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Thread: KTM 690 SMC Fuel Pump

  1. #1
    Join Date
    May 2008
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    Default KTM 690 SMC Fuel Pump

    I've got a '09 690 SMC with a strange problem. I had the dreaded fuel pump problem, and eventually got the "Code 41" and the bike wouldn't run. I installed a new pump/filter assembly, and the bike has been running perfectly ever since. But I still had the FI light blinking at me (or solid when riding).

    I finally got my TuneECU cable and got connected, then cleared the codes on the ECU. Unfortunately, the same codes keep coming back, as does the blinking FI light. The blinking code is still "41", while the codes in TuneECU are P1231 and P1232 (both indicating a short to the battery for the fuel pump).

    One thing I did notice is that when I turn the key on (even without starting the bike) is that the fuel pump just runs continously. I thought it was just supposed to prime for a second or two, then turn off until the engine was started.

    Any ideas on what to check. Is there a fuel pump relay? Thanks for any tips!
    -Dan

  2. #2
    Join Date
    May 2008
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    Binghamton, NY
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    539

    Default

    Pretty sure there is a relay. And yea, it should only last like 2 seconds.
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  3. #3
    Join Date
    Aug 2008
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    673

    Default

    Maybe there is a problem with the pressure regulator... that provides power to the pump

  4. #4
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    May 2008
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    Default

    Thanks for the ideas and information. Knowing it should only click on for a few seconds definitely confirms that there's an actual problem. I didn't pull out the regulator when I changed out the pump. It's definitely worth checking out. Thanks again for the help.
    -Dan

  5. #5
    Join Date
    May 2008
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    41

    Default ECU blown?

    I thought I'd post a quick update on how things are going with my bike. I looked in to replacing the pressure regulator, but as it turns out, the regulator doesn't do anything with the electrical signal for the fuel pump. When the pump is on, it just regulates the pressure going to the fuel injector by bleeding off any excess back to the tank.

    What I found as the problem is kind of disturbing to me. The fuel pump gets 12V from the power relay, and is grounded through the ECU. There are no switches or relays between the pump and ECU. I ended up finding a good deal on a used ECU, and after swapping that in, the problem is completely gone.

    This disturbs me because this probably means the circuit that grounds the in my original ECU is no longer functioning (but at least it defaulted to a closed circuit). I thought about adding another relay that would protect the ECU from a fuel pump that might stall, but then thought I'd measure the current drawn by the pump. Turns out, the current is under 2.5 amps.

    My solution for the moment is going to be to replace the 10A fuse for the fuel pump with a 5A fuse instead. Hopefully if I ever have a pump problem in the future, the fuse will blow before the ECU does.

    Just wanted to pass along the info in case anyone else had a similar problem with the Code 41. I've been considering opening up the original ECU to see if I can replace the component and use it as a spare. But I always hate clearing all the potting compound off. And technically it works as a spare right now (just with a code flashing on the dash).
    -Dan

  6. #6
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    Feb 2008
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    Atlanta, GA
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    Quote Originally Posted by cord4530 View Post
    The fuel pump gets 12V from the power relay, and is grounded through the ECU.
    This is how most cars/trucks work these days. Nothing new here.
    690 SMC

  7. #7
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    May 2008
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    Kind of. In most automotive cases, the ECU grounds the fuel pump relay rather than the pump directly. Of course, the new cars with a returnless fuel system are all together different.

    I mostly wanted to make other members aware that in the case of a fuel pump stalling, the ECU could have issues.
    -Dan

  8. #8
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    Quote Originally Posted by cord4530 View Post
    Kind of. In most automotive cases, the ECU grounds the fuel pump relay rather than the pump directly. Of course, the new cars with a returnless fuel system are all together different.
    This is what I was referring to. Every Honda/Acura vehicle currently produced is this way, so to someone like me it's not that uncommon. Returnless systems are now the norm also.
    690 SMC

  9. #9
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    May 2008
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    Ya, what's crazy is that my wife's F650GS twin uses a pulse-width controlled returnless system for the fuel pump. Of course, the fuel pump/system on those bikes isn't any better than the KTM 690's. Strange having two adventure bikes, both with potential to leave you stranded from fuel pump problems.
    -Dan

  10. #10
    Join Date
    Jul 2012
    Location
    Longmont, CO
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    This seemed like the best thread to post this in.
    I bought my '09 690 SMC in the beginning of July.
    Had stalled and would not restart for about 15 min a few times when hot. No error codes.
    I replaced the fuel pump with the ca cycleworks pump and Napa in tank filter.
    A month after the replacement, the ca cycleworks pump died. Fl error code 41.
    The pump shows totally open between the power terminals when removed from the bike.
    Contacted ca cycleworks and they are sending me a new one! Good customer support!
    I hope I can get this bike running reliably - I love it when it's running, but getting a bit frustrated with being stranded.
    '08 WR250X
    SOLD - '09 KTM 690 SMC

  11. #11
    Join Date
    Jan 2009
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    36

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    Quote Originally Posted by cord4530 View Post
    I thought I'd post a quick update on how things are going with my bike. I looked in to replacing the pressure regulator, but as it turns out, the regulator doesn't do anything with the electrical signal for the fuel pump. When the pump is on, it just regulates the pressure going to the fuel injector by bleeding off any excess back to the tank.

