Adventures replacing my fuel line

[urthen]

Hey all,

So in what is quickly becoming a pattern, I dumped gasoline everywhere. Again. At least this time it wasn't my fault, the first time I left the petcock in PRI for a couple days. This time, the fuel line failed and leaked the tank empty.

I figured this seems like a good first repair for me to do, since removing the tank and attaching hoses are both pretty simple. Of course, anyone who's done this knows (as I now do) that the main and remote petcocks are slightly different sizes. I got 1/4" fuel line to start with, but it just wouldn't work. I tried setting them out in the sun, cutting little slits in the ends, warming them up with a lighter and shoving a pair of pliers into them to expand them... no dice.

Fast forward to a few days (and many visits to various shops around town) later, and I've finally got a solution that works for me. Here's what I ended up doing for both the RES and ON lines from the main petcock under the tank to the remote petcock on the frame:

On one side, I've got a 1/4" hose on the main petcock. On the remote petcock I've got 3/8" hose. I joined them with a 5/16" male to male bronze fuel fitting I found at AutoZone. The 1/4" hose slipped on quite tight, but the 3/8" was very loose... the fitting could slip entirely through the hose easily. However, strategic application of hose clamps at all joints seems to work.

(Side note: as I was putting things back together, I noticed there was no hose for the water drain out of the fuel tank. Poked around that area and couldn't find anything, as far as I know it was never there. Should I pick one up and install it or is there nothing really to worry about?)

I slowly filled the tank, watching for any leaks, and didn't notice any. Starting it up took a while, even on PRI (Yes, I remembered to turn it back this time!). Eventually got her running and, after being satisfied I didn't see anything wrong, took her for a quick and easy 30min ride. Frequent stops to check my handiwork, no fast acceleration and I kept the engine under 5k RPM and under 50MPH.

This was about 4 hours ago now. Nothing wrong so far, I've been checking on it periodically to make sure nothing starts leaking as it cools back down. I'm wondering if I went completely bonkers though with my fix. Thoughts? Suggestions? Predictions of a fiery doom?

I may end up just buying the stock parts from Ron Ayers, looks like I can get both hoses for under $20 + S/H.  Once they come in I can take apart my wacky fix and replace it with the stock parts, just for my own sanity. But if anyone's got dire warnings in the meantime, please, let me know!

[Snake2715]

First are you using the thin wall (typically clear) fuel line or are you using the thick black reinforced fule (injection) line?

I have 1/4 line on mine and literally put 1/4 on a 91 tonight. Its tight but it does slide on all fittings.


The vent at the bottom of the tank should have a long hose that routes down under the air box and out near the bottom of the right case.

That vent is actually the fuel tank overflow.. if you have no hose on it and go to fill up its possible it will dump gas right onto your hot engine... so yeah get it replaced right away.


And as far as fuel line.. order from MCmaster and have them in just a few days. Tygon is the best stuff, but their regular fuel line works as well: I promise if you order the 1/4 it will fit. I have it on 2 bikes right now and others have as well in 1/4.

http://www.mcmaster.com/#catalog/118/124/=nkhq6e

I also bought this in a 3ft length to cover and protect the fuel line.

Super Duty Nylon—0.041" Wall Thickness
Part#   9337K1

http://www.mcmaster.com/#catalog/119/815/=nkhrsc

[urthen]

I'm using the thick black kind. I was under the impression that it was required for street bikes, and the thin wall stuff was for off-road bikes?

I might be way off, though, as I'm basing this only on the few packages of clear thin-wall hose I say saying "for off-road use only."

[Snake2715]

I'm using the thick black kind. I was under the impression that it was required for street bikes, and the thin wall stuff was for off-road bikes?

I might be way off, though, as I'm basing this only on the few packages of clear thin-wall hose I say saying "for off-road use only."

Maybe they didnt pay for DOT approval or some such thing?


Thick black no wonder you had problems its for fuel injected bikes, not our carbed bikes. Maybe it works on harleys or whatever, but not the GS so well.  The petcock fittings are so close its hard to get it to fit.

The stock stuff was black but it was thin walled as well.

on my link above order this:

OD
1/ 4 5187K63.. .61

Or this:

1/ 4  ....
.5552K25.. 1.49

The price is per foot. I would say 5ft gets you set with a little to spare that way if you make a bad cut etc.

Shipping is reasonable and it will be in the mail tomorrow afternoon. I had it 2 days later and am a few states away. Crazy fast.

Its all yellow so if that bothers you order the sleeving as well.

[urthen]

Fantastic, thanks for the help. I'm loving this forum so far!

Ordered the tubing + mesh (Not sure if I'll care that much, but at $3, why not) and will replace as soon as I get them. In the meantime, though, assuming it doesn't start leaking or have any other obvious problems should I be well enough to go?

As for the overflow line, I'll dig around tomorrow for it again. I seem to remember a hose running that path but couldn't find the beginning of it. Maybe the end just fell down out of sight. If I can't find it, will any old tubing that fits work fine or should I get more fuel line?

[Janx101]

hmmm .. yellow fuel line... saw a mention of this around the site a few weeks back and forgot.... thanks for the reminder...

'everyone knows' bright yellow fuel line has to be 'good for another 2 hp and/or 1k rpm' !! ... makes sense!! yellow is a racing car colour!!.. not as fast as red of course... but still pretty good!! 

[Snake2715]

hmmm .. yellow fuel line... saw a mention of this around the site a few weeks back and forgot.... thanks for the reminder...

'everyone knows' bright yellow fuel line has to be 'good for another 2 hp and/or 1k rpm' !! ... makes sense!! yellow is a racing car colour!!.. not as fast as red of course... but still pretty good!! 

haha.

Yeah I wish it were not yellow.

OP it should be fine to drive on sure, watch for leaks, etc. If you put any fuel filters in you may have issues with that.


Cut the mesh with hot knife.
Good luck.