In-Tank Fuel Filter / Mahle KL 97 Stock Upgrade

Installation Instructions

     The KTM'S and HUSKY'S, seem to have more fuel related issues, with thier fuel systems, than any other manufacture has. Most likely because they cheap out on components and try to make things as small as possible. 

     That is just the cost of trying to make a profit and trying to make the lightest motorcycle out there.  It's no big deal, as we have figured out how to easily fix the issues.

    The fuel pumps themselves are now crap, becasue they are made in china and probably cost $1 to KTM. Many of them have only lasted a few hours or miles and then people have walked home.  No problem, we have much better pumps from Taiwan.  Godd thing is, our pumps come with a new, better fitting fuel stainer.


     And this is our first in tank filter needed.  The strainer, which is what you see on the bottom of pump pic, on the left, is the first thing the fuel sees before it gets to the pump.  This is your only line of defense to keep crap out of your pump.  And the one that comes on our pump, is the best, because the plastic adapter that holds the strainer to the pump, actually fits tight to the pump.

     The stock one fits loose, on the stock pump assembly. This means fuel ( and crap in the fuel ) can suck through the loose fitting and not the strainer.

     So using our better pump, with attached better strainer, is a great start to not having a failure and walking home.


     The next filter in line, and the one that fails and leaves you walking home ( if left stock ) is the one in the line between the pump and the regulator.   The reason you even need a filter between the pump and regulator, is to protect the regulator from failure.  If enough junk gets into the regulator, it will cause it's seal to leak.  This will keep it from holding and controlling fuel pressure, which is it's job.  So the 50 - 52 psi or 58-60 psi it's suppose to create to the fuel injector, will drop. Then the bike will run lean.


     Above is your choice of "in tank " fuel filters.  On the top is the stock filter.   It's worhtless because the outside shell is plastic.  And the problem is it can't handle the higher fuel pressures of the 50-60 psi that flow through it.  Therefore the plastic likes to split.  When this happens, you lose the needed fuel pressure and the bike harldy runs, if it runs at all.

     Without enough pressure, you walk home, or ride home real slow.  The filter element in the stock filter, is a 40 micron filter.  Because the stock filter can easily fail, it needs to go

     The filter below the stock filter, with the metal case, is a filter that people who don't know better, may choose to use.  Its available through WIX filters, or NAPA brand filters. It's NAPA number 3095.

      Even though the case won't split, and leave you with a loss of fuel pressure, the filters element is only rated for a pressure of 35 psi.  Which means the filter blows apart from the pressure that these bikes run. This means there is nothing to keep junk from getting to the regulator and ruining it.  When that happens, the fuel pressure in the system drops again and the bike runs bad.    So these filters aren't an option


     This leaves the 2 filters that we make, shown above, as the only two viable options for non failure.      The filter on the bottom, is the one we've sold for awhile now.  It's a billet housing so it can't fail, and it has a large 10 micron filter in it.

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     You can see that it's pretty big and has a big filter.  You can take it apart and can blow the filter out, from the inside, if needed.  The only downsides to it, are since it's bigger than the stock one, sometimes people have issues fitting them in their tanks.  These cost a lot to make so they are $94.95


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      So we made a smaller one, which we call the Stage 2 intank filter.  As you can see, it's the same size as the stock one, so it easily fits anywhere in any tank.   We have also replaced the bigger pleated filter, with 2 smaller stainless stell filters.

      The first one the fuel hits is a 35 micron filter and then the fuel hits a 20 micron filter.  It doesn't filter as much as the bigger filter, but since the 'quick disconnect" inline fuel filter we make is a 10 micron filter, it still gets filtered to the same amount.

      This filter is easily rebuildable as well but can be cleaned easily and wil never wear out.  So it's a lifetime filter.

This filter is $59.95 but is usually on sale for $49.95.

      Either way you want to go, we have you covered.   Most everone gets the filter and new pump with strainer, at the lower bundled price