[eward162]

Hey all,

I have an 05 Yamaha R6s with a filthy fuel filter. It was a pain to get to and clean and I wanted some thoughts on an idea I had: could I remove the fuel filter from the pump entirely and splice an in-line fuel filter into it? That's how my old 2001 R6 was and the maintenance on it was super easy! Thoughts?

 

[Intuit]

Would the in-line be post fuel pump or pre fuel pump?

 

[eward162]

Post fuel pump. I wouldn't modify the fuel pump at all other than removing the filter sock so fuel can freely flow through. Then I would put an inline fuel filter between the gas tank (fuel pump) and the fuel intake.

 

[Spider64]

Hey all,

I have an 05 Yamaha R6s with a filthy fuel filter. It was a pain to get to and clean and I wanted some thoughts on an idea I had: could I remove the fuel filter from the pump entirely and splice an in-line fuel filter into it? That's how my old 2001 R6 was and the maintenance on it was super easy! Thoughts?

"DUDE"! ya read my mind? I've had the same pain in the ass drama with my 05-R6 fuel filter & have thought this over & already got the parts just in case? Where I've got 2 x 3/8" brass barb elbows, a small length of 12.7mm EFI fuel hose, 1/2" & 3/4" hose clamps, 500mm long of 8mm EFI fuel hose, a in fuel tank ready EFI to 40 microns 8mm fuel filter. But because the 05-R6 fuel module carries the fuel level sensor fixed to the original filter, space access is very limited, but you can cut away most of the section holding the OEM filter leaving only the section with the clip in's & fuel level sensor fix slot. Using the 3/8" hose & 8mm brass barb elbows to the new filter & with 3/8" hose over the filter exit just as a sleeve & then the 12.7mm efi hose sliped over that because the fuel module section that connectes to the oem filter has a large OD connector that will need the 12.7mm hose to have any chance to join up to. I've really put shit loads of thought into this bet, & if this falls together? As I've gone over & over this retro install, where I've not attempted this yet, as you can bet ya left nut I'll give it a go as soon as a situation with a 05-R6 comes along, as I'm looking at the high percentages that this should work,, without any difficulty to the fuel level sensor's ability to correctly work, & the fuel system's performance & flow rate will all be in the original R6's spec performance requirments.
Photos~ compared a A.M 40 micron in tank EFI fuel filter to the OEM 05-R6 fuel module clip in fuel filter that also has the mount clip in point for the fuel level sensor that will have to be left after a large section of the OEM filter will need to be sectioned away for this retro fit to work.
All the fittings & hose in this retro fit has to be 3/8" (8.7mm) inside diameter to keep flow drag to it's minimum. All these parts ~ the 3/8" & 12.7mm EFI hose, hose clamps, fuel filter, & 3/8" brass barb elbows, came to a cost of $31 AU dollars.

 

[eward162]

Let me know how that setup works out for you!

 

[Intuit]

No harm in having both. My only concern (as I'm sure you guessed) is the fuel pump itself is then subject to all the tank-crud. If you've looked them up, they're neither plentiful or cheap. Is there some other fuel resistant material that can be used to replace the sock? (that won't get sucked into the pump)

 

[Intuit]

Will CLR clean up the sock?

 

[eward162]

No harm in having both. My only concern (as I'm sure you guessed) is the fuel pump itself is then subject to all the tank-crud. If you've looked them up, they're neither plentiful or cheap. Is there some other fuel resistant material that can be used to replace the sock? (that won't get sucked into the pump)

What if you covered the fuel pump intake with a fine mesh screen? Not so fine that it would get clogged (that would ruin the whole point of doing this in the first place), but fine enough that it wouldn't let harmful debris through.

 

[eward162]

Here's what I ended up doing and it works great! I cut the in-tank fuel pump off (it wasn't working anyway) at the base of the tank using a Milwaukee oscillating tool. Then I ran a fuel line directly from the tank to an inline filter then to a high pressure inline fuel pump using barbed 90° elbows to make corners without kinking the line. Runs like a champ and total cost was $50. Also makes the maintenance way easier. I'll attach pictures.

 

[whoang40]

Aren’t you worried that there’s a fire risk with the fuel lines next to the battery? What if you have a leak and it sprays all over the electrical? Your seat is right on top of the filter.

 

[eward162]

The terminals would have to arc and spark at the same time as a fuel leak, and I don't have any wires near there that could touch both terminals. I'm not worried about it.

 

[Hoonatic]

The terminals would have to arc and spark at the same time as a fuel leak, and I don't have any wires near there that could touch both terminals. I'm not worried about it.

You’re on the edge of a dangerous cliff. But I see it working well. I’d be more cautious of a loose ground arcing or a fuse blowing. Also when working on the bike/removing battery your high risk. You seem smart enough to work around the risk but damn lol

 

[eward162]

I think I'll take some sort of thin fire resistant cloth and place it between the fuel line and battery. Your concerns are valid, and I think that's a good solution. Thoughts?

 

[Hoonatic]

I think I'll take some sort of thin fire resistant cloth and place it between the fuel line and battery. Your concerns are valid, and I think that's a good solution. Thoughts?

