Replacing my first-gen KTM 390 Duke's fuel pump

I filled the tank back with fuel and let it rest flat for an hour. No leaks! We're good to go.

BHPian SunnyBoi recently shared this with other enthusiasts:

I grew impatient and wanted to finish it off ASAP.

Remove seats, remove tank cover, remove tank. Fairly straightforward. Drained the existing petrol into a clean can, and flipped it over to remove 6 bolts holding the fuel pump.

Well whaddaya know two of them are broken as well. Probably from being over-tightened when the fuel pump was changed to a new unit. Sigh.

So off comes the grinder, chop off those 2 bolts, and then the fuel pump is free.

Luckily I had a bunch of new bolts for these fuel pumps.

New bolts, new gasket and old pump in the new tank. I added lots of anti-seize to the bolt threads and torqued to 5Nm as per the service manual.

Fill the tank back with fuel and let it rest flat for an hour. No leaks! We're good to go. Decided to reuse the old fuel cap and not use the new one. I'll get a new lock set and will put the new lock and new cap together once and for all.

Rest of new parts for today's change. General service items and the fresh new injector.

Tank is now back on the bike with the new injector.

New coolant bottle with fresh Glysantin. I'll replace the coolant bottle cap with a new one again.

The bike started and ran fine. By now I ran out of time to change the oil and filters, Will finish it off today!

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