Dirty fuel and filter issues.

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by KTMbageera, Aug 23, 2013.

  1. KTMbageera

    KTMbageera Adventurer

    Sep 8, 2011
    Kingdom of Cambodia
    I really like my 09' 990R, it is perfect for my travels in SE Asia. We have plenty of fuel these days, from gas stations with underground tanks and pumps, or 55 gal. drums with a crank pump, to 2 litre soda bottles filled from big jugs. Fuel here is routinely dirty and sometimes under refined, or cut with kerosene or diesel. We have no ethanol.

    Craig at CJ Designs has come up with a great filter solution for our big Katooms. I was on my way back over to Cambodia and he rushed his already busy life to get me a prototype to test drive. Below are pics of the install which took all of about 10 minutes.

    <img src="https://farm4.staticflickr.com/3829/9545593832_0fcaa68ff7.jpg" width="500" height="375" alt="cjfc1"></a>

    <img src="https://farm4.staticflickr.com/3820/9545597042_f293aeb3e9.jpg" width="375" height="500" alt="cjfc2"></a>

    CJ Designs fit and finish on their parts is first class, just beautiful. You won't be disappointed. The filters fit perfect, slip fit into the fuel ports, with Acerbis caps and check valves.

    Removing the OEM filler caps is easy, you will reuse the OWM rubber gaskets below the new filler ports. Match up the gasket and allen bolt holes.

    <img src="https://farm4.staticflickr.com/3832/9542813371_e10b2f51fa.jpg" width="500" height="375" alt="cjfc4"></a>

    <img src="https://farm6.staticflickr.com/5476/9542819233_29507cb091.jpg" width="500" height="375" alt="cjfc6"></a>

    I sent the OEM allen bolts to a local chrome shop to make them black. I like black. It cost me two hours and $1.50 in Phnom Penh.

    <img src="https://farm8.staticflickr.com/7318/9545612346_7d23588d46.jpg" width="500" height="375" alt="cjfc7"></a>

    <img src="https://farm8.staticflickr.com/7307/9542793813_acf5a8bc31.jpg" width="375" height="500" alt="cjfc10"></a>

    <img src="https://farm4.staticflickr.com/3820/9542791513_b4d73a9cb2.jpg" width="500" height="375" alt="cjfc11"></a>

    <img src="https://farm3.staticflickr.com/2853/9545567090_fecdaa6914.jpg" width="500" height="375" alt="cjfc13"></a>

    Do the pumps at your local ARCO have these warning stickers?

    <img src="https://farm3.staticflickr.com/2855/9576279842_9a565af3a4.jpg" width="500" height="375" alt="IMG_0809"></a>

    <img src="https://farm6.staticflickr.com/5539/9546097772_111db74887.jpg" width="500" height="332" alt="DSC03044"></a>

    2 litres at a time, a dirty funnel, and no worries with the new filters on board.

    <img src="https://farm8.staticflickr.com/7336/9573489957_25823c79c0.jpg" width="500" height="375" alt="IMG_0806"></a>

    I have a fresh set of fuel filters in my pump. Next full maintenance I will report with pics what the filters look like "with protection." Thanks again Craig for over the top help.

    Dave in Cambodia
  2. Deviant666

    Deviant666 Been here awhile

    Jan 23, 2010
    Athens, Greece
    That's just great, kudos to Craig for making such a product...one thing that I'd keep though from the original design is the locks and key...especially in an urban environment and with the price of fuel reaching unprecedented heights I wouldn't trust leaving my bike unattended...furthermore you can always use a small Mr, Funnel filter that does a great job for sampling fuel out...If it passes the first time you can proceed filling up without the filter and without worries...the smallest one will do for that...gas station owners don't like it but that's the least of my worries...changing a fuel filter in the middle of nowhere doesn't register as fun...
  3. crashmaster

    crashmaster ow, my balls!

