fuel filtration system in or below fuel cap for KTM, BMW and others

Discussion in 'Vendors' started by guglemonster, Apr 2, 2015.

  1. guglemonster

    guglemonster Crivens!!! Supporter

    Joined:
    Aug 28, 2007
    Oddometer:
    1,687
    Location:
    Italy
    Patented Tank Fuel Filters system for most modern bikes, such as KTM, BMW, Aprilia, Yamaha, Suzuki, Honda, Kawasaki, Triumph, you name it :D

    The system is covered by patent and allows a complete and safe fuel filtration while refueling.

    Apart from KTM, most of modern bikes DO NOT have a fuel filter which can be replaced if clogged. BMW has a record for this, you can only change the whole fuel pump assembly in all new models.

    Here below some BWM filters, on the left the KL 0433, used outside the tank (!!!! Alluminium??) on RT and ST 1200, in the middle KL 145, used on all 1100-1150, both had to be changed, BMW spec, every maximum 40.000 km, on the right the KL 315, same size as the KL 0433, but cannot be changed, once clogged, new fuel pump set, 450/500 bucks just the part

    [​IMG]
    Furthermore, modern EFI bikes are more sensitive to badly contaminated fuel,

    Carburetors bike have no problem digesting particles up to 40/60 micron, but modern EFI system work, at injector, with smaller contaminants, around 5-10 microns, therefore filtration has become an issue.

    To keep the whole tank clean is the key to avoid expensive reparation, reduce risk during travel and spoil rides and fun.

    Here a filter which has worked only in Italy, Arezzo and Siena, less than 14.000 km, 20 microns, on a EFI bike, say a KTM 990/1190/1290 having all these bike the same filter/pump set-up, it would have fully clogged the prefilter and paper filter either stopping the bike during a ride, or forcing an early filter change, in Italy using original components is 73euros for the filter set and 40 euros for the two pump o-rings.


    [​IMG]
    here my prepump design filter after a 8.000 km ride through albania, macedonia, bulgaria romania, normal petrol stations, no bottle or canister/jar refuelling, look how much the filter had to withstand


    [​IMG]



    As for the filter set our inmate Gefr has a solution, as for the o-rings, I can provide a complete set or a travel companion, below the composition and prices.:D

    To test the filters I had many bikes and protos running around the world, and the lab tests were run at the Special Fuel Dpt of the Wroclaw “Polytecnika Institute” ( Polish Wrocław University of Technology, famous for it’s advanced studies in fuel evolution) to check results and material specifications.

    To achieve the best filtration and allow anyway a good refueling speed, alla filters are multi layer based, using special medias and design, ranging from 20 microns high speed flow to 0 microns high filtration.


    The technology used replies the 3d filtering concept used in the latest filter cartridges and filter aggregates in the transport and Avio industry in order to trap the finest particles not only through direct filtering ( mono layer design) but also while the petrol has to flow around fibers/material and different layer having the particles removed from the petrol and trapped between the fibers and labyrinths, allowing also a better fuel flow than through a simple membrane since the filtering surface is multiplied by the 3d design,
    Also the clogged area (mono layer paper impregnated filter) will not be a problem anymore since the petrol can flow in the 3d design, this meaning that the filter will be easier to clean even after being heavily loaded by contaminants.
    All our filters can be washed and reused without limits, are big and will take a lot of abuse, both mechanical and chemical.
    Accordingly to the shape of the tank, filters have specific design and properties, for example ADV 1190, SMR,.


    A plus to this design is that from now on nothing can fall inside the tank even while leaving the cap open for some work on the bike


    The 20 microns high flow speed, say for example for the KTM 950 ADV, have almost the same refueling speed like with no filter.

    All other 20 microns design will be 20% slower than without filter but filter capacity is better than KTM pre-pump KTM filter (40microns approx.) and BMW pump strainer (60 microns approx.) thus blocking a lot of contaminants which would clog it all.
    The 0 micron are by 20% slower but filtration capacity is 0 microns being far more efficient than for example the mini paper filter at KTM Pump, approx between 5 and 10 microns like all modern IE fuel system requires.


