If you own a 2010-2012 off-road KTM model with fuel injection you need to know there is an update to the little tiny fuel line filter leading into the fuel rail on the throttle body. You might not even know there is filter in there, we didn’t until ours clogged up on both our 2012 500 XC-W and 500 EXC, causing the bikes to run like the injector was clogged. Once the original filter starts clogging, it loads up quickly, sometimes within ten miles of riding and trying to get home. KTM fixed the issue about half way through the 2012 production run so if you have a 2012 you can check with your dealer to see if your serial number is one that needs the updated filter or not.The sensation of the filter clogging can be different depending on how quickly it happens but here are some of the symptoms. Any loss of power, especially at higher RPMs is the first sign. Secondly, the bike will be slightly erratic acceleration progressively getting worse. Then the bike will start popping and hiccupping. The FI light will not come on since this is not an electrical related issue. If a sensor is the culprit for a FI system failure, the light will usually come on. We have not been able to tell what causes the filter to clog but suspect it is related to poor quality gas or additives that are not friendly with the tank coatings or fuel lines.The job of the little filter is to keep any debris from making it to the injector, extending the life of the injector. KTM cautiously recommends changing the little filter every five hours, which isn’t realistic seeing as how we ride more than five hours at a time! We now carry an extra one with us and if the bike starts to stumble because the fuel line filter is clogged and for some reason we loose that tiny little booger in our tool bag, we just take it out until we are home and can replace it.
The easiest way to get to the fuel rail and the little inline filter is to remove the gas tank. Don’t forget to unplug the fuel pump and the fuel line is super easy to remove as well.
Using a screwdriver, remove the piece that holds the fuel line into the rail.
When you pull it out, the o-ring will probably stay in. Remove it, your life will be easier if you put it back on the 90 degree piece before putting everything back in.
This is the updated kit from KTM. A hose clamp and three tiny filters. You’ll only use one at a time but they gave you extra cause they love you.
To get to the filter you’ll have to cut off the crimped hose clamp. Brute strength is helpful.
The black filter is stock so you’ll be throwing that one away and using the gray one provided.
Side by side you can see subtle differences between the new filter and the old.
By depressing the mechanism in the fuel line with the end of an air nozzle sprayer, you can blow out the line to ensure there isn’t any crud left in the line.
This is what it looks like when your sweet new inline filter is installed.
With the o-ring back on and the provided hose clamp in position, it’s time to put it all back together. The plastic 90-degree piece is only held on by one screw. You can use a tiny bit of oil on the o-ring before you reinstall it to help it go back into position easier.
It’s important to place the hose clamp as shown so you can get to it easily next time you have to change the filter. Now that you’ve cut off the crimped clamp you won’t have to remove the 90-degree piece to change the filter when the time comes.