I have had many similar fuel problems with my EGS-E Adventure over the years.
I replaced the fuel pump at one point and that helped a lot, although I agree it doesn't have any bearing on the emergency tap, because, as you say, this bypasses the pump.
In my opinion this is quite simply poor design, as the fuel from the emergency tap is lower than the carb.
Whenever I got really stuck in the past I always managed to get going in the end by using the choke and then keeping the revs high while tentatively releasing the choke.
Once it gets going the carb will generally continue sucking the fuel out the tank; its getting it going in the first place that can be a bit tricky. If it feels like it's going to stall again, (e.g. at a junction) a little flick of the choke may help keep it going.
God knows what this must be doing for the life of the engine, but it’s always got me going in times of desperation.
One of these days I will write to KTM about what I see as this design fault. Also I will look into getting a better fuel pump (possibly electric?) before going away on a long journey again.
Regards,
Graham.
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