Fuel hose routing

[BaoQingTian]

I'm confused on fuel hose routing.  I have a '92, the california model.  When I got it, it wasn't ridable, it would barely idle.  So I cleaned carbs, changed oil, emptied gas tank, added seafoam and refilled, and cleaned out air filter with gas.  I was able to drive it about 50 miles over 2 days.  Then, while going down the highway at 65 mph after work yesterday, it just died on me.  Engine just sort of shut off, kind of like it was out of gas or something.  I couldn't restart.  So I let the bike sit for about 5 minutes.  It started up and idled, but when I tried to get going it died again at about 50 mph.  Repeat this about 5 times until the battery died from too much cranking. 

I'm figuring it's a problem with fuel hoses.  Whoever had it b4 had an inline filter which I haven't replaced because I can't find the correct size tubing. 

Now here's the funny thing. My hose routing doesn't quite match up with this diagram:
http://www.gstwin.com/images/how_to/fuel%20hose/www_gs500_de_HoseRouting.jpg

Instead of the reserve hose coming out of the rear of the frame mounted petcock, that's where the hose with the filter is- which goes right into the T connection on the carbs.  Everything else looks pretty normal, just the reserve and outlet hose are switched?  If that was the case, how did I ride it for 50 miles??? 

[mjm]

I bet that every time you let it sit the bike was on the sidestand - the tilt of the bike putting fuel on the low side and filling up the float bowls.

There is always a bit of gas left when it will not pull any more from the reserve opening.  Tilting/shaking the bike moves some gas from the low point on the right side of the tank to the low point on the left

You were out of gas - and you could not switch to reserve because you already used it up.

[BaoQingTian]

I had a full tank.  Visually examined it and had filled it up the day before.  Very full

[scratch]

You're saying the hose from the reserve spigot on the frame mounted petcock is routed to the lower T connection(in the diagram) in between the carb, instead of to the longer spigot underneath the tank.  No fuel flow there, if the vacuum diaphragm is in place and in good condition.
And, the outlet hose from the frame petcock is connected to the long spigot under the tank.  Again, no flow, if the diaphragm is in place and no holes.

[BaoQingTian]

That's what I'm saying.  So I've got a problem with a diaphragm somewhere do I?  Could such a hookup actually tear a diaphram that was previously ok?  That would suck.  Also mjm-I realize I was out of fuel-that is the reason the engine would not run was fuel related.  However, the gas tank was full of fuel.  Hope that clarifies.

[MarkusN]

With that hose routing you are passing fuel through the petcock in reverse (entering through the out port, exiting through the RES in port)

It will run only in RES and PRI.

Other than that, your problem sounds like the common fuel starvation problem with the vacuum petcock. have you tried to run on PRI?

[BaoQingTian]

Yes, that's the only position that it will run in.  It gasps and dies in ON or RES.

Did I rip a diaphram in my carb or petcock by having it hooked up backwards?

[MarkusN]

That probably means that you have a vacuum problem as well. Have you checked if the vacuum line (thin hose) between left carb and petcock is routed properly and not squeezed?

[scratch]

Also, it is a California model, which means that the charcoal canister (if it's still there and connected) could be clogged with gas.  Disconnect it also to see if it runs.

[BaoQingTian]

Thanks for the tip on the canister...I didn't know it could be clogged with gas.  I kind of want to replace all my hoses-vacuum and fuel.  Is it possible to find the right sizes at Autozone and just cut them to length, or do i need to buy oem?

[Oni]

As far as fuel hosing "Michael's" in Carson City will be your best bet.  Most hosing Autozone sells will be a huge PITA because of it's size.  Michael's is a bike shop and those guys are very knowledgeable.  Just tell them what you need and they'll cut you a length.  Pick up a small filter while you're at it.

[BaoQingTian]

Well, I'm not to impressed with Michaels   They only stock Honda fuel hose, and every part I asked for they didn't have in stock.  I went to their service dept to ask how much it would cost to change fork seals and switch my springs to progressive if I provided all the parts.  $245 for labor only ($70 an hour).  What a freaking rip off.  It's going to take a team of highly trained mechanics 3.5 hours to change fork seals?  I was so pissed I couldn't say I word and just left. 

I'm just going to order from Ron Ayers, don't want to give Michael's my business now.  However, this is weird....when I drain my gas tank, fuel only flows from the reserve pipe of the tank petcock.   Nothing comes from the 'on' one.  Is that normal, or is it clogged up?

[Oni]

Sorry to hear about your problems with them.  Any other shops in Carson that work for you?  My SO mentions that since they remodeled that management may have changed.  She and I have both ordered parts from them in the past for different bikes and never had a problem.

Can you get the forks off the bike and take them in to a different shop?  Maybe one in Reno?  Last year for a '98GS500 (forks off bike) was $103 for labor + parts to have the fork seals done.

By the way if you can't score something reasonable for fuel hose let me know and we can work something out.  If you've got a small bike shop or even dirtbike shop hit them up for some hose.  Otherwise I can buy some and ship it to you and do the paypal thing. 

"On" sounds like it's working normally.  Vacuum actuated.  If your hosing is mis-routed weird things will happen.  I can take some pics if you'd like.

[MarkusN]

However, this is weird....when I drain my gas tank, fuel only flows from the reserve pipe of the tank petcock. Nothing comes from the 'on' one. Is that normal, or is it clogged up?

This is normal for tha last about one quarter of the tank. Since the RES pipe is longer it may also be the only one running when you have them open in parallel. (Least resistance, air may be going in through the other pipe instead of the Tank vent.)

But why do you drain the gas? That's what the tank petcok is for.