KTM is on top of the off-road world right now with its new
EXCs and XCWs. They’re so good
dealers can’t get enough. But like
any new bike, there are teething
problems. The most common
glitch is a clogged in-line fuel filter
that can cause the bike to stop in
its tracks. Not all of the new
KTMs have this particular filter,
just late 2012 injected versions.
KTM already has a bulletin on the
issue, and there’s a filter-replace-ment kit available that gives you a
clamp and three spare filters, all
of which flow better than the
original. Here’s how to fix it.
The first run of
KTMs didn’t have
an in-line filter,
just the later
of the fuel rail
body and the
to the throttle
kit is part number 78141013144.
KTM has a service bulletin on the
matter, and it advises removing the
entire throttle body. We found you
can avoid this with a little wiggling.
Start by removing the screw that
holds the fuel rail to the body.
You can carefully wiggle the fuel
line off the bike. It’s better to
pull it to the rear of the frame
The issue with the original fuel line is
the clamp that holds it on. It’s a cheap
one that can’t be removed without
Something sharp will take care
of the clamp quickly. Throw it
far, far away. Pull out the original screen. It might not look clogged, but it is.
If you have air, blow out the fuel
line. It’s important to keep
everything as clean as possible;
EFI systems don’t like dirt.
Reconnect the fuel rail to the hose with
the new clamp and filter in place.
The trickiest part of the whole process is
putting it back together without damaging the O-ring. Take it out of the throttle
body and put it on the fuel rail. A little
grease will keep it there while you put it
all in place. Tighten the screw, put on the
tank and you’re ready to ride! ;