Replacing fuel filter on 2000 S3 - Triumph Forum: Triumph Rat Motorcycle Forums
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post #1 of 10 (permalink) Old 04-08-2019, 03:50 PM Thread Starter
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Replacing fuel filter on 2000 S3

Waiting for female fuel breaks to arrive, so I have tank off and empty. Old plastic ones broke while getting them off, so I have the plate off and I figure I might as well replace the fuel filter. Bike only has 12 k on it, but being 19 years old, it can't be a bad idea. Here's the one I'm about to order...is it the right one? Thanks. Also, is there a trick in getting the plate/pump/filter assembly out from the tank? Got all the screws out but won't come out no matter what angle I move it to. Does something else have to be removed from the front of the plate?
https://www.amazon.com/MAHLE-Original-KL-145-Filter/dp/B005GDJSXQ/ref=asc_df_B005GDJSXQ/?tag=hyprod-20&linkCode=df0&hvadid=312462950315&hvpos=1o1&hvne tw=g&hvrand=2377858766266311293&hvpone=&hvptwo=&hv qmt=&hvdev=c&hvdvcmdl=&hvlocint=&hvlocphy=9012246& hvtargid=aud-643574997066la-492318236851&psc=1&tag=&ref=&adgrpid=70635887228&h vpone=&hvptwo=&hvadid=312462950315&hvpos=1o1&hvnet w=g&hvrand=2377858766266311293&hvqmt=&hvdev=c&hvdv cmdl=&hvlocint=&hvlocphy=9012246&hvtargid=aud-643574997066la-492318236851

Last edited by Rayvin; 04-08-2019 at 03:55 PM.
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post #2 of 10 (permalink) Old 04-08-2019, 05:09 PM
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Yep that's the right filter. Getting the fuel pump plate out is a pain, from memory you have to "hinge" it out rather than pulling it straight out if that makes sense
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post #3 of 10 (permalink) Old 04-08-2019, 05:20 PM Thread Starter
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Yeah, I finally wiggled it around to every angle and it came out, using the 'hinge technique' you mentioned. I was trying to be so careful with it--it took a tiny bit of persuasion. Thanks, Rampant. Now to try the hot screwdriver method of removing the broken break connector threaded pieces that are stuck in there. Unless you can think of a better method. Mine are broken off flush with the plate.
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post #4 of 10 (permalink) Old 04-08-2019, 05:25 PM
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When mine broke I dug out what I could with a screwdriver (didn't think to heat it) and bought a 1/4 BSPT tap to clear the threads fully. If you were in the UK I'd offer to post you the tap lol
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post #5 of 10 (permalink) Old 04-08-2019, 05:32 PM Thread Starter
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Hey, thanks for the offer of the tap (if I were over there). I'll let you know how the hot screwdriver works out.
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post #6 of 10 (permalink) Old 04-08-2019, 07:08 PM
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While you have the tank all apart you might also give serious consideration to lining the tank with a Caswell Plating Tank Liner Epoxy kit - I have done mine and would definitely recommend it as a good barrier from Ethanol/Water absorption.

If you do a search on 'Caswell' in the 'Sport & Touring' section, you'll turn up a few threads on this
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post #7 of 10 (permalink) Old 04-08-2019, 07:40 PM Thread Starter
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I appreciate your quick reply, DEcosse. Is the ethanol/water absorption always an issue with these plastic tanks? Mine is already 19 years old and hasn't been a problem. If I understand it correctly, the problem is that the tank will swell and become misshapen or cracked. Is that it?
The $45 investment certainly sounds worth it, although I can smell those epoxy fumes already.
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post #8 of 10 (permalink) Old 04-08-2019, 07:48 PM
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The Nylon tank on my '98 T595 has not cracked or bubbled the paint, but instead of holding 4.75gal, it will take 5gal. That would be caused by swelling. Also, if you ever decide to remove the tank from the bike and keep off for any length of time, I advise to empty the tank fully. I left my tank off full for 6mo while working on the bike and the tank was a bear to get back on due to alignment issues. I would line the tank. My bike has been sitting for 3+ years now with an empty tank and I plan on using the Caswell.
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post #9 of 10 (permalink) Old 04-19-2019, 10:13 PM Thread Starter
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I've got the fuel pump assembly back in and I see it's 5 nm of torque for those plate bolts. Seems like a lot, and I sure don't want to strip any of those mounting threads in the tank. Anyone using the 5nm without issues? That's like 44 inch/lbs.
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post #10 of 10 (permalink) Old 04-19-2019, 11:40 PM
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I did mine by feel. You don't want to strip, but you also don't want any leaks. The bolt head presses up against a metal insert in the rubber. The first and only time that I used a torque wrench on the oil drain bolt, the bolt leaked until I snugged up by hand. I use torque wrenches sparingly.
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