Fuel filters installed in 990 filler caps.

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by Trail bandit, Jun 27, 2013.

  1. Trail bandit

    Trail bandit Random adventurer

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    Purchased a pair of KTM450 screw filler filters from split stream.

    http://www.split-stream.com/products/splitstream-fuel-filter-honda-crf-kawasaki-kxf-ktm-sxf-efi

    I figured I'd work out how to fit them later... In the neck is almost impossible. Very little room to put a taper sleeve etc.

    Next I thought about glueing or using a band and screws to secure from underside. Two weeks of contemplation later...Bit the bullet after reading up on plastic welding. Worried about what part of the operation was going to turn to crap and very surprised to find that 30 minutes after starting the filters were installed and back in the tank. Virtually painless:D

    Fuel filter change was harder. Without Orange crush I'd have been stumped for ages on how to pull that white plastic thing apart for the little round filter!

    See pic below. I used a little weld (really just heating and spreading material between the 2 parts) each side. Just the two little ones and it was securely held.

    [​IMG]

    Next was fully welding all the way around.

    [​IMG]

    Filters installed and back on bike. First fill I noticed a bit of foaming up while filling. That was near the top of tank fill so no big deal.

    [​IMG]
    #1
  2. crazybrit

    crazybrit Long timer

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    What is the lifetime on these filters? If they need periodic replacement that's going to be a challenge.

    As for plastic welding I've always used the triangular welding rod and a hot air welder. You get much better/stronger results than by smearing plastic using a soldering iron.

    If you have access to a lathe I'd have thought you could make something (out of delron) that was a press fit on one end (into the 990 cap) and a screw thread on the other (for the filter) .... or maybe I'm missing something about the filter design?
    #2
  3. Trail bandit

    Trail bandit Random adventurer

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    Good question. Don't think it's a problem because of the large area. Still, cleaning them out would just be a matter of pulling the bolts and removing them. A few minutes would get that done.


    Yes, watched the video of this being done. Worried that the hot air gun would melt the mesh nearby. Also, confirmed with just the two initial tiny welds there was already plenty of strength.


    This was where I started. Problem is the cap closing latch is very close to bottom of that filler looking at it internally.

    That thread is not really a thread. It is a very small partial thread designed to be wound down into the dirt bike KTM tank.

    Commercially I think a CNC part could be made to fit externally where I welded this. It could be made with a custom mesh filter.

    I'm happy with this 50 dollar solution and should never need to change the fuel filters again and should be able to fill up in very suspect places around the world without problems.

    Then again..... Wife was crying and telling me not to take the bike out in rain today because she was worried so further world travels on 2 wheels could be a problem.
    #3
  4. srad600

    srad600 Been here awhile

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    Good job, I'm not far behind you on this mod. I'd already spoken to the owner of the company and was contemplating how to make them work. This looks like a clean install. :thumb

    The cost and ease of cleaning make this a "must do" on my list. Sure beats replacing the pump filters.
    #4
  5. KaytM

    KaytM Just a fella.

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    Without dissent may I ask if someone's come up with a solution to a problem that didn't exist?:deal
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  6. crazybrit

    crazybrit Long timer

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    Given the issues people have with the OEM fuel filter, additional filtration (assuming it's fine enough) sounds like a good idea.
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  7. KaytM

    KaytM Just a fella.

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    Yeah, I personally have never had a problem, but filtration is never a bad thing.
    I didn't realize it was such a common problem, is it mainly with off roaders or everyone?
    #7
  8. crazybrit

    crazybrit Long timer

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    I don't have a 990 but there are a ton of posts here with people having issues with the OEM in tank filters. Clogging. Difficulty replacing. Cost of replacing.

    That said I kind of wonder how effective a simple single layer mesh filter will be at minimizing the above. Obviously it's unlikely to make it any worse.
    #8
  9. Trail bandit

    Trail bandit Random adventurer

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    Re pre filter. Can't find anything definitive on the OEM tea bag pre filter size. Probably 25 to 30 microns. The split stream filters are 25 micron.
    #9
  10. srad600

    srad600 Been here awhile

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    Yep, the stock filters are not "end of the world" difficult, but a large enough pain, that having a pre-filter system like this to slow down the clogging process seems completely worth it to me. I got approx. 15K miles out of my first OEM set, and that seems to be right about on par with what others are getting as well. Mine gets used equally on and off road.
    #10
  11. crazybrit

    crazybrit Long timer

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    It sounds like a product opportunity for the company owner. With a bit of research I bet he could come up with a version that fit the 990 and was removable for easy cleaning.
    #11
  12. Jaimoto

    Jaimoto Spaniard in Chile

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    It's not that common but it happens. Not a big deal if you're around town since you can see it coming, but I had my filters clogged when riding alone and pretty far from home. I made it home, 200 km riding almost at idle on sunday night, it sucks.
    Down here is easy be riding in the middle of nowhere and sometimes I had to fill my tanks with gas coming from bottles and other stuff, bought from locals, and you never how dirty is that fuel (assuming is fuel :lol3)
    #12
  13. Trail bandit

    Trail bandit Random adventurer

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    Been reading more and it looks like the little barrel filter is a 10 micron so that guy will probably still need changing but possibly at much longer intervals.

    The tea bag pre cleaner should stay clean if it is 25 micron or larger. It seems to have been the main culprit in clogging anyway from what I can tell reading the posts.
    #13
  14. KTMbageera

    KTMbageera Adventurer

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  15. crazybrit

    crazybrit Long timer

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    :huh

    Isn't this the exact same thing the OP is using, only you're holding onto it?
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  16. LocuL

    LocuL Gnarly Infantry

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  17. srad600

    srad600 Been here awhile

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    Yep, but he was under the impression someone else was already doing that research.


    Looks that way to me. Seems like a simple and effective product either way. :freaky
    #17
  18. Trail bandit

    Trail bandit Random adventurer

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    Yeah, this was my worst case option. Good video.

    Really glad the soldering worked out. Buy a second filter , hex key in the electric driver, solder iron and then thirty minutes later you won't need to carry a soggy extra large condom around ever again.:1drink
    #18
  19. azcagiva

    azcagiva new orange flavor

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    Cool idea.

    -John
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  20. guglemonster

    guglemonster Crivens!!!

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    sorry, b ut the splitstream system is too lame

    :D:D:D:D:D

    first is a single layer strainer, it will wash out fine particles, I prefere multylayers with overlock sawn

    second is far too expensive, here in EU 80 euros the couple!!!! :rofl:rofl:rofl:rofl:rofl:rofl
    third the way you fixed it is too delicate :), gluing or soldering may brake and in the right tank it will be hard to recover

    sorry for beeing so direct, but I have being producing and mounting the ultimate product for the last 3 years with 7 different kind of filtration, water separation, micron selection (from 30 to 0 microns) and refueling speed

    there is already a post here of somebody who installed my system

    here some pictures if you want :)

    [​IMG]


    [​IMG]


    plus I did the system also for SMR, SMT, 1190 ADV and BMW 1200 and 800

    :)

    KTM is far behind this one aahahahah


    happy new year :)
    #20