2001 Fuel Hose Routing?

[BigTwin]

I'm trying to figure out which fuel lines go where on my 01, they are different then what is on Kerry's site. I think when the shop was working on my carbs they put it so when I turn my tank to the on position it is running off of the reserve. I think this is why when my bike started to chug, I tried switching to reserve and it wouldn't run (because it is running through the reserve).

A diagram or picture out of the Clymer Manual would be great, I'm buying one soon don't worry.

I just want to know which hose from the frame mounted petcock runs to outlet one (closest to front of bike)?

THANKS, BigTwin

[JetSwing]

just to clarify...there's no separation between RES or ON. it's running from the same source. so it you run it on RES, it should never chug till you're completely out of gas.

[BUZZIN]

Big Twin, unless something has change in the fuel line/petcock setup from the older bikes, connect the hoses as follows.  The hose from the front fitting on the fuel tank valve goes to the rear fitting on the frame mounted petcock; and the rear fitting on the fuel tank valve goes to the front outside fitting on the frame mounted petcock.  Anything else and you will have reversed the ON and REServe lever positions, and have rendered the PRIme position nonfunctional.  The Clymer shop manual shows this as opposite of what I just described, and it's wrong.

[Kerry]

I almost responded to this thread last night, but I ran into a bunch of difficulties.  But I guess I'll post them anyway, and let you in on the UGLY side of documenting all the parts that go into a motorcycle.

First, go to my home page and click on the

Parts Fiche Links link.

Now, click the 2001 MrCycles link.

Finally, select "Fuel chicken" from the dropdown list.[/list:u]OK, now start at the top of the diagram.

Assembly 8 & part 9 have not changed since the pre-'01 models.  What has ALSO not changed is the fact that this part is drawn in the wrong orientation - 180 degrees rotated from the way it is mounted on the bike.  All I can figure is that they wanted to display the On/Off switch part of the petcock, which normally faces toward the middle of the bike.  So ... in your mind, spin the petcock around until the screen filter faces the front of the bike (toward the left).

Moving down the diagram, you will find hoses 5 and 6.  I don't have an '01+ model to look at, so I can't say for sure which one is the ON hose and which one is the RES hose.  But I'm nearly positive that they're mislabeled in the description list below, for 4 reasons:

1) The diagrams have

always shown the RES hose pointing straight for the longer tube from the tank-mounted petcock (which is correct).

2) The diagrams have always mislabeled the RES  and ON hoses.

3) The price list says that hose 6 is the RES hose, but that it is less expensive than the longer "ON" hose 5 (which also has an extra bend in it).  Not likely.

4) On pre-'01 bikes, the RES and ON hoses do not cross over each other  as they drape from the tank-mounted petcock to the frame-mounted one.  I would be very surprised if that has changed.[/list:u]In case you're wondering how I know which outlet from the tank-mounted petcock is which, you can check this yourself (unless you have an '04+ and the fairing is in the way).

Here's the view from the front of my '99, from which the tank-mounted petcock has never been removed:



Just above the (longer) brass tube you can see the letter "R" molded into the shoulder on the petcock.  It's not as easy to get a look at the other brass tube, but if you do you will see an "O" there.  R = REServe, O = ON.

Does anybody care to walk out to their stock '01+ bike and check the hose routing?  I'll bet that the two hoses don't cross over each other, and that the setup is essentially the same as described on my Fuel Hose Routing page ... except that the ON and RES hose connections to the frame-mounted petcock have been rotated counter-clockwise.

[BigTwin]

While looking at my fuel lines the:

1) "R" tank petcock runs to the top of the frame petcock

2) "O" tank petcock runs to the right side of the frame petcock

3) Bottom of the frame petcock runs to the carbs

Does this sound right??? Could someone with an 01/02 check for me? Maybe you JetSwing.

THANKS, BigTwin

[Kerry]

I finally took the plastic off of my new ('89-'02) Haynes manual so I could see what it says about this.  Unfortunately, I think the Suzuki diagram is messing everyone up, even the tech writers.  Check it out, from the "Remote Fuel Tap - Installation" section on page 3-5:

23 [...] On EK to EY models [KJB: meaning '89 to '00] ensure the fuel hose attached to the rear union on the main fuel chicken is attached to the outer union on the forwards side of the tap.  On K1 models onward [KJB: meaning '01+], ensure the fuel hose attached to the rear union on the main fuel chicken is attached to the top (RES) union on the remote tap.