That would be enough to satisfy my concern if it were my ride. I’m not sure what other steps you can really take past that. Just be mindful at all times. Fuel leaks become a problem no matter the setup, but yours looks as solid as it could be

 

[Intuit]

Fuel lines are run with the utmost care to help guard against abrasion damage. Abrasion damage occurs very slowly over a long period and isn't obvious unless you look for it. Abrasion damage is typically not found until there's a failure.

 

[Hoonatic]

Fuel lines are run with the utmost care to help guard against abrasion damage. Abrasion damage occurs very slowly over a long period and isn't obvious unless you look for it. Abrasion damage is typically not found until there's a failure.

That part! The main fuel line off the 2005 pump has a hard plastic shielding around it. The return line is just fuel hose. But doubling up the fuel line with another rubber hose or something similar could help rigidity and keep abrasive damage to a minimum. He has a good layout now he can just refine it for safety

 

[Spider64]

You’re on the edge of a dangerous cliff. But I see it working well. I’d be more cautious of a loose ground arcing or a fuse blowing. Also when working on the bike/removing battery your high risk. You seem smart enough to work around the risk but damn lol

Smart lad? My 05-R6 that i picked up for penny's, had sat for 16 years, where the inside of the fuel tank had turned into a ball of rust! & the seller think'n to sell, didnt look or think , & thought he could just throw in fuel & it would go? But this totally killed the entire fuel system, so after derusting & resto sealing the tank, cleaned the fuel lines & fuel rail, i then went looking for a new pump, filter, strainer, & injectors, i was slapped in the mug with a $1K price tag for a 05-R6 fuel filter? Where ya got'a buy the whole fuel module for that year production? & well you thought outside the box, & i was trying to think inside it, where my same set up as yours was trying to install onto the fuel module minus the old filter, but no matter how i tried? It was too tall to fit in the tank, & i just couldnt find a small enough filter that was no bigger than 40 microns? So i ended up falling in line, & handed over $1000 for a 05-R6 fuel module! I wish i saw ya post before i let the dealer parts counter dude bend me over! & as far as the nervous nelly's out there about your ingenious act? There are electrical insulation products out there to cover any & all exposed electrical connectors, to make it safer than factory. DUDE! Your Da Man!

 

[eward162]

Smart lad? My 05-R6 that i picked up for penny's, had sat for 16 years, where the inside of the fuel tank had turned into a ball of rust! & the seller think'n to sell, didnt look or think , & thought he could just throw in fuel & it would go? But this totally killed the entire fuel system, so after derusting & resto sealing the tank, cleaned the fuel lines & fuel rail, i then went looking for a new pump, filter, strainer, & injectors, i was slapped in the mug with a $1K price tag for a 05-R6 fuel filter? Where ya got'a buy the whole fuel module for that year production? & well you thought outside the box, & i was trying to think inside it, where my same set up as yours was trying to install onto the fuel module minus the old filter, but no matter how i tried? It was too tall to fit in the tank, & i just couldnt find a small enough filter that was no bigger than 40 microns? So i ended up falling in line, & handed over $1000 for a 05-R6 fuel module! I wish i saw ya post before i let the dealer parts counter dude bend me over! & as far as the nervous nelly's out there about your ingenious act? There are electrical insulation products out there to cover any & all exposed electrical connectors, to make it safer than factory. DUDE! Your Da Man!

Thank you! It's still working great! I'm sorry you had to dish out so much for yours. All in all I was under $100 for the fuel pump and filter. I can't remember if I mentioned it or not, but I did have to take an oscillating tool and cut the connection off between the fuel pump inside the tank and the output from the tank. That way the fuel pulled straight from the tank into my in-line filter and pump. Also, you'll have to cut the wiring connection from the original fuel pump and wire it to the new pump. Test that the wires are in the proper position and that the pump is flowing in the right direction before finalizing your installation. Best of luck to anyone reading this!

 

[Spider64]

What if you covered the fuel pump intake with a fine mesh screen? Not so fine that it would get clogged (that would ruin the whole point of doing this in the first place), but fine enough that it wouldn't let harmful debris through.

Know'n ya slayed that Dragon! Which is a cool act! But i would like to know how ya got around the low fuel level sensor? As that little sucker is on the section of fuel module ya had cut away. & know'n the way ya pulled that fuel pump & filter set up rabbit out of ya hat, I'm sure ya pulled another bunny out, on this sensor deal? So i got'a hear & see all about this too? If ya got the time?

 

[eward162]

Know'n ya slayed that Dragon! Which is a cool act! But i would like to know how ya got around the low fuel level sensor? As that little sucker is on the section of fuel module ya had cut away. & know'n the way ya pulled that fuel pump & filter set up rabbit out of ya hat, I'm sure ya pulled another bunny out, on this sensor deal? So i got'a hear & see all about this too? If ya got the time?

If I remember correctly there are two separate plug-ins--one for the fuel pump and one for the fuel level sensor. Only cut the wires to the pump. The fuel level sensor shouldn't be affected as you're leaving the old fuel pump and sensor in place in the tank (while cutting a notch in the output of the old fuel pump so that the in-line pump can do its job). Does that make sense?