Socks for the Christmas gifts and other goodies

One of the factors that strongly affect the operation of the fuel system is the cleanliness of the fuel. We live in Europe, it isn`t that bad here. However, around the world, the quality of petrol may not be that good. To prevent unpleasant surprises and prolong the operation of the pump and fuel injector, I decided to use a three-stage filtration.

Pre-filter, the so-called “sock”, mounted under the fuel filler, is to separate some of the dirt that could drop into the tank and get through the pump filter leading to its early wear. The new filter installed directly on the fuel pump has a higher density and doubled filtering surface compared to the genuine. Both filters are from Profill Australia. More importantly, both are reusable – they can be removed and cleaned as recommended!

Reading through forums and blogs, I paid additional attention to the problems of fuel injectors clogging in various motorcycles. I hope that the solution to this issue will be a reusable fuel filter installed before the injector. Manufactured by Golan Products. The casing is made of aluminium and the filter sieve is made of stainless steel. It has the ability to separate impurities above 10 microns. The assembly required the fuel hose to be run in a different way as the motorcycle manufacturer initially assumed. Due to filter dimensions, it would not fit under the seat before injector. The way I`ve run lines allows me for quick and easy access to a filter in need of servicing it.

On the occasion of its assembly, I replaced fuel line clamps used by KTM on to T bolt clamps which in comparison to old ones are reusable and made of stainless steel. In addition, despite the obvious reinforcement of the hose, I applied a wire harness tape to the outside of a fuel line. The tape is highly resistant to abrasion and high temperatures which should help to protect against external factors.

Inside the fuel tank, between the pump and the pressure regulator, there is an internal filter which must be replaced regularly during service. To get to it fuel pump has to be taken out from a tank, which involves dismounting a large part of the back of the motorcycle, then pulling out the entire set of wires, cables, pipes etc. During assembly there is a risk that the hose will kink, something will detach not allowing fuel to flow freely. As a result, a whole range of negative sensations may be released with some extra swear words like fu… or sh… And then the whole process should start again to correct the problem. As I already have a filter in line with an injector, the internal filter, in my opinion, is unnecessary. In order to minimize the risk of kinked line, the corrugated hose between pump and connector has been replaced with a reinforced submersible fuel hose. Much stiffer and less susceptible to bends.

I would like to answer a hypothetical question which may come to a mind: If I have to clean the pump filter every now and then, why not to replace the internal one at the same time? The reason is simple. To remove the filter on the pump I just need to take out six bolts, without a need to dismantle the pannier racks, fairing, silencer and lifting the entire tank to a vertical position, which in the case of replacing internal filter has to be done. Not to mention a risk of kinked pipes during assembly. And this is a big difference on the road!

Fuel filter update

Fuel filter update 2

Categories: NewsWorkshop


Toast · 23 June 2020 at 15:06

Thanks for the write up! I did similar filter mods myself on the 690 before our Mongolia trip some years ago. Now my OEM pump is dying, and the prefilter has turned dark. Have you managed to get your HUS03 profill prefilter cleaned?

    Luki · 25 June 2020 at 17:45

    Hello Toast.

    No, did not have to clean prefilter yet. Checked it after last year Albania trip and petrol was still running through without a problem. Although mine has turned dark as well, but so far it does not limit fuel flow.
    How many miles/kilometres your OEM pump survived with Profill Australia prefilter and which part of the world do you use fuel from?

John Gravel · 25 June 2020 at 15:13

Luckily the fuel filter on my 2007 Volvo XC90 is a 5-minute job. You detach the fuel lines by simply pressing down on clips. No need for tools

    Luki · 25 June 2020 at 17:20

    Hi John.

    I can only imagine how quickly it can be done in your car ? Well, as for my KTM it takes a little bit more time but also brings fun in a process, as long as you like to fiddle with it (like I do ?)

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