Changing G650X Internal Fuel Filter

After having replaced the in tank fuel filter as part of my Project XCountry rebuild thread I have been asked a number of questions so thought it would be worthwhile documenting the process

I used my XMoto for these photos but the process is identical on the XChallenge and XCountry

The fuel filter can be sourced here :

https://www.ebay.co.uk/itm/Mahle-Fue...53.m2749.l2649

First step is to unplug the electrical plug to the pump and remove the two screws from the fuel outlet



I remove these two screws from the feed pipe rather than trying to remove the hose clamp from the rubber feed pipe as the plastic feed pipe tends to be very brittle and will easily crack off



Next remove the retaining ring than holds the pump onto the tank



Once the retaining ring is removed using a small screwdriver carefully prise the pump body up so it can be removed along with the gasket







So now we have the pump out and can see the filter . It's held in with two screws and a support bracket plus a hose clamp on the feed pipe






Remove the two screws and the one time use hose clamp






As you can see there is quite a bit dirt comes out of the old filter . The old filter was dated April 2007 , thew new one is April 2019





You need a size 10-11.5 Oetiker Clamp (or a jubilee clamp if you prefer using one of those)

https://www.ebay.co.uk/itm/Mikalor-W...72.m2749.l2649

I use a set of the proper pliers to crimp the clip





Put the clamp on the feed pipe then install the support bracket and insert the filter body onto the spigot on the pump body



Re-fit the gasket and the pump into the tank , fit and tighten the locking ring

Re-fit the electrical connection and the fuel pipe outlet , remember to fit the two retaining screws

Turn on your ignition a few times to prime the pump and makes sure it whirrs ;-)



Job done !

Good one John .... must have a look at mine

nicholsonj2252 said:

After having replaced the in tank fuel filter as part of my Project XCountry rebuild thread I have been asked a number of questions so thought it would be worthwhile documenting the process.....

Click to expand...

Very worthwhile - thank you

Marvellous. Much obliged, because I think it was my naive questioning that caused you the grief.

2 fuel filters on order, along with fancy clamps. I hope they are the right ones, because the links have expired! I shall get my local garage man to clamp the clip up for me, because I don't have the fuel clip pliers. I can walk down there with the assembly.

edit:

https://www.onlinecarparts.co.uk/mahle-original-7938332.html Seems the same, with an 8mm fuel pipe stub.

https://uk.rs-online.com/web/p/hose...MDNmG_J3Yc3sncZ3J8hoC9H4QAvD_BwE&gclsrc=aw.ds

Yep brill info there John, going to give that a bash now, cheers.

King Rat said:

Marvellous. Much obliged, because I think it was my naive questioning that caused you the grief.

2 fuel filters on order, along with fancy clamps. I hope they are the right ones, because the links have expired! I shall get my local garage man to clamp the clip up for me, because I don't have the fuel clip pliers. I can walk down there with the assembly.

edit:

https://www.onlinecarparts.co.uk/mahle-original-7938332.html Seems the same, with an 8mm fuel pipe stub.

https://uk.rs-online.com/web/p/hose...MDNmG_J3Yc3sncZ3J8hoC9H4QAvD_BwE&gclsrc=aw.ds

Click to expand...

Fuel Filter is the same but they charge £8.45 delivery so the one off eBay is cheaper

The clamps are the correct ones and about the same price as eBay

You don’t have to use the proper tool , a pair of end cutters will do the job just fine

https://www.screwfix.com/p/end-cutters-7/4927v


Sent from my iPad using Tapatalk

nicholsonj2252 said:

Fuel Filter is the same but they charge £8.45 delivery so the one off eBay is cheaper

The clamps are the correct ones and about the same price as eBay

You don’t have to use the proper tool , a pair of end cutters will do the job just fine

https://www.screwfix.com/p/end-cutters-7/4927v


Sent from my iPad using Tapatalk

Click to expand...

Thank you.

Don't forget to clean the mesh bag, it will be gummed up.
Check the plug pins for faults.
The increase in resistance with an old fuel filter can lead to melting of bits on the plug.
Cheers Josey

Well, I have done the first one, the black X Country. How did you clean the gauze filter please John?

I have washed it and washed it in soapy water, fairly heavily soaped water, and it is still as black as the 'fuel tank'. Yours looks almost white! I have put it all back together, but when I come to do the other one, it would be good to know how to get the gauze strainer cleaner please. Is it a question of taking it somehwre and using a parts washer, or is there some can of something that will clean it without melting the plastic gauze?

I was lucky, no screwdriver needed to prize the top off the fuel tank, my finger nail was enough to lift it, it came out very easily.

ps date on my filter was 08 2006, so not before time Fired up very quickly though, the pump is strong.

I just used an aerosol of carburettor cleaner to clean the strainer and then blew it off with an air line


Sent from my iPhone using Tapatalk

nicholsonj2252 said:

I just used an aerosol of carburettor cleaner to clean the strainer and then blew it off with an air line


Sent from my iPhone using Tapatalk

Click to expand...

Thank you. I can do that at the garage down the road. I'll take the bike down and hide in their shed for an hour or so and do an oil change at the same time.
Much obliged.