    As for the 0 micron filtration, I have been asked how is that possible, I hope I will be able to explain it wit my poor English.

    There are various norms used to evaluate filtration capabilities and efficiency, in our lab test they use the for example the ISO16889, multipass which can test between 4 and 25 microns, and for the other tests, using a ceramic porous cartridge rated for 0,85 microns and than measuring against test material, how much of it was blocked by the various media we were testing J in one single passage.

    The tests are made in order to check all materials blocked which is bigger than the filtering spec, below the referred number, particles will flow unharmed.

    Testing in multipass (meaning the same fluid is filtered many times through the same membrane) is valid for filter units in most application, the same fuel will pass many times in the filter while being circulated via pump/pressure regulator to the injectors, but I was not satisfied since at filler neck it will go through only once.

    The 20 micron, for example for KTM 1190/1290, ADV and SD, tested against both method, resulted in a 75% block of 10 microns and 95% block of 20 microns, thus I refer to it as the 20 micron filter.

    The 20 micron high flow, say for example for KTM ADV 950, tested against only the first method 85% single pass retention,

    The 0 micron was tested only with the 0,85 micron prefiltered suspension, resulting in 93% retention, thus the 0 micron name.

    In multipasses they would both perform much much better, but I must use materials that will work best while being used the way they fit best the design, not the lab analysis J


    The design and shape changes slightly accordingly to the tank cap



    Some big filler necks, such as BMW K and new GS LC, will also allow the use of Acquastop units, which will separate water, contaminants and save also the neck fuel filter during dangerous refueling, say from a bottle in the middle of nowhere on the road J

    The acquastop membrane series can only be rinsed with petrol and will have a limited lifespan accordingly to the level and quantity of highly contaminated fuel you will filter with, but we talk anyway of tens of thousands of km anyway.

    Here some examples

    KTM 990/950 ADV

    [​IMG]

    KTM ADV Safari TT tanks, or IMS, or Clarke for other bikes

    [​IMG]



    KTM 1190/1290 ADV and SADV, SD



    [​IMG] BMW K 1300


    [​IMG]



    BMW 1200 GS LC

    [​IMG]

    [​IMG]





    BMW 1200/800 old fuel cap design

    [​IMG]

    BMW 1100 GS 1150 GS, RT, K, S, ST

    0 micron XXXL proto, usually due to the shape of the tank we prefer to use the 20 micron Revolution

    [​IMG]



    Prices



    KTM 990 EFI 0 microns (PAIR) shipped 55 euros, Australia 60 euros (10 euros for Safari TT/IMS/Clarcke adapters)

    KTM 950 20 microns high flow (PAIR) shipped 45 euros, Australia 50 euros (10 euros for Safari TT/IMS/Clarcke adapters)

    BMW 0 microns, all Bikes, 45euros shipped, Australia 50 euros

    BMW 20 microns Revolution, all Bikes 1100-1150 where the 0 micron won’t fit due to tank shape, 45euros shipped, Australia 50 euros

    KTM 1190/1290 ADV, SADV, SD 20 microns Revolution, 45euros shipped, Australia 50 euros

    KTM 990 SMT/SMR 20 microns Revolution special design, 50 euros shipped, Australia 55 euros

    Aprilia Tuono/Caponord 20 microns Revolution, 45euros shipped, Australia 50 euros

    o-rings to be ordered with filter (saving shipping costs)

    O-ring kit n #1 full set plus spare for the road , radila plus fuel hose quick disc. US EU qta mm

    5-703 168 1x 65,09x3,53

    2-142 3237 2x 59,99x2,62

    2-10 2025 2x 6,07x1,78

    2-11 2031 2x 7,65x1,78

    2-129 3156 1x 39,35x2,62

    2-123 3118 1x 29,82x2,62

    15 euros (shipping NOT included) (new price)

