Fuel Filter Installation in an Accessible Place

The fuel filter on the second generation RSV is located in an area that is pretty difficult to access. It would certainly be difficult to get to in a hurry if you happened to be on the side of the road and needed to change it or try to blow it out to clean it. Because of this, I decided to install a filter in an easily accessible place upstream from the OEM filter. After some searching, I discovered a good quality filter made by Russell and carried by J & P Cycles [ www.jpcycles.com ] (800-397-4844). They call it a "Universal Fuel Filter".

The part number for the filter itself is 7200555. The replaceable element for this filter is part number 7200185. You can also purchase some mini-hose clamps (screw type) that fit 7/32 to 5/8 inch OD fuel line. Those are also easily found at any good parts house. This filter has metal ends with female threads, a clear barrel between the ends which contains the filter element, and also provided are six plastic adapter fittings which will screw into the threads in the metal ends of the filter housing. These have nipples that will fit ¼", 5/16" or 3/8" ID fuel hoses. The ends of the filter housing
unscrew apart to allow easy cleaning or changing of the filter element. This filter can probably be purchased from other vendors as well. From J & P Cycles, you can purchase the filter housing with an element installed, a replacement filter element, and a pair of mini hose clamps for the sum of $14.96 plus shipping.

The installation is simple. Turn off the fuel petcock; remove the driver's seat from the bike; locate the fuel line that is routed from the fuel petcock underneath the tank rearward between the frame tubes toward the battery compartment and then downward toward the OEM filter location. Once you've identified the fuel line (check twice.. cut once!!), cut the line in about the center of the area between the rear of the tank and the place where the fuel line disappears downward. Then either remove a suitable section of it, or push the ends back far enough to allow the filter housing
to be installed in the line. As I recall, I removed a small section of the fuel hose, but have enough slack in the line to allow it to be put back together with a short piece of copper tubing. (Of course, if this became necessary for some reason, the filter element could be removed to allow fuel to flow through the housing unimpeded.)

Install the plastic adapter nipples into each end of the filter housing (you'll need the 5/16" size) and tighten them sufficiently to seal them. The filter housing and the plastic nipples have hex fittings so they are easily tightened, but you can overdo it!!. Slip the mini hose clamps over the cut ends of the fuel hose and push the nipples on either end of the filter housing into place. Tighten the hose clamps, open the fuel petcock, fire up
the engine, let it run for a few minutes to check for leaks and you are done.

Now you have a fuel filter that you can easily see and determine its condition. I still have my OEM filter in place. It's my feeling that it will last much longer than normal with this filter in place upstream from it. However, if I am ever required to expose the OEM filter for some reason, I expect to remove it and splice the fuel line together in that location, and then use only this filter underneath the seat to filter my fuel. I feel much more comfortable now that I can easily access the filter under the seat. In
addition, the replaceable element for the filter is easily carried with me on the bike, so I am always able to easily service the fuel filter if I should get trash or water in the fuel at fill up time.

In the first picture below, you see the filter installed in its suggested location. In the second picture, I am pointing to the filter element contained inside the housing. As you can see, it's easy to tell the condition of the element any time you feel the need. This is a modification that anyone can perform easily for not much money. I believe it could save some grief alongside the road, and possibly even avoid the dreaded tow truck
in the middle of nowhere!!

Forum Comments:

Posted: Mon Aug 28, 2006 10:24 am
    â€”
I know you say it works well for you... but.. I am wondering if pulling the fuel through two instead of one filter media could be causing the fuel pump to work overtime.. and hence lead to an early pump failure?? Especially if the OEM filter had significant mileage and was already somewhat restricted by build up...

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Author: Pudge, Location: NM, Tatum Posted: Mon Aug 28, 2006 12:17 pm
    â€”
You may have a point. I have been too lazy to remove the OEM filter to this point. Good intentions haven't resulted in any action!! I think it would probably be best to remove the OEM filter. It's a fact that a single dirty filter can increase the load on the fuel pump. And two dirty ones would multiply that. I can also say that I've had absolutely no negative issues since I've added the filter under the seat, and it's been in place for well over a year now. And if water in the fuel were to be an issue, I'd think it could possibly get into both filters, and compound the issue along side the road.

I regularly use SeaFoam in my fuel tank, and I'd guess that helps a bit with keeping the filter(s) clean as well as the water issue. But I've felt all along that it would be better to only have the one, and you've strenthened my resolve to remove the OEM one, but not until the good riding weather is gone!!

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Author: Aussie_Dave, Location: ACT, Australia Posted: Mon Aug 28, 2006 1:51 am
    â€”
Thanks Pudge. There has been plenty of talk about this topic and I am glad you put it in one package. I will now have to locate the OEM filter and change over to this set up.

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Author: Venturous, Location: WV, Eastern Posted: Mon Aug 28, 2006 1:54 am
    â€”
This article should help with the locating the OEM filter:

http://www.venturers.org/Tech_Library/index.php?action=article&cat_id=002010&id=275

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• RSV Idle Speed Adjustment
• Synching the Carbs
• Fuel Filter Part Number & Alternatives
• Adjusting the Pilot Circuit
• Gas Gauge Problems
• Intake Boots - Need Replaced?
• How To Change Fuel Filter
• How to remove the gas tank.
• Replacing Air Filters
• AIS Assembly Drawing
• Synchronizing the Carburetors
• Shimming the Needles
• Replacing the Jets
• Carburetor Assembly Drawing