This is for documentary purposes only. Don't do this yourself - get a qualified mechanic to do it. This involves fuel which is highly combustible. Again, get qualified mechanic.
Since Aussie Dave passed away, the pictures he took have more or less disappeared from the net. This is an attempt to document that process again. Thanks to motocopter from the zggtr.org forum for investigating on an alternative replacement fileter than can be used.
The tank/fuel pump removal is documented in the Kawasaki manual. Refer to the manual for detail instructions.
A little as possible fuel needs to remain in the tank.
(http://i8.photobucket.com/albums/a28/gnusblat/1400%20GTR/1400%20GTR%20Green/Fuel%20filter/aa.jpg)
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(http://i8.photobucket.com/albums/a28/gnusblat/1400%20GTR/1400%20GTR%20Green/Fuel%20filter/zrjm.jpg)
(http://i8.photobucket.com/albums/a28/gnusblat/1400%20GTR/1400%20GTR%20Green/Fuel%20filter/zrkm.jpg)
(http://i8.photobucket.com/albums/a28/gnusblat/1400%20GTR/1400%20GTR%20Green/Fuel%20filter/zrlm.jpg)
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(http://i8.photobucket.com/albums/a28/gnusblat/1400%20GTR/1400%20GTR%20Green/Fuel%20filter/zrmn.jpg)
(http://i8.photobucket.com/albums/a28/gnusblat/1400%20GTR/1400%20GTR%20Green/Fuel%20filter/zrnm.jpg)
(http://i8.photobucket.com/albums/a28/gnusblat/1400%20GTR/1400%20GTR%20Green/Fuel%20filter/zrom.jpg)
(http://i8.photobucket.com/albums/a28/gnusblat/1400%20GTR/1400%20GTR%20Green/Fuel%20filter/zrpm.jpg)
(http://i8.photobucket.com/albums/a28/gnusblat/1400%20GTR/1400%20GTR%20Green/Fuel%20filter/zrqm.jpg)
(http://i8.photobucket.com/albums/a28/gnusblat/1400%20GTR/1400%20GTR%20Green/Fuel%20filter/zrrm.jpg)
(http://i8.photobucket.com/albums/a28/gnusblat/1400%20GTR/1400%20GTR%20Green/Fuel%20filter/zrsm.jpg)
(http://i8.photobucket.com/albums/a28/gnusblat/1400%20GTR/1400%20GTR%20Green/Fuel%20filter/zrtm.jpg)
(http://i8.photobucket.com/albums/a28/gnusblat/1400%20GTR/1400%20GTR%20Green/Fuel%20filter/zrum.jpg)
(http://i8.photobucket.com/albums/a28/gnusblat/1400%20GTR/1400%20GTR%20Green/Fuel%20filter/zrvm.jpg)
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(http://i8.photobucket.com/albums/a28/gnusblat/1400%20GTR/1400%20GTR%20Green/Fuel%20filter/zrzm.jpg)
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(http://i8.photobucket.com/albums/a28/gnusblat/1400%20GTR/1400%20GTR%20Green/Fuel%20filter/ztbm.jpg)
(http://i8.photobucket.com/albums/a28/gnusblat/1400%20GTR/1400%20GTR%20Green/Fuel%20filter/ztcm.jpg)
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(http://i8.photobucket.com/albums/a28/gnusblat/1400%20GTR/1400%20GTR%20Green/Fuel%20filter/ztfm.jpg)
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(http://i8.photobucket.com/albums/a28/gnusblat/1400%20GTR/1400%20GTR%20Green/Fuel%20filter/ztjm.jpg)
(http://i8.photobucket.com/albums/a28/gnusblat/1400%20GTR/1400%20GTR%20Green/Fuel%20filter/ztkm.jpg)
(http://i8.photobucket.com/albums/a28/gnusblat/1400%20GTR/1400%20GTR%20Green/Fuel%20filter/ztlm.jpg)
(http://i8.photobucket.com/albums/a28/gnusblat/1400%20GTR/1400%20GTR%20Green/Fuel%20filter/ztmm.jpg)
(http://i8.photobucket.com/albums/a28/gnusblat/1400%20GTR/1400%20GTR%20Green/Fuel%20filter/ztnm.jpg)
(http://i8.photobucket.com/albums/a28/gnusblat/1400%20GTR/1400%20GTR%20Green/Fuel%20filter/ztom.jpg)
(http://i8.photobucket.com/albums/a28/gnusblat/1400%20GTR/1400%20GTR%20Green/Fuel%20filter/ztpm.jpg)
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(http://i8.photobucket.com/albums/a28/gnusblat/1400%20GTR/1400%20GTR%20Green/Fuel%20filter/ztrm.jpg)
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(http://i8.photobucket.com/albums/a28/gnusblat/1400%20GTR/1400%20GTR%20Green/Fuel%20filter/ztum.jpg)
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(http://i8.photobucket.com/albums/a28/gnusblat/1400%20GTR/1400%20GTR%20Green/Fuel%20filter/ztxm.jpg)
(http://i8.photobucket.com/albums/a28/gnusblat/1400%20GTR/1400%20GTR%20Green/Fuel%20filter/ztym.jpg)
(http://i8.photobucket.com/albums/a28/gnusblat/1400%20GTR/1400%20GTR%20Green/Fuel%20filter/ztzm.jpg)
(http://i8.photobucket.com/albums/a28/gnusblat/1400%20GTR/1400%20GTR%20Green/Fuel%20filter/zuam.jpg)
(http://i8.photobucket.com/albums/a28/gnusblat/1400%20GTR/1400%20GTR%20Green/Fuel%20filter/zubm.jpg)
(http://i8.photobucket.com/albums/a28/gnusblat/1400%20GTR/1400%20GTR%20Green/Fuel%20filter/zucm.jpg)
(http://i8.photobucket.com/albums/a28/gnusblat/1400%20GTR/1400%20GTR%20Green/Fuel%20filter/zudm.jpg)
(http://i8.photobucket.com/albums/a28/gnusblat/1400%20GTR/1400%20GTR%20Green/Fuel%20filter/zuem.jpg)
A work of art Asif.......................I note your posting time and take my hat off to you for your dedication and commitment............
