990 fuel filter change...and a wtf

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by Dusty, Aug 10, 2008.

  1. Dusty

    Dusty Long timer

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    So I was changing the oil and had the filter set for the fuel pump in the drawer, so I would change that and see if there were any goodies in the tank. I dumped the last 1/2 gallon in each tank thru a screen, to my surprise it was very clean and just a few specs of debris. While emptying the tank I could hear something rolling around inside, and found these one in each tank, after ten minutes of shaking it around with last bits of gas running down my arms.

    I was guessing they came off the petcocks.
    [​IMG]

    Showa nuff... screwed them back on good and tight... will see how long that lasts.
    [​IMG]

    I noticed that I must have got a rock or rocks between the oil reservoir and the tank; it left some nice gouges in both of them.
    [​IMG]

    Gas tank inside.
    [​IMG]


    I thought I would throw in a few pics of the fuel pump and the filters for anyone interested. I changed the filter and the screen and I would defiantly do both when you do it.


    Fuel pump at the bottom of the clutch lever side, left tank…(edit)
    [​IMG]

    The silver tabs hold the white plastic that houses the paper filter, pry the tabs up and pull the plastic housing off.
    [​IMG]

    There are a couple little tabs that hold the paper filter housing together, pry it apart and you can get at the paper filter.
    [​IMG]

    Looks nasty for only 8000 miles.
    [​IMG]

    The screen filter.
    [​IMG]
    [​IMG]

    Had to take a picture of the wiring so I didn’t get it mixed up. :lol3
    [​IMG]

    All the pieces.
    [​IMG]

    When putting the fuel pump back in I used some of this to lube the hole in the tank so the pump would slide in nice, it took an even pressure and it dropped right in.
    [​IMG]
    #1
  2. 911racer

    911racer dare to explore

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    Cool, thanks for the pics. now I know what to expect when its my turn to change the filters.
    #2
  3. Dusty

    Dusty Long timer

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    Your welcome, just trying to pay back the collective that has helped me so much. Glad somebody found it useful.
    #3
  4. 9nine0

    9nine0 Formally NineFive0 V2

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    This is a GREAT write up. The only thing that I wanted to point out is that the fuel pump is on the generator (left) side of the tank and not on the clutch side. Typo I'm sure but I didn't want to see someone taking off the wrong tank when they don't have too.
    #4
  5. Dusty

    Dusty Long timer

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    Woops, ya the clutch lever side.
    #5
  6. KrustyKustom

    KrustyKustom Lets Go....

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    Dusty,

    Did the parts nessessary for the filter change come as a replacement "kit", or did you have order them seperately? I have not looked at the parts diagram in a while, seems I recall the fuel pump listed as like a assembly.

    Thanks for the writeup, dont think anyone else has done similar.
    #6
  7. Dusty

    Dusty Long timer

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    KK, I odered them of the fishy, I didnt see a kit but i never asked anyone. There were lots of o-rings in the breakdown. I think next time i would just get the 2 big ones at the base of the pump housing and the 2 filters.
    #7
  8. Dusty

    Dusty Long timer

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    [​IMG]

    I put everthing back on after a test start up and went for a spin..WTF ran like shit bogging popping... i was expecting a wheely monster:lol3

    It was very late so i had to wait till this morning to see what was up... slept like shit.

    So on the reassembly of the fuel pump.. MAKE SURE THE SILVER TABS LOCK INTO POSITION.. Just dont assume that when you here it click together visually look at bith sides and make sure they are flush with the sides and locked down.
    #8
  9. MT950

    MT950 "OLD" Adventurer

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    OK so after reading this, I figgered? I maybe should have these filters/o-rings, on the shelf, just in case.(the dealers don't have parts in stock as you know or will find out). Filter kit-$115 O-rings $60 this KTM is a little$$$ to service ! even doing the labor yourself! Be back shortly( had to make beer run) :freaky This bike will cause this to happen:freaky I'm lucky I kept the Harley to run for parts&beer!:clap
    #9
  10. Dusty

    Dusty Long timer

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    Yep the parts for these bikes aren’t cheap. Did 100 miles tonight and it runs real strong.

