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KTM Fuel Pump Filter Replacement
Installing Zip-Ty Stainless Filter
As you saw last week, having ruined one gas tank, it was time to swap it out for a different one. While I had everything apart, it seemed a good time to replace the stock filter in the fuel pump. This is the filter inside the tank, not be confused with the filter that is in the exterior fuel line.
A good rule of thumb for this filter would be to replace it every 100 hours. In our case, I believe this pump has about 200 hours on it. I have only seen one case of a failure regarding this filter. It was in a bike that had somehow gotten an extreme amount of dirt in the fuel. It was enough that when the filter was removed, there was an obvious sludge that poured back out of the filter.
The stock filter is a simple paper style. We are replacing it with a new stainless steel 10 micron filter from Zip-Ty racing.
I cut the used filter open to look at the contents. Similar to one we did a year ago, the paper was coated with a fine black grit. It is difficult to judge its condition, but I am sure it was well past due for replacement.
Here are some photos of the process of removing the fuel pump and replacing the filter.
remove the 4 screws at the back of the tank remove the 17mm and 13mm caps that secure the pump to the bottom of the tank pull pump out from back of tank, there will be left over fuel that spills out here is a view of the fuel filter in place use a small flat blade screw driver to remove crimped clamps, pry the the crimp open and pop the clip end from the small anchors here is the new serviceable filter ready to install the Zip-Ty kit includes new clamps, use dykes to crimp these in place I use safety wire to make help fish the pump back into the tank. Wrap one end of the small post. Make a loop on the other end. This lets you catch it with a pick and pull it through the hole in the bottom of tank here you can see the fish coming out the bottom, then gently pull the pump into place and secure the 17mm cap, make sure the 17mm cap is centered so it doesn’t pinch the plastic of the tank here you can see some of the varnish that has accumulated in the 17mm cap