Picture story book with just the right info content..........................Must of taken hours.................Respect :punk:
Are you going to do more like this ?
Very informative indeed, it doesn't even look too complicated a job.
Quote from: Charlie747 on June 29, 2014, 08:29:08 AM
A work of art Asif.......................I note your posting time and take my hat off to you for your dedication and commitment............
Picture story book with just the right info content..........................Must of taken hours.................Respect :punk:
Are you going to do more like this ?
charlie, I've done loads of these. Search the forum! !
:clap:
Good job. That fuel filter was filthy, what's your mileage? You woudn't think so much crap could get into the fuel.
Quote from: Stephen.Stallebrass on June 29, 2014, 11:04:45 AM
:clap:
Good job. That fuel filter was filthy, what's your mileage? You woudn't think so much crap could get into the fuel.
30000 on the clock
Quote from: The Wolf on June 29, 2014, 08:35:33 AM
Very informative indeed, it doesn't even look too complicated a job.
It's all the messing with the fuel. No fuel and it would be much easier
to be fair I did a few other jobs at the same time like bleed the clutch reservoir, top up with coolant etc
Hi
Great guide, thanks
Richard
Hi,
Great, fabulously detailed guide, but why replace the bolts? They are not load bearing or subject to wear
Coman
Quote from: coman37 on June 29, 2014, 02:30:33 PM
Hi,
Great, fabulously detailed guide, but why replace the bolts? They are not load bearing or subject to wear
Coman
Don't want them working loose due to vibrations, hence why they have thread locker on them. Best to replace with a new set that come with the thread lock already applied.
You ride a HD, Asif?
Quote from: virginiajim on June 29, 2014, 03:14:26 PM
You ride a HD, Asif?
Hell no! I can't see what the big thing is about them
Asked from the vibration point of view... I came up on one the other day at an intersection and it's a wonder the rider wasn't thrown off at idle.
I talked to one of the owners recently (both our bikes were parked next to each other). He had some old HD that he'd restored. Absolutely loved it, but his main comment was "can it shake!"
Interesting that Kawasaki say the filter is not a service item, and is only replaceable with a pump assembley !
Also in the workshop manual [Section 3-44, for 2010 onwards] is the routine for checking the flow rate of the pump, so you can at least eliminate the fuel filter if you have fuelling/running problems
Nice simple looking job Asif .. well documented. :yes:
If it's not too much trouble, can you post the gist of that service procedure. Thanks. I have an 08 so it's not in my service manual.
Quote from: Kwikasfuki on June 29, 2014, 11:11:09 AM
30000 on the clock
Mines probably due a change too then.
Quote from: virginiajim on June 29, 2014, 04:24:24 PM
If it's not too much trouble, can you post the gist of that service procedure. Thanks. I have an 08 so it's not in my service manual.
•Turn the key knob to OFF.
•Wait until the engine cools down.
•Prepare a fuel hose and a measuring cylinder.
•Remove the fuel tank bolts (see Fuel Tank Removal).
•Open the fuel tank cap to lower the pressure in the tank
•Remove the fuel hose from the fuel pump (see Fuel Tank Removal).
○Be sure to place a piece of cloth around the fuel outlet pipe of the fuel pump.
•Connect the prepared fuel hose to the fuel outlet pipe.
•Secure the fuel hose with a clamp.
•Insert the fuel hose into the measuring cylinder
•Close the fuel tank cap.
•Turn the engine stop switch to run position.
•Push and turn the key knob to ON.
○The fuel pump should operate for 3 seconds, and then
should stop.
•Measure the discharge for 3 seconds.
○Repeat this operation several times.
Amount of Fuel Flow Standard: 67 mL (2.3 US oz.) or more for 3 seconds•Turn the key knob to OFF.
If the fuel flow is much less than the specified, replace the fuel pump (see Fuel Pump Removal/Installation).
•Install the fuel tank (see Fuel Tank Installation).
•Start the engine and check for fuel leakage.
Excellent! Thanks.
The two outlets at the rear of the tank - there's a risk of fuel leaking if the tank hasn't been drained fully. I suggest blocking these before raising the tank to disconnect the pipe from the pump
Had the first proper run of the bike today. Much more responsive and the roughness is all gone.
Did you find any crap in the old filter then Asif?
Quote from: shaggs147 on June 30, 2014, 07:25:11 PM
Did you find any crap in the old filter then Asif?
I just chucked it away. In hindsight I should have disected it
With reference to this pic
(http://i8.photobucket.com/albums/a28/gnusblat/1400%20GTR/1400%20GTR%20Green/Fuel%20filter/lm.jpg)
Its probably best to block the pipes from the tank as fuel could leak when manipulating the tank (all depends on how much of the fuel is drained from the tank)
thanks for share, the guide is the very good and clear.