KTM Dirt Bike In-Tank Fuel Filter Replacement

Josh demonstrates how easy it is to check and replace the fuel filters & screens on the fuel injected Austrian enduro & MX bikes, specifically the 500EXC. This method should be the same for most of the 4-stroke KTM & Husky enduro & motocross models. No special tools are required for this simple maintenance job. The filter specific to this type of bike is the Mahle KL97.
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Josh: 2015 KTM 500 EXC
Nat: 2016 KTM 350 EXC
Cameras: GoPro Hero 7 Black | Hero Session | Panasonic HC-V180

[@DCV65]

Good stuff, I normally put a bit of copper grease on those bolts that go into the tank inserts, helps to stop them seizing and trying to spin the insert in the plastic.

[@MVDBR]

What's your bike mate? They're actually self tappers straight into the plastic on these 😫 Would have been a good tip for me WR days tho I had a few spinning nutserts on that tank I can tell ya! Thanks for the comment 🤙

[@DCV65]

Have a 16 350 EXC. Haven't pulled the pump from tank, so thanks for the heads up with the screws. Something i am due to do shortly.

[@MVDBR]

@@DCV65 well there ya go :) Cheers mate

[@D_J_G88]

Just like to make a note even if you use a funnel it's usually important to spill at least half a litre on the floor. Pay homemade to the dinosaur fossils for the fuel 👌🏼💯

[@MVDBR]

Hahaha yessss 👌 Helps clean some of the commo oil stains off the concrete too 🤙

[@D_J_G88]

@@MVDBR 😂 Hahahaha rip greenies

[@MVDBR]

😅

[@shaunryan4174]

Saved me loads of money. I was convinced I had issues with the fuel pump or the injectors. Pulled this filter out and replaced it following your instructions and the bike is running like a fire breathing dragon again. Found $12 filters that shipped overnight from Amazon. KTM and their $100 ask for a filter is insane!

[@MVDBR]

Good result! Thanks for dropping a comment, cheers 🙌

[@zackk695]

Where is the place we go to for KTM parts instead of KTM directly to save money? I have a 2008 KTM 450

[@BrokenSprocket]

KTM is a rip off $115 wtf. Great informative video mate.

[@MVDBR]

No kidding man I just gotta shake my head sometimes. Thanks for watching bro 🤟

[@JoeJoeMoto]

Far out KTM have some CRAZY prices!!!

[@MVDBR]

Ah mate, not wrong! It would be funny if it wasn't so insulting 😁

[@Buckbear5]

Thanks buddy,my boy and I just about spent $350.00 on filters and gaskets for our bikes.awesome video!!!!!!!

[@MVDBR]

Cheers 👍

[@rickos_moto]

Loving the new intro’s Josh.

[@MVDBR]

Thanks mate! Just wanted to make it a bit shorter but ended up spending ages perfecting it. I like it too 🤙 Cheers

[@chevyman551]

Intro was cool and I liked the choice of music and the end of the video. I don’t have a bike yet so I can’t use the content......YET! Lol. I’ll get me a 500 sooner or later. Thanks for the videos Josh

[@MVDBR]

@@chevyman551 thanks mate yeah good choice! 💪

[@frazzle657]

Thanks for the video. I recently put an inline filter on and the bik is bogging at low revs. So thought i should really find out where the fuel filter is to change it 😂

[@darrylgibb2693]

This kiwi reckons your video is a classy no nonsense smooth as well executed how to... Well done Josh.

[@MVDBR]

Thanks mate! I know there are other vids on the subject on KZbin but figured it could do with an MVDBR spin 😁

[@inthepumpkinpatch5383]

Thanks for sharing that Intel on the fuel filter KTM prices are always stupid for parts

[@MVDBR]

Hopefully in the US it's not as bad as here tho! Cheers Stacy 🤟

[@danblekeberg2470]

Here is a tip. When you pull out the fuel pump. attach some dental flosss to the gas line. When installing use dental floss to guide the fuel lines into the outlet side. It will work a lot easier than trying to wiggle it into place. And a lot less swearing..........

[@MVDBR]

👍👍

[@corradettimotorsports360]

nice detail work Josh your bike is well taken care of.

[@MVDBR]

Thanks Jeff 🤟 I guess I hope if we take care of the bikes they'll take care of us 🙂

[@jimalvarez3687]

I buy my filters elsewhere was well. A lot cheaper. Time to change my husky fe 501 filter again so watching your video before I get started to make sure I don't forget anything. Great video.

[@MVDBR]

Thanks for the comment Jim glad the vid was of some help :)

[@theklxdude1]

Thanks just ordered one for my husaberg fe501. Looks like an easy swap watching your video

[@MVDBR]

Good stuff Steven yeah piece of cake mate if I can do it anyone can. Definitely one of those things worth keeping on top of. Thanks for the comment 👊

[@syntaxmsi]

Hey MVDBR, thanks for doing this video! It inspired me to replace the filter on my Husky FE350s, which is basically same bike as Nat's KTM 350 EXC-F. Glad I did - it was full of dirt! Turns out the 350 uses the same Mahle KL97 filter as the 500. Cheers!

