Ducati 748/916/996 Fuel Filter

The fuel filter is in the gas tank, so that has to come off. Try and get the tank as empty of fuel as possible. It will make maneuvering the thing much easier (as will an extra person). Note that fuel will leak, almost unavoidably, once the tank has been disconnected. It’s messy and it stinks.

One 5mm Allen bolt under the seat holds the tank in place.  Once you can lift and pull back on the tank, you must disconnect the four fuel hoses and fuel pump wiring before you can pull it fully off the bike.

The fuel nozzles that plug into the tank are delicate, especially on my ten-year-old 916, so be careful. Try and remove them before moving the tank too much. Pinch the metal tabs in, then pull out the plastic fittings. If you put stress on them, they will break. They’re $70 each from Ducati (part number 58840121A for white). Ask me how I know.

Set the tank on a clean, soft surface upside down.

For some reason, fuel kept pouring out of one of the loose hoses, so I connected the two together, which put a stop to it. Fuel still made its way out of the locking gas cap. The pump assembly is held in place by three 4mm Allen bolts. It is also held in tightly by a green gasket ring. To avoid prying (which could potentially scratch your paint), you can use the three bolts in the other threaded holes to push the assembly out from the tank.

My green gasket was loose, so it slipped down inside the tank once the assembly was pulled out. It is supposed to go in the little stepped groove near my thumbnail.

To remove the fuel pump assembly fully, you’ll need to disconnect two hoses that are held in place with standard hose clamps towards the front of the tank.

Note the filter’s orientation. The flow arrow should be pointing out of the tank. Disconnect the two hoses and clamp attached to the filter (3mm Allen bolt). Replace it with a new filter.

Ducati wanted $70 for a fuel filter, so I did some research and learned that the OEM Ducati filter is a Mahle KL 145, which is OEM equipment on many BMW and Triumph motorcycles as well. The BMW filter was $20 (part number 16 14 2 325 859). It’s the same part.

When reinstalling the assembly into the tank, be sure the gasket is snug in its ring, not floppy and falling out. If it won’t stay put, replace it. $15 from Ducati (part number 88650011A). Line the bolt holes on the assembly up with the holes on the tank, and press firmly to reinstall. The gasket will provide plenty of resistance. Bolt it back up.

Hold the tank up to check for leaks around the assembly ring, reinstall it in the bike, and go for a test ride.