel pump.

If the fuel pump primes every time the key or kill button is set to RUN, and the fuel pump always sounds the same, strong and steady, not weak and strained, THEN replace the fuel filter.


Here's the no-middle-man source for the 30mm fuel pump: http://www.ca-cyclew...el-carbs/fp-hus

Edited by OlderHuskyRider, 09 July 2012 - 12:02 PM.

BryanK, on 06 July 2012 - 07:16 AM, said:

Do you have a fan?  Does the fan come on when the bike starts for 5 seconds?  There's a possibility that the thermostat is bad and is sending a signal that the bike is so hot, that the ECU kills the pump, to save the "overheated" engine.  unplug your thermostat and see if the bike remains running.

Edited by OlderHuskyRider, 10 July 2012 - 08:16 AM.

OlderHuskyRider, on 09 July 2012 - 11:57 AM, said:

OlderHusky....I hear you about the middle man....but the funny part is that when you register with KTM-parts...you get for 10% off the $129....cheaper than buying direct from CA cycleworks.

Thanks for the help. Problem has been solved. Turns out it was the fuel pump. It tested over 40PSI, but that is on the edge of the bike working. After swapping with a good pump, the bike fired up. The good pump puts out over 50PSI

I confirmed it was a fuel problem when I could get the bike to run on carb cleaner squirted into the throttle body. It richened up the mixture enough to fire. I guess the low fuel pressure was leaning it out to much. I did see the injector was squirting, but not enough pressure to run.

The bad pump is a ca-cycleworks pump. They have been kind enough to replace it under warranty.

I had the same problems with my bike you were having. It turns out whoever replaced the fuel pump used an overtightened zip tie on the fuel pump wiring near the connectors and the small connector was bent out of shape causing a loose connection. It was also a CA Cycleworks pump. In this case the pump was fine once I corrected the poor electrical connection.

Same issue here :/
I found a fix until I have time to cure the actual problem, pour a squirt of gas (like 2ccm) down the intake, then it starts and runs as nothing ever happened.