NHTSA ID Number: 10180158
Manufacturer Communication Number: TB1802
TSB/Document Date: 2020-09-30
Summary
Due to market feedback, KTM
North America, Inc. has found that on the select models listed above there is a possibility that the fuel filters and/or fuel pump motor could cause a lower than recommended fuel pressure which could decrease the performance of the engine. To aid in preventing a fuel pressure decrease, a replacement kit for the fuel pump has been specially developed consisting of new seals, gaskets, filters and pump motor to stabilize and maintain recommended operating fuel pressure.
TB1802 KTM TECHNICAL BULLETIN - USA
NOVEMBER 20, 2017
FUEL PUMP MOTOR REPLACEMENT KIT
AFFECTED MODELS: 2017 KTM 1090 ADVENTURE R, 1290 SUPER
ADVENTURE R, 1290 SUPER ADVENTURE T, 1290 SUPERDUKE R
RESTRICTIONS: AFFECTED MODELS ARE LINKED BY VIN IN KTM
DEALER.NET
INITIAL INFORMATION:
Due to market feedback, KTM North America, Inc. has found that on the select models listed above
there is a possibility that the fuel filters and/or fuel pump motor could cause a lower than
recommended fuel pressure which could decrease the performance of the engine. To aid in
preventing a fuel pressure decrease, a replacement kit for the fuel pump has been specially developed
consisting of new seals, gaskets, filters and pump motor to stabilize and maintain recommended
operating fuel pressure.
KTM North America, Inc. is recommending that the fuel pump motor is replaced on all affected
motorcycles including the current inventory prior to PDI following the procedures given later in this
document. Please contact all of your customers who own affected motorcycles to have the fuel pump
motor replacement kit installed as soon as possible.
Warning
Danger of poisoning: Fuel is toxic and poses a risk to your health.
• Do not allow fuel to come in contact with your skin, eyes, or clothing. Do not inhale fuel
vapors. If contact occurs with the eyes, rinse with water immediately and contact a
physician. Immediately clean contaminated areas on the skin with soap and water. If
fuel is swallowed, contact a physician immediately. Change clothing that has been
contaminated with fuel. Store fuel correctly in a suitable canister and keep it out of the
reach of children.
Warning
Environmental hazard: Improper handling of fuel is a danger to the environment.
COPYRIGHT NOTICE: The user acknowledges that all components of this technical information are KTM’s and/or third parties’ copyright protected
property. Alteration, assignment, distribution and reproduction are forbidden.
LIMITATION OF LIABILITY: The information included in or available through this technical information may include inaccuracies or errors. In no event
shall KTM and/or its suppliers be liable for any damages whatsoever, arising out of or in connection with the use of this technical information. Please
always refer to the KTM owners and repair manuals for proper instructions or contact the KTM Dealer Services Department.
KTM NORTH AMERICA, INC.
38429 Innovation Court // Murrieta, CA 92563
1119 Milan Avenue // Amherst, OH 44001
8701 Rue Samuel-Hatt // Chambly, QC J3L-6V4
www.ktm.com
1
DEALER SERVICES DEPARTMENT © 2017 KTM North America, Inc. – All rights reserved
SAFETY ADVICE:
Danger
Fire hazard: Fuel is highly flammable.
• Never refuel the vehicle near naked flames or lit cigarettes, and always switch off the
engine. Be careful that no fuel is spilled, especially on hot vehicle components.
Wipe up any spilled fuel immediately.
• The fuel in the fuel tank expands when heated and may leak out if the tank is
overfilled. Note the specifications on filling the fuel tank.
TB1802 KTM TECHNICAL BULLETIN - USA
NOVEMBER 20, 2017
PROCEDURE FOR REPAIR:
Please reference the latest HTML repair manual in the KTM Dealer.net download center, or on the
CD-Rom (p.n.3206290 for SUPERDUKE R, p.n.3206296 for ADVENTURE) for fuel filter and pump
removal instructions.
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
COPYRIGHT NOTICE: The user acknowledges that all components of this technical information are KTM’s and/or third parties’ copyright protected
property. Alteration, assignment, distribution and reproduction are forbidden.