    O-ring kit n#2 , travel kit for emergency chek and wash
    US EU qta mm

    5-703 168 1x 65,09x3,53

    2-142 3237 2x 59,99x2,62

    2-10 2025 0 6,07x1,78

    2-11 2031 2x 7,65x1,78

    2-129 3156 0 39,35x2,62

    2-123 3118 0 29,82x2,62


    13 euros (shipping NOT included) (new price)

    all 990/1190/1290 use the same o-rings :)





    Mounting is fairly simple



    BMW, dismount the fuel cap, and accordingly to it’s design, insert the fuel cap inside the filter, use the extra length wire too loop through the vent holes, or mount it below the fuel level clip or drill 1 hole in the plastic neck and pass the steel wire through it, or mount the neck around the steel cap fixing it with the wire (all 1100-1150 and early 1200)

    [​IMG]

    [​IMG]



    For other types, such as KTM and Aprilia for example, simply dismount the cap, drill two, three holes at the bottom of the fuel cap, say 25mm from lower lip, mount the filter and fix it with wire through the media e the hole. :D:D

    [​IMG]

    [​IMG]


    [​IMG]


    Make sure the filter will not impede the seal to close properly, :D:D



    [​IMG]

    Orientation for the KTM 990



    [​IMG] Orientation for the KTM 1190/1290 all

    [​IMG]

    Orientation for 990 SD and SMR/SMT



    [​IMG] This is the result after a simply drilling job at tank cap below the key, so that you can lock the cap with the filter in position and for filter cleaning you only have to remove the 3 screw and lift all of it off the tank



    in case you have other questions or proto, I ma here :)


    should you decide to purchase or ask about more info please contact me at guglatech@gmail.com


    thank folks


    ciaps


    :D:D:D:D:D
    #1
  2. guglemonster

    guglemonster Crivens!!! Supporter

    Joined:
    Aug 28, 2007
    Oddometer:
    1,687
    Location:
    Italy
    here the Tests I run while checking :)

    I played a bit in the garage with highly contaminated petrol derived from the cleaning and tank service of three bikes using fuel injection cleaning solvent (whynn’s is my favorite) 150ml in 3 liters of petrol instead of the regular 40/60ltr.


    [​IMG]

    The contamination is really heavy, debris, fine particles, solved contaminants and dark in colour.
    At first I tryed the mono layer design so popular nowadays using a 30 micron monolayer mesh (100microns-30 microns -100 microns in order to make it stronger, my design)




    [​IMG]

    Filtered less than half the liter, not even dirty, petrol was the one on the surface not the one at the bottom.

    [​IMG]


    Same petrol just filtered was passed through a 20/30 micron multilayer (100 microns-high density 3d mesh sandwich-100 microns for strength), just after the same amount of petro the filter already shows traces of contaminants trapped in the mesh


    [​IMG]

    [​IMG]



    To go on with the experiment, all was passed again in the 0 micron (old shape/design) and again the difference is .

    [​IMG]


    The petrol is a light shade less dark, but the high content of solvent and solved carbon contaminants make the petro like ink
    The rest of the 3 liters were first filterd with the 20/30 micron and than through a 0 micron acquastop membrane .. and again the difference is amazing



    [​IMG]



    At the end of the 3 liters.
    20-30 micron filter


    [​IMG]


    [​IMG]



    Turned the filter inside-out to check the contamination

    [​IMG]

    [​IMG]


    0 micron acquastop filter



    [​IMG]


    [​IMG]








    All the macro pieces would have being stopped by a single layer filter (25 o 50 micron) too, but as for the rest ..... no way jose


    After that, passed the petrol through 4 strata of paper



    [​IMG]


    It makes you proud :D:D:D


    In case of the std 20/30 microns or 0 micron NON acquastop, a special extreme ride membrane can be added in the cap itself, it will stay below the cap, will stop anything and also water permanently, can be removed without dismounting anything and emptied from water or high contamination

    [​IMG]


    [​IMG]




    Unfortunately it slows down the refueling, but is simply unbeatable in case of the worst petrol you may find in Africa, USSR or similar countries.

