Duke FI problem ????

[bajadog]

Originally Posted by Reshad

And again I got the F1 problem 4x short 1x fast, fuel pump problem

Bike took a light shower last night, but started without trouble in the morning and no problem either starting it after work. Got home, then when i wanted to start it the third time: error 41 fuel seems not to go down...

What is going on here, I'm well frustrated...

Please help...

Dig around this thread a bit.

http://www.supermotojunkie.com/showt...-duke-FI-light

Sorry I can't help, but my KTM and Berg are both carb bikes.

[Reshad]

Thanks for the link to the Supermotojunkie thread, unfortunately it doesn't really address the F1 4x long 1x short error I'm experiencing.

Following the advice of the previous owner, i removed the fuel pump and tested it directly on the battery and effectively it didn't turn at all. A light tap on the pump body got it turning again. I re-assembled and tried starting again, heard the pump come on but as my battery had died by that time i jump started with a mate's bike and the fuel pump died again, same error code

We believe the poor quality of fuel in the country may be causing the internals of the pump to stick or maybe the pump has reached its time (14,000 km). Seen as it's a completely sealed unit and i can't service or let alone check its insides, i think it may need to be replaced

Anyone ever had a similar problem and found a solution that didn't require changing the unit?

Cheers,
Reshad

[Reshad]

Okay, I decided to clean the pump as thoroughly as I could. I completely removed the fuel pump, screen and filter and soaked them all in clean fuel. The filter was filthy and full of fine black particulates. As I couldn't get hold of a new fuel filter, I pumped 3 litres of clean fuel though it in the reverse direction to get as much of the crap out as possible... After 3 litres, the fuel came out clean. I got the pump running again on a 12V line and put 3 litres of clean fuel through it too, till it ran smoothly and what seems reliably. I put all that back together and tried starting it again today... still no luck, but at least the pump runs smoothly on turning the ignition on and I have no error 41 as yet.

That leaves me with 4 possible causes for the bike still not starting:

1. The fuel line between the pump and the pressure regulator is clogged
2. A problem with the pressure regulator itself
3. The fuel line between the pressure regulator and the injector is clogged
4. The injector itself is clogged

I ruled the 1st out by checking that fuel flows freely though that line. That leads me to No2, the pressure regulator. I tried to remove it to clean it; unfortunately I can't remove the regulator from its plastic housing. Anyone know why it’s stuck in the housing, how to remove it, and how best to clean it? There are 2 allen screws on one side of the housing, but they have blue paint marks across them and I'm unsure about removing them as they may be screwed in at precise depths. Any ideas/suggestions?

I’ve checked the fuel line from the pressure regulator to the first connector and that’s free of obstructions. Now I need to check the remaining length of fuel line leading to the injector and if that's clean assume the injector is clogged. If that is the case how should i go about cleaning the injector?

Cheers,
Reshad

[Reshad]

FYI, my injector was clogged, but my pump is also quite tired see this great thread on advriders: http://advrider.com/forums/showthread.php?t=641042 which deals thoroughly with the 690 fuel pump problem. It appears failure is a result of any one of the enumerated factors below (suggestions to reduce pump failure between parentheses) Also seems that the 2008 models are particularly prone to fuel pump failures

1. Fuel levels that are too low in the tank don't cool the pump sufficiently possibly leading to premature failure (Keep fuel levels as high as possible in the tank)

2. Ethanol in fuel attacks the pump's brushes, leads to accelerated disintegration of the brushes and loosening on the braided wire from the brushes. This will contribute greatly to the black dust in the fuel filter (Some one mentioned using fuel cleaner)

3. Fuel filter gets clogged with carbon residue (black crap) from the fuel pump brushes and puts strain on the pump (Injector cleaner every 3/4 tanks or every 1k service, check and change fuel pump regularly)

4. Pressure regulator blocked by accumulation of varnish from crappy fuel and possibly also the black crap from the pump (Injector cleaner every 3/4 tanks or every 1k service)

5. Fuel injector clogged (Clean the injector with pressurised injector cleaner from both sides) Note soaking didn't do it for me i had to activate the injector with 12vDC then force the cleaner at elevated pressure through the injector for results.

Hope this can help someone someday.

Thanks for listening.
Reshad