LIMITATION OF LIABILITY: The information included in or available through this technical information may include inaccuracies or errors. In no event
shall KTM and/or its suppliers be liable for any damages whatsoever, arising out of or in connection with the use of this technical information. Please
always refer to the KTM owners and repair manuals for proper instructions or contact the KTM Dealer Services Department.
KTM NORTH AMERICA, INC.
38429 Innovation Court // Murrieta, CA 92563
1119 Milan Avenue // Amherst, OH 44001
8701 Rue Samuel-Hatt // Chambly, QC J3L-6V4
www.ktm.com
2
DEALER SERVICES DEPARTMENT © 2017 KTM North America, Inc. – All rights reserved
1. Follow the fuel pump disassembly instructions provided in the repair manual as described in
Chapter 12.11 to the point of replacing the cartridge filter element.
2. Then mount the new filter spring, filter element and O-rings to the filter housing (Fig.1).
3. Assemble the filter housing and ensure the locking tab engages (Fig.2).
4. Replace the O-rings on the fuel pump housing base (Fig.3).
5. Mount the O-ring and sealing element on the new fuel pump motor (Fig.4).
6. Mount the fuel pump motor to the housing base and mount the plastic housing with spacers
(Fig.5).
7. Install the retaining brackets and tighten the screws to 3.5Nm (Fig.6).
TB1802 KTM TECHNICAL BULLETIN - USA
NOVEMBER 20, 2017
8. Mount and tighten screw to 1Nm (Fig.7).
9. Plug in the blade connectors (Fig.8).
10. Mount the new rubber sleeve with the opening hole diameter of 8mm towards the top (Fig.9).
NOTE: During service work, if using the spare parts filter replacement set p.n. 61007090100 be sure
to mount the rubber sleeve with the 8mm diameter hole away from the pump motor and the
6mm hole towards the pump motor (Fig.10).
11. Replace the O-rings on the fuel pipe and mount it (Fig.11).
12. Mount the filter element housing and be sure the locking tabs engage (Fig.12).
13. Install the fuel pump according to the repair manual instructions and assemble the motorcycle,
start the engine and allow it to idle for 2 minutes while checking to ensure there are no leaks
present and then perform a short test ride to verify correct operation.
14. Please take a photo of the removed parts and attach the photo to the warranty claim before
submission. Store the parts for 180 days per our warranty parts storage policy.
Fig. 7
Fig. 10
Fig. 9
Fig. 12
Fig. 11
COPYRIGHT NOTICE: The user acknowledges that all components of this technical information are KTM’s and/or third parties’ copyright protected
property. Alteration, assignment, distribution and reproduction are forbidden.
LIMITATION OF LIABILITY: The information included in or available through this technical information may include inaccuracies or errors. In no event
shall KTM and/or its suppliers be liable for any damages whatsoever, arising out of or in connection with the use of this technical information. Please
always refer to the KTM owners and repair manuals for proper instructions or contact the KTM Dealer Services Department.
KTM NORTH AMERICA, INC.
38429 Innovation Court // Murrieta, CA 92563
1119 Milan Avenue // Amherst, OH 44001
8701 Rue Samuel-Hatt // Chambly, QC J3L-6V4
www.ktm.com
3
DEALER SERVICES DEPARTMENT © 2017 KTM North America, Inc. – All rights reserved
Fig. 8
TB1802 KTM TECHNICAL BULLETIN - USA
NOVEMBER 20, 2017
PARTS ORDERING:
Please order 1 QTY 60307088050 (Retrofit Kit FFP) for each affected motorcycle. The figure below
displays the complete retrofit kit and it has been labeled with the corresponding repair procedure steps
from the previous page to show which parts are used in the steps (Fig.13).
Step 2
Step 4
Step 6
Step 10
Step 11
Fig. 13
COPYRIGHT NOTICE: The user acknowledges that all components of this technical information are KTM’s and/or third parties’ copyright protected
property. Alteration, assignment, distribution and reproduction are forbidden.