If the "main fuel chicken" were installed on the fuel tank in the orientation shown in the MrCycles diagram (which came straight from Suzuki) then this description would make sense to me.   But how is a writer to distinguish reality from a diagram, when the diagram is all they have available?  :dunno:

The best clue from the above description is where it uses the label RES for the "top union on the remote tap".  Given what you already know about which outlet from the tank is the RES outlet, I think we have our answer.

But it would still be nice if someone could check.  

[JetSwing]

i think you have O and R mixed up.  i couldn't see the O label but i'm assuming it's the one next to R.

the ? goes some where up in the carbs...i don't know exactly where...

[JetSwing]

Does anybody care to walk out to their stock '01+ bike and check the hose routing?  I'll bet that the two hoses don't cross over each other, and that the setup is essentially the same as described on my Fuel Hose Routing page ... except that the ON and RES hose connections to the frame-mounted petcock have been rotated counter-clockwise.

it's hard to say with '01+ frame mounted petcock being different from pre '01. the fiche diagram does seem to have the tank petcock rotated.

[BigTwin]

So the "R" tank petcock should run to the right side of the frame petcock? If so, the mechanic screwed up.

And if I try to switch them (at the tank mounted petcock), how much gas will leak out?

I want to do this soon, what would this setting (how it is now) do to my bike?

THANKS FOR ALL YOUR HELP, BigTwin

[JetSwing]

So the "R" tank petcock should run to the right side of the frame petcock? If so, the mechanic screwed up.

And if I try to switch them (at the tank mounted petcock), how much gas will leak out?

I want to do this soon, what would this setting (how it is now) do to my bike?

THANKS FOR ALL YOUR HELP, BigTwin

if RES and ON hoses were swaped, it wouldn't do anything to your bike. no harm done.

[BigTwin]

I'm just making sure one last time before I switch them around, the "R" tank petcock SHOULD run to the right side of the frame mounted petcock, right?

Just clarifying one last time because I hate messing with things that aren't necessarily broken.

-BigTwin-

[Kerry]

JetSwing, what was the source for the annotations on the diagram?  Is the connection labeled 'R' in the diagram actually stamped with an 'R' like the longer tube on the tank-mounted petcock (in my previous photo)?

I'm asking because with the arrangement in the diagram the hoses WOULD cross over each other as they go from the fuel tank to the fuel tap.  Which is the opposite of my theory.  :dunno:

If we can just find someone with an "untouched" '01+ machine and have them trace the fuel hose (by feel) from the front outlet tube under the fuel tank....  :x

the ? goes some where up in the carbs...i don't know exactly where...

It's a vacuum hose that should connect to a vacuum takeoff on the right carb.  (The corresponding hose on pre-'01 models attaches to the left carb.)

Just clarifying one last time because I hate messing with things that aren't necessarily broken.

Excellent policy!  

[JetSwing]

what was the source for the annotations on the diagram?  Is the connection labeled 'R' in the diagram actually stamped with an 'R' like the longer tube on the tank-mounted petcock (in my previous photo)?

this morning, i printed out BigTwin's questions and went outside (it was freezing) and took a look at the hose routing. i followed the end that i've marked R and it led to the connection that's stamped "R" on the tank petcock.

I'm asking because with the arrangement in the diagram the hoses WOULD cross over each other as they go from the fuel tank to the fuel tap.  Which is the opposite of my theory.  :dunno:

what do you mean by "crossover"? actually, they might be...i'll check again and verify the diagram i've made.

if i had more time, i would ahve taken off the tank and took some pictures.

[BigTwin]

Thank you to all who replied.

I have one last question, is there any way to shut the tank mounted petcock valve so fuel doesn't spurt out when I'm switching the two hoses?

Or what do you suggest? I can't switch them at the frame mounted one because the hoses won't reach.

THANKS, BigTwin

[JetSwing]

undo the tank bolts. life it up just enough so that's you can shut the tank petcock off (get someone to help you). then, drain the hose into a container.

or you can use a vise grip to pinch the hose. either way you'll have to drain some of the fuel. so get it over with it!

[BigTwin]

how do you shut the tank petcock off?

[BigTwin]

nevermind, I noticed the "off" location.

THANKS to ALL, that's why I love this forum.

-BigTwin-

[DaemonD]

I have read all the topic and didn't get final conclusion.   The "R" tank petcock SHOULD run to the right side of the frame mounted petcock, or to the top?
Thanks. 

[gsJack]

Here is the setup for all years of GS500s, there were 3 different frame petcock arrangements used over the years.

[DaemonD]

Thanks a lot