    What I found as the problem is kind of disturbing to me. The fuel pump gets 12V from the power relay, and is grounded through the ECU. There are no switches or relays between the pump and ECU. I ended up finding a good deal on a used ECU, and after swapping that in, the problem is completely gone.
    Is this part 75041032000 or what KTM calls "TIMING CHARGER EPT"? I'm having this problem with my 690 SMR after having to replace a fuel pump.
    -Rob
    2010 KTM 990 SMT, 2008 KTM 690 SMR
    --
    "The KTM really likes being ridden hard. If you never ride like a dumbass, and have no intention of ever riding like a dumbass, KTM probably doesn't make a bike for you."

  12. #12
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    May 2008
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    I think you're correct. Looking at the parts fiche I'm seeing two ECU's. One is 75041032000, TIMING CHARGER EPT 07. The other is 75041031000, TIMING CHARGER EFI 07. The first one is the smaller of the two. The second is larger. Unfortunately I don't remember which one ended up being the problem when my fuel pump circuit failed. I suppose you can follow the wiring from the fuel pump back and see where the ground for the pump goes.
    -Dan

  13. #13
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    May 2008
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    I did a little more homework, looking back through my notes. The fuel pump is grounded through the larger of the two ECU's (75041031000, TIMING CHARGER EFI 07) on pin 16. Unfortunately this is also the more expensive of the two.
    -Dan

  14. #14
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    May 2012
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    Quote Originally Posted by cord4530 View Post
    I think you're correct. Looking at the parts fiche I'm seeing two ECU's. One is 75041032000, TIMING CHARGER EPT 07. The other is 75041031000, TIMING CHARGER EFI 07. The first one is the smaller of the two. The second is larger. Unfortunately I don't remember which one ended up being the problem when my fuel pump circuit failed. I suppose you can follow the wiring from the fuel pump back and see where the ground for the pump goes.
    -Dan
    Timing Charger EPT = Timing Charger Electronic Power Throttle

    Timing Charger EFI = Timing Charger Electronic Fuel Injection

  15. #15
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    Jan 2009
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    So what is the "dreaded fuel pump problem"? That wording makes it sound like this is a common issue.

    My 690 has been about as reliable as an anvil until now (37K miles) but recently the fuel pump died and now I'm having this issue with it dying and throwing the P1231/32 codes. It starts fine after shutting off the key and turning back on. I also wonder if riding it this way is likely to damage my fuel pump...?
    -Rob
    2010 KTM 990 SMT, 2008 KTM 690 SMR
    --
    "The KTM really likes being ridden hard. If you never ride like a dumbass, and have no intention of ever riding like a dumbass, KTM probably doesn't make a bike for you."

  16. #16
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    Quote Originally Posted by phxrider View Post
    So what is the "dreaded fuel pump problem"? That wording makes it sound like this is a common issue.

    My 690 has been about as reliable as an anvil until now (37K miles) but recently the fuel pump died and now I'm having this issue with it dying and throwing the P1231/32 codes. It starts fine after shutting off the key and turning back on. I also wonder if riding it this way is likely to damage my fuel pump...?

    Can't speak to the codes.

    But a good bit of the troubles seem tied into the fuel filter issue - at least IMO. The issue being that the filters clogged up very very early and badly. With a clogged filter, the pump has to work harder, gets hotter etc etc and thus it's life is reduced. At 4k miles, my filter looked more like a capsule of coffee grounds.

    So, have you checked the filter and cleaned the injector?

  17. #17
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    Jan 2009
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    Isn't the fuel filter part of the fuel pump assembly? If that's the case, wouldn't it have been replaced when I got a new fuel pump?
    -Rob
    2010 KTM 990 SMT, 2008 KTM 690 SMR
    --
    "The KTM really likes being ridden hard. If you never ride like a dumbass, and have no intention of ever riding like a dumbass, KTM probably doesn't make a bike for you."

  18. #18
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    Quote Originally Posted by phxrider View Post
    Isn't the fuel filter part of the fuel pump assembly? If that's the case, wouldn't it have been replaced when I got a new fuel pump?
    Nope. There's a few inches of hose between the pump assembly and the filter. The pump does have a pick-up screen that's part of it. But that's just for 'large' objects. The filter i'm speaking of is in-line in the line from the pump to injector and is for small sized dirty suspended in the fuel.

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