    I have to say my bike starts much quicker it hardly even makes one turn and it’s fired up. It pulls real strong in the first few gears and lifts the front off in 1st gear with just a roll on, even with me trying my best to keep it on the ground; it was making my bad shoulder start to hurt hanging on. Yep it gave me the chills like it did the first few times I got on it. The scalded cat is back!!!!:clap

    It was a piece of mind thing for me (trip next week, Montana, Idaho, Wyoming, South Dakota, and home) wanted to make sure that the tanks were clean inside.
    #10
  11. Venteuri

    Venteuri I don't give a shit

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    For the filter kit read here: http://www.advrider.com/forums/showthread.php?t=369482&page=2 CP's post 20
    for O-rings: http://www.mcmaster.com/ - Does somebody has the dimensions? ..
    #11
  12. gefr

    gefr Life is a trip

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    Hi there,
    Opening up a fuel pump, realised there are three wires connecting to the fp. The one stops at the bottom of the fp. Do you guys think this wire grounds the fuel? Is gas good electrical conductor?
    #12
  13. Vicks

    Vicks gets stuck in sand

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    My understanding is that the 990Adv, Super Duke & SuMo use the same wiring harness for the fuel pump portion, but have a slightly different fuel pump unit in that the SD & SM have an integrated low fuel level sensor which uses the 3rd wire in the harness. The 990Adv has a seperate low fuel sensor with seperate wiring harness and connector hence does not use the 3rd wire in the FP harness.

    Gas is a bad conductor of electricity AFAIK.
    #13
  14. Peanuts

    Peanuts Long timer

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    Do you think a spell in an ultrasonic cleaner would refresh the filters?
    Could buy an ultrasonic cleaner on ebay for less money than the cost of the filters.......
    #14
  15. Kenbike

    Kenbike Been here awhile

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    I cleaned my sock filter with carb cleaner and compressed air and it can out perfect. eliminated the paper filter and installed an in line $3.57 NAPA universal FI filter next to the air box. Found orings at the local tracor dealer for $1.30 ea.
    I did not use the oring lube but will pick up a tube. You can reuse the sock no problem but the paper is a throw out.
    #15
  16. Yascher

    Yascher Been here awhile

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    do you have pics of the installation of the paper filter next to airbox?
    #16
  17. xcflyn

    xcflyn Long timer

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    +1

    Also great write up, makes a guy think a little more "proactively" when he see what those filters looked like :thumb
    #17
  18. Kenbike

    Kenbike Been here awhile

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    I don't have a photo but it is a steel encased fuel filter that is 1.5" od and 3" long with 5/16" tube sticking out of both ends that the fuel line slides over and is held in place with small hose clamps. I held it place with plastic wire tyraps so it would not interfere with the throttle bodies. I picked a small universal filter with 125 PSI rating that was set up for Ford cars. They had 5 different filters in the book that could work at my local NAPA dealer. Picked up an extra 2 ft of gas line
    and installed it on the out put side and ran it to the original fuel line connection on the throttle bodies.

    Good Luck and I was really happy to do the entire job for $10 vs. $160 for the KTM filter and O ring kit
    #18
  19. alpo996

    alpo996 Adventurer

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    BUMP......anyone?

    Kenbike, would you happen to have that NAPA part number for the filter? Thanks
    #19
  20. crashmaster

    crashmaster ow, my balls!

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    This is the smaller of the two big rings, about a buck fifty a piece from mc master, but you have to buy a pack of 10. This is the one I tend to chew up when putting the pump back in, so I carry a couple of spares with me at all times. I have never changed the larger ring in the base of the pump and it still works.

    http://www.mcmaster.com

    <table id="PageHeadDivTable"><tbody><tr><td id="FamilyDescColumn"><nobr>O-Rings, Cord Stock, and Accessories</nobr>
    This product matches all of your selections.

    </td> </tr> </tbody> </table> <table id="PageHeadLowerDivTable"><tbody><tr><td id="idsParamImageDivColumn"> [​IMG]
    </td> <td id="ItemTableDivColumn"> <table id="ItemTable" cellpadding="0" cellspacing="0"> <tbody><tr> <td id="PartNumberCell"><nobr>Part Number: </nobr>1201T321</td> <td id="PricingDataCell"> <nobr> $14.82 per Pack of 10</nobr>
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    </td> <td class="featureValueCell">932
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    </td> <td class="featureValueCell">O-Ring
    </td> </tr> <tr class="featValRow"> <td class="featureNameCell">O-Ring Type
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    </td> <td class="featureValueCell">.118"
    </td> </tr> <tr class="featValRow"> <td class="featureNameCell">Inside Diameter
    </td> <td class="featureValueCell">2.337"
    </td> </tr> <tr class="featValRow"> <td class="featureNameCell">Outside Diameter
    </td> <td class="featureValueCell">2.573"
    </td> </tr> <tr class="featValRow"> <td class="featureNameCell">Material
    </td> <td class="featureValueCell">Viton® Fluoroelastomer
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    </td> <td class="featureValueCell">Shore A: 75
    </td> </tr> <tr class="featValRow"> <td class="featureNameCell">Temperature Range
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    </td> </tr> <tr class="featValRow"> <td class="featureNameCell">Color
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    #20