    If you have any questions write to me, I’ll try my best to answer your doubts

    Guglatech @gmail.com

    Hope you were not too much bored by my enthusiasm and paranoia fixing attitude

    Ciaps


    :D:D:D:D:D:D:D
    #2
    Jay... likes this.
  3. guglemonster

    guglemonster Crivens!!! Supporter

    Joined:
    Aug 28, 2007
    Oddometer:
    1,687
    Location:
    Italy
    hallo everybody :)

    after 3 weeks of testing, Im proud to announce e new patented media for the KTM ADV 990 EFI.

    the 0 micron will always be the best solution to preserve filters ad pump, but some of my customers would like a faster filter for URBAN everyday use :)

    so be it :) :D:D:D:D:D:D:D:D

    the Evolution is the same as for the KTM 950 high flow 20 micron, here we have a 10 micron High flow for the 990 EFI KTM ADV

    9 liters in less than 45 seconds, washabel, and cheaper than the extreme 0 micron

    the filter price (PAIR) shipped 45 euros, Australia 50 euros (10 euros for Safari TT/IMS/Clarcke adapters)

    I am at the moment testing the same patented media also on other bikes, hope to be able to report same or even better success :)

    have fun

    ciaps

    :D:D:D:D:D:D:D:D:D:D
    #3
  4. guglemonster

    guglemonster Crivens!!! Supporter

    Joined:
    Aug 28, 2007
    Oddometer:
    1,687
    Location:
    Italy
    KAG, you're the best, and I love your DOG ahahhah

    :D:D:D:D:D

    here's a video where Kag was so kind to explain how to mount the filter on the
    KTM ADV 1190, same system for the KTM SADV 1290 and KTM SD 1290.

    I would recommend to take off the fairing, just to avoid tools to scratch it, like it happened to me on a Honda :baldy:baldy:baldy:baldy:baldy:baldy

    as for the rest it's just perfect

    EDIT

    now i't a simple drop-in adapter :)

    [​IMG]

    :D:D:D:D:D:D:D:D
    #4
  5. guglemonster

    guglemonster Crivens!!! Supporter

    Joined:
    Aug 28, 2007
    Oddometer:
    1,687
    Location:
    Italy
    original thread and questions to be found here


    hallo syzygy9,

    I was using the early version of the profil and had some very slow refuelling time with not such a great filtering efficiency, that is why I had to make my own filter and patent it :)

    price for the 0 micron, safari fuel cap adapters included, for Australia is 70 euros shipment included.

    should you revert to std tanks, the same filter can be mounted below the fue cap.

    the 50 euros refers either to the 20microns for the ADV 950, or 10 micron for the ADV 990 Urban

    taking into consideration that the prefilter works at roughly 40 microns and the paper jimmick beteen 5 and 10, I recommend for long trip in remote areas the 0 micron, to be combined eventually with acquastop membranes, also 0 micron.

    the main reason for havin, so many filtering media derives from the refuelling speed, 20 microns are fast, 10 also, 0 micron is the slowest.

    it' also true that the Safari big refuelling cap and big tank space, not twisted like the original tanks, allows for a much faster refueling time.

    I can also send o-rings should you need them to overhaul the pump

    should you be interested, please send me an email at guglatech@gmail.com

    thanx

    ciaps

    :D:D:D:D:D:D:D:D:D
    #5
  6. GB

    GB . Administrator Super Moderator Super Supporter

    Joined:
    Aug 16, 2002
    Oddometer:
    67,810
    I just received mine. Thank you. I'm going to install it this weekend and try to take a photo. :thumb
    #6
  7. guglemonster

    guglemonster Crivens!!! Supporter

    Joined:
    Aug 28, 2007
    Oddometer:
    1,687
    Location:
    Italy
    Hallo GB, happy it arrived, any issue? :evil:evil:evil

    let me know if the mounting will be as smooth as on the prototype we did in Italy :)

    thanx again for the support :)

    ciaps

    :D:D:D:D:D
    #7
  8. guglemonster

    guglemonster Crivens!!! Supporter

    Joined:
    Aug 28, 2007
    Oddometer:
    1,687
    Location:
    Italy
    here we go, anothe easy peasy mounting on a Beemer

    [​IMG]

    [​IMG]


    [​IMG]

    the owner was surprised by the look of the bottom of the fuel cap, as if it had been sawn..........