    Mar 9, 2007
    Thats some good Baja stuff. I'm ordering up now. I used to use a Mr. Funnel (20 micron filter) to filter my fuel in Baja and in South America, but this looks like a great option.
  4. Decepticon

    Decepticon Been here awhile

    Aug 21, 2013
    Medellin, Colombia
    Thanks, my problem is the same with gas Quality and apparently I have to change fuel filters
  5. KTMbageera

    KTMbageera Adventurer

    Sep 8, 2011
    Kingdom of Cambodia
    I have been using a KTM OEM sock filter for the year I have had my beast in Cambodia. See video clip:


    This method works but is not ideal. The filter stores in my tank bag in double layer ziplock bags. Gas fumes still permeate the plastic and stink up the inside of my tank bag.

    I have to handle the sock which puts fuel on my hand. Oh my, will this carcinogenic contamination give me cancer? According to the state of California it will and needs a warning sticker. The number one cause of death for missionaries like me worldwide is not cancer, malaria, dengue, insurgents with AK47s', or snake bite. #1 is motorcycle crash fatality. So I am not worried about the gas.

    I like the convenience and cool looks of Craig's new filter/caps, and I got tired of my stuff in the tank bag smelling like Shell Oil. You can see CJ's product offer if you like at:

  6. AJ990R

    AJ990R motorcycle guy

    Dec 13, 2011
    looks sharp Dave!
    looks good in black :deal

    I live in the states & this set-up works awesome for much quicker fill-ups, with minimal splashback (i'm not currently running the filters) compared to the oem units! You can actually aim the nozzle now. Hated having the stock caps with fuel stains down the tanks after a fill-up :D

    Soo nice to not have to use the key at fill-ups...


  7. KTMbageera

    KTMbageera Adventurer

    Sep 8, 2011
    Kingdom of Cambodia
    OK, so don't laugh.... any of you. I posted the install pics for these way cool filters and filler caps not long ago. We are currently in the middle of a significant "monsoon" season in Cambodia which means BIG rain every day. My Katoom get wet, no big deal.

    Then my cool Katoom begins running like crap. Oh, maybe the plugs need changing. They are old. Considered lots of things to fix. Then my friend says, "maybe it's just water in the fuel, or clogged filters." Naw, can't be. I got these new whizbang filters to keep stuff out.

    Which is easier, check filters or change plugs? OK, so I find the right size allen wrench and unscrew the left side CJ Designs super cool filler cap. What do I find but a bunch of water collected around the breather holes for the OEM cap. Hummmm, if there is that much water just sitting there, must be enough that leaked down into my fuel to make my Beast stutter, fart, and crap.

    Then I reflected back on my conversation with Craig about the filler/filter units. Gosh, he did say something about using the OEM rubber gasket around the top of the old cap to give it a finished look........ and keep the water out.

    Oops. Fully diagnosed the problem, "short between the handlebars and the seat." Installed the OEM gaskets under and around the top of the fillers. Then drained the H2Oized fuel from my tanks and refilled with fresh go juice.

    Started and did the 15 min. reset. Hadn't done that for a few months and thought it couldn't hurt. Now my bike is back to normal. Runs like a scalded dog, loud and fast!

    I still have a couple of months of monsoon to ride in so will keep you posted.

    Ever consider how our creativity is an expression of God's character? I was thinking about the "Big Bang" theory not long ago while traveling through the Cardamom Mountains here in Cambodia. If someone took a big box, filled it with iron ore rocks, crude oil, silicon sand, a bit of gold and silver, a few lumps of bauxite and closed the lid. Tape it shut. Apply time, heat, maybe some pressure, and agitation for a long time. How long would it take for all the ingredients to morph and randomly sort themselves out until a KTM 990 rolls out the end. One that starts and runs, stops when you want. An amazing piece of engineering/creativity that I love to ride, slow or fast, wet or dry. Without those creative dudes in Austria putting their minds and skills to work, we would have no orange beasts, no matter how long we could wait.

    It takes a creator to have a creation. Just saying.
  8. cjracer

    cjracer AWD please!!

    Sep 26, 2005
    Mukwonago, WI
    Hi Dave, Great pics. Can we see what kind of fuel you are filtering with these? Safe travels. :freaky
  9. armourbl

    armourbl Adventure Life

    Jun 22, 2011
    Phoenix, AZ
    Would also be cool to see what the filter catches.

    If I can make a recommendation, safety wire the check valve hoses to the gas caps. Also, consider changing the hose at least once a year. They can dry-rot and the next thing you know you have lost your check valve.