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#Post#: 415--------------------------------------------------
Fuel Filter Service (Parts Needed)
By: Dogfarm Date: February 23, 2014, 3:16 pm
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Hi, I am gathering the materials to change the fuel filter in my
2009. Here is what I think I need, but I haven't done this
before and would appreciate any advice if I am off base.
I ordered a Mahle KL 97 filter from Amazon. My understanding is
that the 2009 filter was a Mahle KL 15 but KTM changed the
filter in later years. The parts microfiche show the same part
number for the fuel filter kit for all the years but it doesn't
specify the actual filter. So I am assuming KTM is providing the
KL 97 in all the filter kits for all the years.
I also picked up some Oetiker 15.9mm stepless single ear clamps
from a KTM dealer to attach the filter. I am shopping around for
clamp pliers but it looks like I might be able to get away with
some "hoof pliers" or "knippers" to bend the ear on the clamp
and cut off the current clamps. I am assuming I don't need
clamps with a side clamp, just a front.
I am assuming that I don't need to disconnect the lines from the
fuel regulator to change the filter. There hopefully is enough
slack in the lines to change the filter. If I do need to
disconnect the fuel lines from the injector, I need to buy the
Rally Raid tool,
HTML http://www.rally-raidproducts.co.uk/ktm-fuel-pump-disconnector-clip.
I am thinking that the screen on the bottom of the filter can be
cleaned and reused so I don't need to buy a new one.
#Post#: 594--------------------------------------------------
Re: Fuel Filter Service (Parts Needed)
By: Dogfarm Date: March 18, 2014, 8:26 pm
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I posted this on the megathread but I thought it may be helpful
to somebody here too.Here is an update of my fuel pump/filter
replacement. It didn't quite work out the way I had planned it.
I bought the KL 97 filter but I couldn't use the original hose
because the nipples are larger on the KL 97 filter than the
original KL 15. So I had to replace the stock fuel hose between
the pump, filter and regulator using the NAPA submersible fuel
hose (5/16 ID). I ended up purchasing a tool to take apart the
quick connectors between the fuel pump and regulator. I didn't
change the return line hose. I put in the Ebay (Felco) pump in
place of the stock pump. In the picture you can see the stock
pump next to the final assembly. I didn't use the Oetiker
clamps, I just bought some fuel line clamps. So the total cost
was: $35 for the felco pump, $22.5 for 1 foot of new fuel line,
$3 for four fuel line clamps and $6.50 for the fuel filter.
[img]
HTML https://lh3.googleusercontent.com/wYHZPHoY90Cv-_ertRZOz-BZybW9p_PLGxaLpNkOfg=s199-p-no[/img]
[img]
HTML https://lh4.googleusercontent.com/w_LEqmK2-TUl9vaJaP65UF1yquLALM29o8oCv_WKvw=s199-p-no[/img]
#Post#: 597--------------------------------------------------
Re: Fuel Filter Service (Parts Needed)
By: Rusty Shovel Date: March 19, 2014, 10:04 am
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Good tips! Thanks
#Post#: 607--------------------------------------------------
Re: Fuel Filter Service (Parts Needed)
By: seabeegt Date: March 20, 2014, 7:44 am
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Did the fuel pump replacement on my 08E last summer. Used a
CAworks pump. That job is a nightmare :P Those hoses get all
jammed up and pinched when ya stuff it back in the gas tank. My
suggestion, use excessive amounts of zip ties to make sure the
fuel lines don't wander. Live and learn. 8)
#Post#: 614--------------------------------------------------
Re: Fuel Filter Service (Parts Needed)
By: Dogfarm Date: March 22, 2014, 6:08 pm
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Thanks for the tip about the zip ties. I has some stainless
steel ties so I used those. Your were right, it was a pain to
get everything in the tank. Hopefully, won't have to go back in
for a while.
#Post#: 937--------------------------------------------------
Re: Fuel Filter Service (Parts Needed)
By: Guymcfly Date: April 28, 2014, 8:07 am
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[quote author=seabeegt link=topic=106.msg607#msg607
date=1395319453]
Did the fuel pump replacement on my 08E last summer. Used a
CAworks pump. That job is a nightmare :P Those hoses get all
jammed up and pinched when ya stuff it back in the gas tank. My
suggestion, use excessive amounts of zip ties to make sure the
fuel lines don't wander. Live and learn. 8)
[/quote]
When you do this job and get around to stuffing the hoses back
in, a couple of chopsticks with some duct tape (form a little
'u' ) and use it to lift the top of the hoses as you ease
everything into the tank. I clean my in tank screen every 6
months and have never had a problem with kinking the hoses.
#Post#: 1116--------------------------------------------------
Re: Fuel Filter Service (Parts Needed)
By: Muddaholic Date: May 28, 2014, 10:38 am
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I did mine when I added the Safari tank. Very annoying job.
My issue with it was I striped the threads on the fuel pump
plate at the very beginning of the threads. I was still able to
get the bolts in and set with Loctight blue, but is does not
bode well for future maintenance.
#Post#: 1379--------------------------------------------------
Re: Fuel Filter Service (Parts Needed)
By: Guymcfly Date: July 18, 2014, 7:31 pm
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Grab yrself a short clean piece of tube or a blunt ended
screwdriver. Put multiple zip ties on the lines. Put the tube or
screwy against 1 of the ties farthest up from pump. The idea is
as you push the pump up into the tank, you push the lines in
from a higher point to stop them crimping.
I regularly run my tank low and pull the filter to
check/clean...this method is easy (just take yr time and be a
little patient) and I have never crimped my lines.
#Post#: 2949--------------------------------------------------
Re: Fuel Filter Service (Parts Needed)
By: RiverRunner Date: July 3, 2015, 1:27 pm
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Hi Guys,
On the Cafe Husky forum, ZipTy Racing stated they have had
problems on New (racing) Huskies and KTM's with the paper fuel
filters reacting to the alcohol in our fuel, partially
dissolving and causing injector problems.
They came up with a stainless steel 10 micron filter that goes
in the fuel tank. It is expensive, but I will put it in our
690's when I install the Safari tanks.
I have no experience with the Zip Ty filter, but I have bought
other ZIPTY items for our Husky 511 and 310 and they have been
very well engineered, very high quality products. I trust these
guys.
RR
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