    :eek1:eek1:eek1:eek1:eek1

    [​IMG]

    [​IMG]


    [​IMG]


    with this simple wire loop the filter will never get loose :)

    it will be mounted parallel to the axis of the bike on the right side of the tank

    15 minutes including fairing removing and installing

    much easier than the KTM aahhaha

    :D:D:D:D:D:D
    #8
  9. TN Traveler

    TN Traveler Adventurer

    Joined:
    Aug 31, 2012
    Oddometer:
    55
    Location:
    Middle ,TN
    Great idea, I have almost been stranded twice in the middle of nowhere on paved roads, because of fuel filter being clogged. I'm headed to Mexico in a few months and want to install this on my ktm 990 with factory tanks, how long does It take to fuel a bike with the 0 micron filter, and what would be the cost of the 0 and 10 micron sets shipped to the U S, zip code 37075, thanks
    #9
    petdav likes this.
  10. guglemonster

    guglemonster Crivens!!! Supporter

    Joined:
    Aug 28, 2007
    Oddometer:
    1,687
    Location:
    Italy
    hallo TN traveller

    the 0 micron will slow down refueling, std caps and std tanks, 20% more time, 10 micron much les, like I said 45 sec 9 ltr of petrol with std fuel pistol

    most of the slowing down comes from the fuel wich arrives already in a foam condition from the pistol itself, the media, being thick and efficient, will take foam slower than liquid

    one shipment for 0 micron and 10 micron (2+2 filters) to USA is 85 euros, you can add also the oring pump kit, #1 or #2, or the acquastop membrane to be used in case of bottle or canister refueling, 15 euro each membrane

    thank you for your interest, please, should you wish to procede, send me all details to guglatech@gmail.com

    ciaps :)

    :D:D:D:D:D:D:D:D
    #10
  11. guglemonster

    guglemonster Crivens!!! Supporter

    Joined:
    Aug 28, 2007
    Oddometer:
    1,687
    Location:
    Italy
    Hallo Kim

    as explained via PM and Email, for the Settao I have prepared the special design to use as much space as possible

    please let me know


    the family has grown, starting from the left upper row 990/950 KTM ADV (0,10, or 20 micron), KTM 1190/1290 ADV, SADV, SD, RC8 (10/20 micron), lower row left, BMW R/KF, GS, GS/LC, K, KLT F 800 GS (0 micron, 20 micron for the 11xx series), the new F 650 GS Sertao (asimmetric, 20 or 0 micron)

    [​IMG]


    :D:D:D:D:D:D:D

    Please, post some picture while mounting it

    thank you

    ciaps

    :D:D:D:D:D
    #11
  12. guglemonster

    guglemonster Crivens!!! Supporter

    Joined:
    Aug 28, 2007
    Oddometer:
    1,687
    Location:
    Italy
    due to it's small diameter, I had to come up with an adaptive solution for the fuel cap filler of the Adventure rear tanks for 990 and upcoming 1190/1290

    [​IMG]

    shape is slightly different, filter is too big to fit in the 30.5mm hole, so it was reshaped at the bottom

    elastic adapter

    [​IMG]

    [​IMG]


    these were made for an ADV 990 in Australia, 10 micron NExt Urban media on all three filters, original fuel caps and rear tank

    it can be also done with the 20 Micron NExt for 950, but unfortunately, not with the 0 micron, the filter is too massive to fit in the reduced filler neck.

    hope the owner will post some pictures :)

    :D:D:D:D:D:D:D
    #12
  13. guglemonster

    guglemonster Crivens!!! Supporter

    Joined:
    Aug 28, 2007
    Oddometer:
    1,687
    Location:
    Italy
    #13
  14. guglemonster

    guglemonster Crivens!!! Supporter

    Joined:
    Aug 28, 2007
    Oddometer:
    1,687
    Location:
    Italy
    I run already on many KTM 990 the external fuel system with modified big "teabag" and fuel cap prefilter, the bikes run much much better

    using an external unit is also much better in fluid dynamics, bigger media surface optimize pressure loss and decrease the pump fatigue, the paper filter is far too small

    capital is to keep all of them clean in the first place, so the pump will not work to hard and will keep it's temperature under controll

