I'm helping a friend bring his 1995 Ninja 750 zx7r back to life after it sat for more than 15 years. I've got the carbs and much of the bike operational again and am now just getting to the fuel tank. Unfortunately, he left fuel in it with the petcock on during its slumber so the tank is full of varnish. I went to take the fuel pickups off (fuel filters reserved and on) and both literally crumbled when I showed them my wrench. I can find a replacement "reserve" 49019-1070 part but the "on" 49019-1074 part looks to have been out of stock for some time.

I know from the forum that the thread size for the 49019-1074 part is 10mmx1.0 and I've been trying to cross reference those threads with similar "on" fuel filters. The 49019-1071 part looks correct but I cannot find any specifics as to its size and thread pitch.

Can anyone tell me if 49019-1071 might be an acceptable substitute for 49019-1074 or if there is some other part that might also work?

Thanks,

Jeff

 

or
scrap the original filter design and use an inline fuel filter.

 

The bike already has a downstream filter inline after the fuel petcock. I suspect these tank filters are about protecting the petcock from getting clogged. It really seems like a silly design as there doesn't seem to be a convenient way to remove the tank from the bike without spilling fuel since you need to disconnect the tank hoses from the petcock in order to pull it all apart.

It took a number of days to get the old fitting out. Lots of PB Blaster and seafoam didn't seem to help. Spiral extractors were a bad idea and by the time I switched to a straight fluted extractor they didn't work either. I removed the really old smelly gas sometime ago and kept blowing air through the tank to remove fumes. I then tried a reverse drill bit to no avail. I finally started to drill the brass out bigger and bigger hoping I'd be able to peal away the remaining brass but that dang brass seemed to be welded to the steel tank. I finally drilled until I got to the size needed for a M10x1 tap and eventually I was able to use the tap to remove the remaining brass. What a pain!

I ended up ordering the reserve 49019-1070 filter and the "ON" filter 49019-1076 which fits the 1100 hoping that the thread size is the same. The other "ON" filter that might fit is the 49019-1071. It looks to be about 1/2" shorter than the 1076 part but unfortunately I have no idea how either of those lengths compare to the original 49019-1074 part that I can't get. I figured the longer 1076 part would provide more reserve capacity so I went with that one.

If the part I ordered doesn't fit I'll likely plug the "ON" port and just run on the reserve port.

 

Quick update. The 49019-1076 part does indeed have the same thread as the 49019-1074 part and fits in the tank fine. The part itself seems to be quite long but since I don't know the dimensions of the original 49019-1074 part I have no idea how it might impact when the tank will need to be switched to reserve. I am fitting the tank now but with snow in MN it will likely be some time before I find out.