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How to Remove the Fuel Filter in a Yamaha XT600

Built to both tackle dirt trails and paved highways, Yamaha's XT600 dual-sport motorcycle has become a classic ride among adventure-seeking motorcyclists. Keeping these single-cylinder machines in working order requires a steady flow of fuel free from contaminants that could adversely affect the carburettor and motor. A fuel filter placed between the fuel tank and the carburettor ensure that dirt and rust don't enter into the carburettor. The filters should be replaced regularly to prevent the build-up of material from restricting the flow of fuel.

Park the motorcycle on a level surface and turn the fuel valve to the "OFF" position. Allow the motor to cool completely.

Locate the pair of seat bolts under the tail cowl. Using a socket wrench, remove the seat bolts and pull the rear of the seat upward. Pull the seat to the rear of the motorcycle to disengage the plastic tab on the front of the seat from the frame. Set the seat aside.

Remove the bolt on the bottom of the frame's side cover with a socket wrench. Pull the mounting tab on the front of the side cover out of the frame's grommet. Pull the side cover down, then forward, to disengage it from the tail cowl. Repeat on the opposite side.

Remove the air ducts from the fuel tank, using a socket wrench to unscrew the mounting bolt. Pull the duct's mounting tab out of the frame's grommet. Pull the duct forward and away from the fuel tank. Repeat on the opposite side.

Follow the fuel line from the fuel valve to the fuel filter between the carburettor. Grasp the hose clamp on fuel tank-side of the fuel filter. Squeeze the clamp's legs together to loosen the clamp and pull the fuel line off the fuel filter. Allow any fuel remaining in the line to drain into a container. Loosen the clamp on the opposite side of the fuel filter and pull the fuel line away from the filter.

Install a new fuel filter onto the fuel line. Align the filter's flow-direction arrow so that it is pointed towards the carburettor. Loosen the hose clamps and press the fuel lines over the filter's nipples. Slide the hose clamp up and around the fuel line and filter nipples.

Turn on the fuel valve and observe the fuel filter for leaks. Readjust the fuel line and hose clamps as needed. Reinstall the air ducts, side covers and seat in reverse order of removal.

Warning

Gasoline will harm painted surfaces. Protect painted components with a towel prior to beginning this project. Gasoline is extremely flammable. Allow the motorcycle to cool completely before beginning this project to prevent the risk of serious burns caused by the ignition of gas fumes.

Things You'll Need

  • Socket wrench and sockets
  • Container
  • Fuel filter
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About the Author

An avid motorcyclist, Chris Gilliland has immersed himself into the two-wheeled world while balancing work life and raising three daughters. When he is not managing the parts department of a local, multi-line motorcycle dealership, Gilliland can often be found riding, writing or working on his motorcycle blog, Wingman's Garage.