[@MVDBR]

Yeah I imagine a lot of the injected Austrian 4-stroke enduros use that same filter :) Thanks for dropping a comment man glad we could help!

[@mmaaddict78]

Nice video. I need to do the filter in my 350 here soon. This video should come in handy.

[@MVDBR]

👍👍

[@prestonthomas9406]

The OEM filters have a tendency to split down the seam from what I’ve read and seen online so I replaced it with a larger beefier aluminum housing and reusable filter. Also the pump motors are chinese junk so I re-placed it also with a Taiwan manufactured one. I also went with a larger filter from the tank to the injector to re-place that tiny one that plugs fairly easy if you get any debris in the tank, and its also re-useable. My 2 cents. Good luck and thanks for the video.

[@zappa916]

good work Joshie!

[@MVDBR]

Cheers, Zappie :)

[@hookedandcooked9434]

Awesome video man !!!

[@MVDBR]

Thanks mate :)

[@behindbarswithnoodles]

thanks for sharing very helpful indeed🤙🤙 least the floor is now cleaner 🤣

[@MVDBR]

Ayyy no worries mate. Yes indeed sneaky cleanup of the Commo oil stains 🤟

[@danted232]

Great video looking to do this on my 2020 husky tx300i

[@derekbratsch991]

Buy a quantum fuel pump while your at it, better than stock on my Te300i

[@christianwilliams1136]

You might want to replace the in tank fuel filter with an aluminum one so it wont crack or split on the trail from the pressure. Here is a little video explaining why those plastic ones are crap, the aluminum one from bestdualsportbikes only needs to be changed every 4000 miles and you can buy a filter replacement kit. Here's the video if you guys are interested kzbin.info/www/bejne/r6TEpnRvp5eJoac

[@MVDBR]

Do you work for those guys or something? 😉 They have a LOT of great upgrades for these bikes that I would get if I had unlimited funds. Thanks for the info mate 🤟

[@christianwilliams1136]

MVDBR Enduro No I don’t work for those guys, but I bought a lot of their upgrades and they are legit. I wanted to fix most of my flameouts issues and bought their power bundle kit and it gave me 11HP and the fuel rail that came with the bundle that cured all of my flameouts. If you get just one thing from these guys I’d get the fuel rail for you’re KTM’s. All of their stuff tho is extremely durable and very well made. It’s a shame it is so expensive.

[@MVDBR]

Yeah awesome mate good to know, cheers 🤟 It's not really that expensive in US dollars but once converted to AUD and add overseas shipping it's pretty pricey ay

[@christianwilliams1136]

MVDBR Enduro Yeah I live Canada and it cost a lot when it arrives at my door. Duties, exchange of money and shipping just are almost not worth it, it’s a shame the good stuff is so hard to get. Love you’re videos keep em coming.

[@MVDBR]

Thanks mate appreciate it 🤟

[@alphawolfadventures1470]

Damn 2015 Xcfw350 here . Didn’t even know I had one of these 😂 at 97 hrs now

[@dannysdirtbikeadventures2606]

Good video, you're not wrong about the ridiculous prices for KTM fuel filters ....

[@MVDBR]

Yeah gotta be a rich man to own a KTM aye Danny I know you know the pain

[@dannysdirtbikeadventures2606]

@@MVDBR Yeah I agree, they cost a bit to keep running

[@stevethomas9848]

Great video

[@MVDBR]

Cheers

[@craigcarr5049]

Awesome - thanks! Now I know what those little rubber bungs are for and I can stop stealing shit from the kitchen cupboards to block up the fuel lines when the tanks off... Thx!

[@MVDBR]

😅👌 no worries

[@wv4life375]

Only additional recommendation is to orient the new clamps so that no sharp portions of the clamp will touch the other fuel lines.

[@MVDBR]

Yah, good idea 👍

[@MAKENTRAX]

Sweet👌

[@MVDBR]

Sanx chief ✌️

[@JorgeGonzalez-ei6ft]

Fuckn mint!🤣🤣 learnt heaps hey. Also loved the schellaks fuel pouring. 🤣🤣

[@MVDBR]

😅 yeah every fkn time! You'd think I'd learn. Cool mate gettin prepped up for your 500 dayz 🤙

[@JorgeGonzalez-ei6ft]

@@MVDBR 100%

[@lukasilec1987]

Inline fuel filter 5:27 Here is some interesting fact. I bought KTM 250 EXC TPI 2018 with 50 hours, now i have 100 hours and i wanted to change this inline fuel filter and when i removed this fuel line filter was missing. So if you are wondering if this filter is really necessary here is the answer. Bike still running with no problems, maybe it is just a luck. But of course i don't recommend you to do this.

