Questions on changing 02 EV fuel filter

[Tony/CT]

I promised myself that once I retired I would spend more time learning about and completing more of my own maintenance. Of course having the time and having the knowledge are two different things! I pulled up a shop manual from Greg Bender's This Old Tractor site but it covers EV years 1997 to 2000 and my EV is a 2002 so I am not sure of the difference. But the manual says the fuel pump is in the tank and I think my fuel pump is outside the tank. Of course, I haven't found it yet. So the tank is off, and I would like to change the fuel filter. It looks like I need to remove the nut in the front which has two hoses attached, one going to the pressure adjuster, the other I'm not sure, and then remove the hose behind the filter. Of course if I accomplish that I then have to somehow remove the filter from the frame which has frame members on either side and one on the top. It looks tight. How is that accomplished? Teaching high school biology for 30 years certainly hasn't equipped me for motorcycle maintenance. Handling dissection tools and understanding mammalian anatomy is a breeze but this stuff??  ???

P.S. Also, in the bottom of the air filter box is a puddle of oil. What is this all about?

[Rich A]

This may help:  http://archive.guzzitech.com/FuelFilterReplace-Rich_A.html

Rich A

[twhitaker]

The crankcase ventilation system dumps into the air box. A bit in there is to be expected.

[Kent in Upstate NY]

Not that complicated. Cutting a few cable ties will make things easier to move around. It took me about 1/2 hour, give or take a beer or two. The puddle of oil in the airbox may be a sign of too much oil in the sump. The oil level should be about halfway between the lines on the dipstick.

[Kiwi_Roy]

A slight variation,
Disconnect the battery Negative, this will stop you thinking "I will just turn the key on to check something" and spraying gas everywhere, don't ask me how I know. Even with the tank off there's quite a bit remaining in the pump and filter.
You are going to spill some gas so consider doing it outside, but less if the tank is not full. try to have it half or less and you need to sit it flat or tilted against the wall, if you have too much gas it will run out the return line.
The two hoses at the front center of the tank have to be disconnected, one has a nut but you may just want to disconnect the hose at the barb, either way it doesn't matter.
I suspect the 2002 has polarized plugs under the tank, if not you must be very carful not to get them swapped around as this results in burning out the fuel level sensor a $190 mistake.
To get the filter out you need to disconnect both hoses and slide it out of the bracket at the same time it comes out of the frame.
I have never replaced a filter even though the one on my EV was completely plugged with one finger over the inlet, pour a little gas in the outlet, shake it around for a bit then let the dirty fuel run out the inlet end.
This is what you might find, My bike spent it's early life outside.


While you have the tank off remove the cap and dribble a few drops of light oil into the moat drain, if it flows away that's good, if not you have a plugged drain that needs fixing or you end up with water in the tank which promotes rust as pictured.

[Wayne Orwig]

I pulled up a shop manual from Greg Bender's This Old Tractor site but it covers EV years 1997 to 2000 and my EV is a 2002 so I am not sure of the difference. But the manual says the fuel pump is in the tank and I think my fuel pump is outside the tank.

 It looks like I need to remove the nut in the front which has two hoses attached, one going to the pressure adjuster, the other I'm not sure, and then remove the hose behind the filter.

Of course if I accomplish that I then have to somehow remove the filter from the frame which has frame members on either side and one on the top. It looks tight. How is that accomplished?

P.S. Also, in the bottom of the air filter box is a puddle of oil. What is this all about?

#1. Until about 2004, or about mid 2003 actually, the pump and filter are OUTSIDE the tank. If you can see a pressure regulator, then your pump/filter/regulator are outside the tank.

#2. Yes, remove the regulator. There is also a water drain line under the tank, below the cap. The fuel feed line on the tap (turn that off if manual, be very careful with the wires if electric) Unplug the fuel level sensor. Do NOT confuse the sensor with an electric petcock.

#3. You will need a saw to cut the frame in half.  ~; It is a royal pain to get to. Lots of cursing and thin wrenches.

#4. The engine breather dumps into the air box. It collects oil in the bottom of the box. Clean it out some. Keep the engine oil level below the half way mark. Much more and it starts to blow in out into the airbox.

[Tony/CT]

O.K...thanks all. You guys are a wealth of information. You're right Wayne, lots of cursing going on in the garage. Well, the fuel filter is out. Went to my local Napa shop and they don't have the 3008 in CT. so would not be able to get one here until tomorrow afternoon. Think I will order the proper filter from MG. Their price is actually three dollars lower for OEM than Napa's filter. Now, as far as the tank goes, the petcock on the left side has a screen in it that can be cleaned?

[Kent in Upstate NY]

Yes. Just remove the petcock and you will see it.

[Tom]

I've used a fuel filter for a 924 Porsche.  Had a spare and it had the same threaded ends.

[Tony/CT]

So does the tank need to be empty of fuel before the petcock is removed to clean the screen?

[Chuck in Indiana]

So does the tank need to be empty of fuel before the petcock is removed to clean the screen?

Well, if it isn't, it soon will be..  ;D
Or, you can get most of it out, and stick the tail of the tank in the air.

[Wayne Orwig]

Well, if it isn't, it soon will be..  ;D
Or, you can get most of it out, and stick the tail of the tank in the air.

Of course, with the tail up in the air gasoline may pour out the front opening IF you have the style with the regulator in the front, and it is off.
You can lay it on the right side, with the petcock side up.