    [​IMG]

    [​IMG]

    [​IMG]

    big automotive MAZDA fuel filter, 8mm inlet/oulet, 90 degrese pipes, it fits perfectly before the snorkel on the 990 :)

    [​IMG]

    [​IMG]

    24.000km of city petrol, ain't that clean no??

    bike runs like a bullet now :) and prefiltering will make it bullet proof :)

    keep the filters clean and most of ktm issues will be long forgotten :)

    :D:D:D:D:D:D:D
    #14
  15. guglemonster

    guglemonster Crivens!!! Supporter

    Joined:
    Aug 28, 2007
    Oddometer:
    1,687
    Location:
    Italy
    well, bad way to start the week-end

    due to the massive modification between the US Dollar and the Euro, I am forced to increase the price of the 0-ring kits

    I went for shopping yesterday and some items went up 300%!! what the heck??


    O-ring kit n #1 full set plus spare for the road , radila plus fuel hose quick disc. US EU qta mm

    5-703 168 1x 65,09x3,53

    2-142 3237 2x 59,99x2,62

    2-10 2025 2x 6,07x1,78

    2-11 2031 2x 7,65x1,78

    2-129 3156 1x 39,35x2,62

    2-123 3118 1x 29,82x2,62

    15 euros (shipping NOT included)

    O-ring kit n#2 , travel kit for emergency chek and wash
    US EU qta mm

    5-703 168 1x 65,09x3,53

    2-142 3237 2x 59,99x2,62

    2-10 2025 0 6,07x1,78

    2-11 2031 2x 7,65x1,78

    2-129 3156 0 39,35x2,62

    2-123 3118 0 29,82x2,62


    13 euros (shipping NOT included)

    all 990/1190/1290 use the same o-rings :)

    old orders will receive old price obviously, but from today unfortunately I have to apply new prices, hoping it will stop.

    thank you all for your interest

    ciaps

    :D:D:D:D:D:D:D
    #15
  16. c-m

    c-m Long timer

    Joined:
    Apr 14, 2008
    Oddometer:
    1,177
    Location:
    UK
    Is one of these available to fit the BMW G650 x challenge / xCountry / xMoto?
    #16
  17. guglemonster

    guglemonster Crivens!!! Supporter

    Joined:
    Aug 28, 2007
    Oddometer:
    1,687
    Location:
    Italy
    hallo CM

    the one on the right bottom, now with evolved design, has being made specifically to fit the gs650

    [​IMG]

    it is awailable both in 20 and 10 microns

    ciaps

    :D:D:D:D:D:D
    #17
  18. c-m

    c-m Long timer

    Joined:
    Apr 14, 2008
    Oddometer:
    1,177
    Location:
    UK
    Thanks for the quick response.

    The G650x (xChallenge, xMoto, xCountry) are completely different from the G650, or G650 Sertao. Just want to make sure we're talking about the same bike:

    [​IMG]

    The tanks get filled right up to the bottom of the fuel cap.

    Any filter I buy needs to fit this bike and ensure that it is airtight otherwise it won't siphon from the auxiliary tank.
    #18
    Bli55 likes this.
  19. guglemonster

    guglemonster Crivens!!! Supporter

    Joined:
    Aug 28, 2007
    Oddometer:
    1,687
    Location:
    Italy
    than I do not know
    can you make a picture with the cap off and some measurement?

    thank you

    :norton:norton:norton:norton:norton
    #19
  20. c-m

    c-m Long timer

    Joined:
    Apr 14, 2008
    Oddometer:
    1,177
    Location:
    UK
    Ok, this is the best I could do. I only had a tailors tape.

    [​IMG]

    [​IMG]

    [​IMG]

    Fuel is filled right up to the bottom of the cap when the bike is on it's sidestand.

    The screws on the metal flange attach it to another metal flange. One either side of the plastic tank.
    #20