I'm trying to take a cycle trip tomorrow and need to do the fuel filter bypass on my DL650, but I have found only one place where the game plan is outlined for a bike newer than 2006, and even that spot is missing a couple pictures. Here's the only place I've found instructions and pictures:
Scroll about 60% down the page to Reply #232 here: External Fuel Filter modification
I see only 3 pictures, but I believe there should have been 5 (2 links are broken).
Is there any other place you can think of with a more complete set of instructions and pictures? It would be nice to know how to get the plastic filter-holder off of the pump assembly, and to see down the outlet hole in advance. It may be evident once I have it all in front of me, but timing is important and I'd like to be well armed in advance. Thanks for your help!
I ordered a pump screen, quick connects and some fuel hose clamps. I have some fuel hose already and will go to my favorite auto parts store to see what suitable filters they might have once I see how much space is available. Also ordered 4x Iridium spark plugs and an air filter so will have almost everything necessary to service stuff under the tank.
The part number quoted for quick connects (Dorman 800-081) is not correct for my 07. The fitting is too large - so I ended up cutting off the old connectors for re-use after all. Hope to finish tomorrow.
The inside diameter of the quick connects was 1 or 2 mm larger than the originals and would not seal on the fittings.
Got the bike back together and tested (idling in the garage while it poured outside) for about 10 min with no leaks. Away for work now but eager to get home and take it for a spin - see if the top end power is there now.
Just make sure you tighten those hose clamps realllly tight. I had not tightened it enough, and it left me stranded on the highway when the hose came loose from the filter. Luckily I was able to tighten them on the side of the highway.
So I carried out the bypass tonight after work and it works like a bloody charm. My 2008 weestrom has never been so smooth all the way up the band, acceleration is awsome. Thanks to you fellow stromtroopers. All in all (and I'm a novice) it took me 2.5 hour's from start to finish, thanks again all.
The hardest thing about doing this in all honesty was removing the bloody quick release from the engine side, need small fingers, my son came in handy lol
Secondly was removing the old quick release clamps from the hose without damaging the little rubber orings inside the inner sleeve.
I've got my list of parts to buy for this job, but reading the service manual it suggest new O rings for the fuel pressure regulator and fuel pipe, plus the large O ring on the tank.
Sound right?
The regulator o-ring is cheap and worth changing to be sure. The one for the pump mounting plate may or may not need changing but it's cheap insurance to have a spare in case it sticks and tears when you pull the pump out of the tank.
I didn't need them so just used the ones that were there.
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StromTrooper
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