Customer service Help & hints
To ensure that "KTM EFI models" function and perform reliably, we ask that you follow these service recommendations,
Checks of faulty EFI components often reveal damage caused by stone impacts or contamination caused by the introduction of dirt and water during cleaning and maintenance.
The use of pressure cleaners in particular often leads to the ingress of water and dirt into cable and plug-in connections and EFI components.
To prevent this, KTM developed protection cap 771 11 014 050, which will be installed as standard beginning with model year 2012, but which can be retrofitted in all 2011 models.
An important measure when cleaning the motorcycle when the tank is removed is to use the wash cap set,
part.no. 812 12 016 000.
Before disconnecting the fuel line coupling, it is important that the coupling and its immediate vicinity be cleaned thoroughly and that the wash caps not be mounted beforehand. This ensures that dirt cannot enter the coupling to the injection valve .
When the tank is set down, the coupling with the mounted wash cap should not touch the ground (Figure D). Instead, the fuel hose should be held up on one side (Figure E).
Other important steps to take when cleaning an offroad motorcycle are closing off the intake opening to the filter box (Figure F); inserting a cloth in the opening under the wash cover to prevent water from entering the throttle valve body - be sure to remove the cloth again after washing; and closing off the main silencer (Figure G) and the engine breather (Figure H).
After washing, it is important to start the vehicle and let the engine warm up so that the plug-in connections can dry, thus preventing corrosion. This is also mentioned in the Owner's Manual. We also recommend blowing them off with an air line.
Defective injection valves are usually the result of dirt in the integrated filter (red arrow). Dirt analyses have shown that a wide variety of substances are involved.
To prevent dirt from entering the filter integrated in the injection valve (see figure above), an additional fuel screen 781 41 013 044 can be installed in the fuel line and will be std in model year 2012.
The new fuel screen can also be retrofitted in vehicles already on the market.
Part number 781 41 013 044 , This must be taken out and cleaned after the running in
Period, and is also a service item which can be changed at the same time and you would do your oil and filter.
Before replacing the TPS, the injection valve, or other EFI components, the plug-in connections to these components must be checked. Experience has shown that faults in the EFI system are often simply caused by faulty plug-in connections.
Ensure that connectors are free of damage, dirt, and corrosion. They should never be opened with screwdrivers or pliers.
Ensure that the ground cables are securely attached and make good contact.
It is urgently advised not to treat plug-in connections in the EFI system with so-called contact sprays.
These substances can lead to "creepage currents" which may lead to malfunctions due to the extremely low control voltages and currents.
Special attention needs to be paid to the spark plug connector. Dirt and water can lead to creepage currents, to shorting of the ignition voltage, and to the ensuing malfunctions.
In addition to cleaning the spark plug connector regularly and thoroughly using brake cleaner and blowing it out with compressed air, ensure the following:
a) The ignition wire is firmly seated in the spark plug cap
b) The spark plug cap is firmly seated on the spark plug
c) The spark plug housing is not in contact with the cylinder head
d) The spark plug housing is not damaged
If the engine is not running smoothly, is not starting properly or is misfiring, check the above-mentioned points first and replace the spark plug connector when in doubt.
A considerably improved, new spark plug connector with art. no. 771 39 090 000 is available for the 250cc EFI models in store at Redline mc.