[@MVDBR]

Yeah, probably depends how clean your fuel supply is. Not sure about the 2-strokes but I know you don't wanna risk blocked injector on the 4-stroke. Would really ruin your day :)

[@katojimmybling]

Lol i got two of those inline filters from ktm ,charged me $7 each so i spent $40 and put a tank filter in so just take it out of top of tank and clean now and then other filters will last lots longer

[@MVDBR]

Good stuff Jimmy, still worth replacing that in-tank filter now and then as it seems like a lot of people are saying most of the shit that ends up in them comes from the actual fuel pump itself. KTM quality... 🙈

[@katojimmybling]

Thx for that bro i plan on waiting until my ride is 12 months old at least

[@MVDBR]

I think they say yearly anyway, been a year since I did mine 👌

[@katojimmybling]

MVDBR Enduro be up your way over xmas found a guy i work with has a property at Kenilworth plan on some camping

[@MVDBR]

Awesome we'll have to try n meet up 🤙

[@bengriswold2243]

Great vid! Getting ready to do this on my 2016 fe350. I was thinking the same on simply cleaning up the screen in the fuel pump. I'd guess my question is. How did the hose clamps hold up? And how long did you have em in the tank for before you got the new ones with the eBay filter purchase? Just wondering. Thanks again for the vid. Ride on mate🤙👊✊🌫️

[@MVDBR]

Those clamps were in there since last time I did the filter, about 5,000km ago. Probably around 12 months minimum. They held up just fine. The eBay ones seem to be holding up fine also. Thanks for watching mate. Get onto that filter before it clogs up and kills your fuel pump :)

[@frazzle657]

Mine didnt have an inline filter and didnt fit one in the quick connector either.

[@brapamaldi7666]

"dont do what i do" haha. i wont. hence why my rags are clean, i would have cleaned up the spilled fuel with my lighter :D

[@MVDBR]

Hahaha I'd fkn blow myself up 😄 Thanks for the comment mate

[@gary444]

About to do mine, what size clamps did you use? Great video 👍

[@MVDBR]

Thanks Gary I'm not sure what size they were mate they came with the filter. Pretty standard fuel line size I assume.

[@MrSTEALTH125]

What do you use to get your bike so clean and shiny? Looks like it came right off the show-room floor...(thanks for the filter video!)

[@MVDBR]

Shit it's been a while since I had the old 500 mate, but basically just pressure washer. Every now and then a touchup of the white plastics with a bit of Gumption cleaning paste. Cheers

[@thedonnybrookghost8394]

👍👍👍

[@MVDBR]

😊😊😊

[@callummalseed7908]

Is there anything to replace the filter with so you can just open it and replace with a filter, not the hole unit,

[@MVDBR]

Not sure mate 🤷‍♂️

[@human1513]

The original filter on my 2022 KTM 300 XC TPI is black plastic. So no way to just look at it and see if it is dirty.

[@MVDBR]

I'd replace it periodically anyway, not sure if they've improved the fuel pumps in later models but the older ones dirtied up the filters pretty quick

[@frazzle657]

The filter you linked is the kl97 OF theyre a lot cheaper. Are they not the correct one?

[@MVDBR]

Thanks for letting me know, the listing has changed. I can't seem to find the normal filter on Amazon anymore 🤔

[@frazzle657]

Turns out they're the same. I checked it out and just fitted it but the problem remains. I need to test the pressure as the pump could be fucked

[@MVDBR]

@@frazzle657 thanks for letting me know, good luck with it man

[@bicigaming531]

​@@frazzle657cleaning the injector helped me a few times

[@Efsane45.]

Türkiye'nin ürettiği benzin filtresini kullandığını görmek güzel 👏

[@MVDBR]

Evet! 👍

[@human1513]

LOL. Thanx for the video. But please hands off my bike and gas. LOL

[@macca462]

Fuel filters?!? Pfftt yeah righto... next you'll be telling us to refill our indicator fluid!! XD (Maintenance is not my forte - (either is the actual riding unfortunately!))

[@MVDBR]

👌😅 Blinker fluid goes without saying haha. Guess if ya not riding much cuts down the maintenance... what's stopping ya Macca 🧐

[@macca462]

@@MVDBR Nah, I'm out there just about every weekend.. On the bike for as long as my old bones or time allows! Feel free to have a look at some of my dodgy vids if ya like!

[@MVDBR]

@@macca462 oh rito this ought to be good :D

[@macca462]

@@MVDBR You'll laugh, you'll cry, but mostly... you'll just roll your eyes and think "why even bother?"

[@MVDBR]

Yeah pretty much 😅 You 2 stroke riders 🤦‍♂️

[@kimh4589]

ya.... I WISH that the pump would just drop into place!!!! :-)

[@kimh4589]

Fish tape worked awesomely!!!!

[@MVDBR]

Haha yeah sometimes it can play hard to get 😅

[@bmwlane8834]

Great vid. You really should be wearing gloves, fuel is bad, brake cleaner very bad.

[@MVDBR]

I know :( Thanks for the comment!

[@blaze6732]

Thanks for the video. Whoever designed this system at Ktm is a complete moron!!!! First off it’s great when your bike cuts out on the face of a jump because the filter is dirty... why even have this? It’s so dangerous! And a pain in the ass to change! I’m going back to Yamaha!

[@MVDBR]

Yeah, not the best design. And their fuel pumps shed debris continually. KTM know this, which is why they say to change the filter regularly 😬