Author Topic: Fuel Filter Service (Parts Needed)  (Read 2221 times)

Dogfarm

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Fuel Filter Service (Parts Needed)
« on: February 23, 2014, 03:16:19 pm »
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, http://www.rally-raidprod...el-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.



 

2009 KTM 690r
2009 KLR 650
2008 WR250R

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Dogfarm

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Re: Fuel Filter Service (Parts Needed)
« Reply #1 on: March 18, 2014, 08:26:05 pm »
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.



2009 KTM 690r
2009 KLR 650
2008 WR250R

Rusty Shovel

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Re: Fuel Filter Service (Parts Needed)
« Reply #2 on: March 19, 2014, 10:04:18 am »
Good tips!  Thanks
D==[#)
2014 KTM 690 Enduro R

seabeegt

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Re: Fuel Filter Service (Parts Needed)
« Reply #3 on: March 20, 2014, 07:44:13 am »
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)
Shay with tha guage and Nilla with tha nine.... word to your mutha.

Dogfarm

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Re: Fuel Filter Service (Parts Needed)
« Reply #4 on: March 22, 2014, 06:08:33 pm »
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.
2009 KTM 690r
2009 KLR 650
2008 WR250R

Guymcfly

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Re: Fuel Filter Service (Parts Needed)
« Reply #5 on: April 28, 2014, 08:07:27 am »
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)

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.

Muddaholic

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Re: Fuel Filter Service (Parts Needed)
« Reply #6 on: May 28, 2014, 10:38:19 am »
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.
Doing your mom since the 80's.

Guymcfly

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Re: Fuel Filter Service (Parts Needed)
« Reply #7 on: July 18, 2014, 07:31:57 pm »
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.


RiverRunner

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Re: Fuel Filter Service (Parts Needed)
« Reply #8 on: July 03, 2015, 01:27:31 pm »
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