LIMITATION OF LIABILITY: The information included in or available through this technical information may include inaccuracies or errors. In no event
shall KTM and/or its suppliers be liable for any damages whatsoever, arising out of or in connection with the use of this technical information. Please
always refer to the KTM owners and repair manuals for proper instructions or contact the KTM Dealer Services Department.
KTM NORTH AMERICA, INC.
38429 Innovation Court // Murrieta, CA 92563
1119 Milan Avenue // Amherst, OH 44001
8701 Rue Samuel-Hatt // Chambly, QC J3L-6V4
www.ktm.com
4
DEALER SERVICES DEPARTMENT © 2017 KTM North America, Inc. – All rights reserved
Step 5
TB1802 KTM TECHNICAL BULLETIN - USA
NOVEMBER 20, 2017
WARRANTY INPUT INFORMATION:
This Technical Bulletin only affects certain VIN numbers! Please check the VIN by performing a
Motorcycle History search in KTM Dealer.net to determine if it’s affected. If the motorcycle is
affected you will see a link to the bulletin and its repair status in the history results. KTM North
America will not warranty units whose VIN numbers are not linked as this bulletin does not
apply to them. It is the responsibility of the dealer to determine if the unit requires this update
by checking the vehicle history and understanding the instructions provided by this bulletin.
Please note that when entering a warranty claim on an affected model, you must perform a vehicle
history search, expand the Technical information window and click the orange arrow on the right
side of the corresponding bulletin message.
You can now choose the TI Number from the list. The TI number for this procedure is according to the
repairs performed and listed in the warranty claim input information; click Continue with selected
action code.
The Warranty Claim is automatically entered for you, including parts & labor. You must enter
additional information in the required fields marked with an asterisk “*” before submitting the claim to
KTM. The flat rate time for this repair is based on the action performed and provided in minutes.
Warranty type:
TI Warranty
Subassembly group:
07 - Fuel pump
Failure code:
700 - Series improvement
Part causing failure:
61007089000 - O-RING SET FOR FUEL PUMP 05
Campaign code:
07_533288_00 Reworking of fuel pump
Spare parts:
1 QTY. 60307088050 - Retrofit Kit FFP
Labor time:
50 minutes
Stock parts affected:
No – EXCEPTION NOTE: During service work, if using the spare
parts filter replacement set p.n. 61007090100 be sure to mount the
rubber sleeve with the 8mm diameter hole away from the pump
motor and the 6mm hole towards the pump motor (Fig.10).
COPYRIGHT NOTICE: The user acknowledges that all components of this technical information are KTM’s and/or third parties’ copyright protected
property. Alteration, assignment, distribution and reproduction are forbidden.
LIMITATION OF LIABILITY: The information included in or available through this technical information may include inaccuracies or errors. In no event
shall KTM and/or its suppliers be liable for any damages whatsoever, arising out of or in connection with the use of this technical information. Please
always refer to the KTM owners and repair manuals for proper instructions or contact the KTM Dealer Services Department.
KTM NORTH AMERICA, INC.
38429 Innovation Court // Murrieta, CA 92563
1119 Milan Avenue // Amherst, OH 44001
8701 Rue Samuel-Hatt // Chambly, QC J3L-6V4
www.ktm.com
5
DEALER SERVICES DEPARTMENT © 2017 KTM North America, Inc. – All rights reserved
WARRANTY CLAIM INPUT INFORMATION
- 6X better wear protection on critical engine parts than...
- 1.3X better sludge protection than industry standards*
- 3X Stronger against viscosity breakdown than leading full...
- Protection for 10,000 miles between oil changes
- Meets or exceeds the following specifications: API SP/SN...
- Formulated for engines with 75,000 miles or more, Valvoline...
- Delivers 20% better wear protection and 15% better sludge...
- Extra detergents safeguard against friction, corrosion and...
- Advanced friction-fighting additives help maximize...
- Provides performance benefits for high mileage, new and...
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TSB/Document ID: TB1802
Replacement Service Bulletin Number:
MFR Communication Date: 2017-11-20
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP
MFR Component System:
MFR Component Subsystem:
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