gas overflow leak @ petcock fuel lines

[brandiwine]

i though i was all done after rejetting, but i've got a weird leaking problem now.  no leaks from the carbs or the on, res., prime tap, but from the hozes attached to the petcock.  i printed out kerry's fuel lines for dummies info and so i'm pretty sure i hooked them up correctly.  what is happening is the fuel is filling up the hozes and overflowing.  this didn't happen before i took them off the tank to get to the carbs.  i have a spare tank i'm waiting to get pained so i even changed out the petcock just to see what would happen and they still leak.  i'll reluctantly believe that they are stretched out and need to be replaced, but it's weird timing.  they are pretty hard to get on there, meaning they are pretty tight.  does anyone have any other suggestions before i have to go order fuel line?  reason i say order is because it seems like autozone and the like just carry the thicker fuel line which makes it impossible to get both hozes on the petcock side by side at the same time.    ideas?

and just for pity's sake my hard drive crashed tonight too!  

:dunno:

[yamahonkawazuki]

i would go for replacement. (i had same issues) :x ,go to stealer if need be. also invest in those small hose-clamps. (just for piece-of-mind), what i did on mine. hasnt leaked since :dunno:  

[Kerry]

Let me get this straight.  Your hoses are leaking at their ends - where they attach to the fuel-tank petcock?  (That is, not in the middle of the hose somewhere, right?)

If so, here are the possibilities I can think of:

1) The hoses are cracked on the ends.  (Both of them?  I doubt it.)

2) You haven't pushed them on far enough.  (Possible, but I doubt this one too.)

3) You haven't reapplied the hose clamps correctly.  Each hose needs to be pushed about 3/8" to 1/2" past the "bulges" on the ends of the metal tubes.  The stock hose clamps should be applied JUST above those bulges.  I would describe the correct position as:

* Far enough up the hose that the bottoms of the clamps aren't spread out by the bulges...

* ...but close enough that the hoses are tightened against the bulges as they "round the corner", or make the transition from the curve around the bulges to the straight part of the tubes above.  Actually, close proximity to the bulges probably isn't strictly necessary - it's just the easiest method given the room you have in that area.[/list:u]4) I guess it's also possible that the stock hose clamps have been "unclamped" too far and need to be crimped tighter again.  But this has never happened to me.

[brandiwine]

well, the new fuel lines did solve the problem. they were definatley leaking at their ends.  i didn't have any clamps installed on the old fuel lines and the suzuki dealer didn't give me any for the new.  there are lots of little things missing from this bike, like the screws that hold the air box in place and the screw that holds the fuel tap on the frame.  never replaced them because i couldn't figure out what size to buy.  anyway,  the new fuel lines are a bit small though and were HARD to get on there.  took forever to finally get them pushed far enough on there so they wouldn't push off.  so  i rode around for about 30 minutes today and there are no leaks.  i think everything is good now.  

[Kerry]

OK, so the hoses got old and stretched out, and without the hose clamps it was a losing battle.

Just so you know, the stock hose clamps look like the ones that come with this lawn mower valve.  Only they're not yellow:



EDIT: Changed link from sisna.com to bbburma.net