Tygon fuel line size

[max]

In the process of replacing the fuel lines on my 2006 GS500, I realised that standard automotive fuel line is too thick for the petcock connectors, and also that the tank and remote petcock have different sized connections (thanks Suzuki...).

I've looked into Tygon fuel lines (F-4040-A), but after a lot of comparative research there's discrepancies on here between people using 1/4" (6.35mm) or 5/16" (7.94mm) tubing.

After some rough measuring I put together a crude diagram of the dimensions of my 2006's hoses and connectors (attached below).

(Note for anyone using this as a reference that the hoses are the OEM ones but their sizes will have been deformed due to being stretched by their connectors over numerous years).

Based on these measurements, can anyone that's replaced their lines with non-OEM parts provide some information/recommendations?

[gregjet]

Originally I kept the furl line stock line config and used quality hose with inline adapters. I don't know if you can buy them as I turned them down myself. I have since gone to a simpler 2 hose with a inline fuel pump which is much simpler. Still experimenting with it though and I still had to make adapters.

This sort of thing. They allow you to use quality fuel line.

[max]

Originally I kept the furl line stock line config and used quality hose with inline adapters. I don't know if you can buy them as I turned them down myself. I have since gone to a simpler 2 hose with a inline fuel pump which is much simpler. Still experimenting with it though and I still had to make adapters.

This sort of thing. They allow you to use quality fuel line.

I've definitely seen fuel hose reducers available, but in my opinion the more connections the greater chances of leaks. The reduced hose method sounds very interesting!

I'm thinking I might just stick with the OEM hoses as 8mm Tygon F-4040-A seems pretty scarce and expensive in the UK. I'll cut up my old hoses when I get a chance to check ID's to see if a fuel filter and quick connectors will fit in suitable locations too.

[Kookas]

Originally I kept the furl line stock line config and used quality hose with inline adapters. I don't know if you can buy them as I turned them down myself. I have since gone to a simpler 2 hose with a inline fuel pump which is much simpler. Still experimenting with it though and I still had to make adapters.

This sort of thing. They allow you to use quality fuel line.

I've definitely seen fuel hose reducers available, but in my opinion the more connections the greater chances of leaks. The reduced hose method sounds very interesting!

I'm thinking I might just stick with the OEM hoses as 8mm Tygon F-4040-A seems pretty scarce and expensive in the UK. I'll cut up my old hoses when I get a chance to check ID's to see if a fuel filter and quick connectors will fit in suitable locations too.

You're in the UK? I got these hoses for my F: https://www.advancedfluidsolutions.co.uk/8mm-72mm-nitrile-rubber-fuel-hose-516-596-p.asp. Pretty much identical size to stock, inside and out. You do need to use a hairdryer on the end that will go onto the massive petcock nipple though, but it will stretch to fit just fine without too much warming up.

[alpo]

I used automobile fuel line on mine. Plain black stuff; inexpensive and readily available.  I had some 5/16" ID (inside diameter) lying around that worked great from the petcock to the carbs, but had to use small hose clamps on it - the OD (outside diameter) is too large for the stock clamps.

I had to use 1/4" ID from the tank fittings to the petcock. The OD of the 5/16" line is too large to fit two lines in that tight space on the tank. The 1/4" lines are just small enough to get both of them on and use the stock clamps. Squirt a little WD-40, or similar, inside them and they slide right on.

If you don't like the writing on the automotive fuel line (I don't) it will rub off with a little lacquer thinner without hurting the lines.

The 1/4" line cost me $1.49/foot. 

[Kookas]

To be honest I didn't bother with the clamps for mine, they're already a bugger to get off without them - they're not coming off with anything less than a focused, directed effort!

[max]

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You're in the UK? I got these hoses for my F: https://www.advancedfluidsolutions.co.uk/8mm-72mm-nitrile-rubber-fuel-hose-516-596-p.asp. Pretty much identical size to stock, inside and out. You do need to use a hairdryer on the end that will go onto the massive petcock nipple though, but it will stretch to fit just fine without too much warming up.

I ordered stock hoses at a total of £30 ( ) before seeing your post. But they were on supplier order from MSP.eu until the 4th (today), then when I checked today and they're now on backorder until the 10th, so I might just cancel it and order some of the hose you posted.

What year is your F for reference? Also did you go for the 7.2mm ID hose?

[Kookas]

...


You're in the UK? I got these hoses for my F: https://www.advancedfluidsolutions.co.uk/8mm-72mm-nitrile-rubber-fuel-hose-516-596-p.asp. Pretty much identical size to stock, inside and out. You do need to use a hairdryer on the end that will go onto the massive petcock nipple though, but it will stretch to fit just fine without too much warming up.

I ordered stock hoses at a total of £30 ( ) before seeing your post. But they were on supplier order from MSP.eu until the 4th (today), then when I checked today and they're now on backorder until the 10th, so I might just cancel it and order some of the hose you posted.

What year is your F for reference? Also did you go for the 7.2mm ID hose?

2007, and yeah, the 7.2mm one. It was weirdly difficult to find a supplier for such small hoses without any braiding or such, but AFS shipped it out pretty quick.

[max]

...


I ordered stock hoses at a total of £30 ( ) before seeing your post. But they were on supplier order from MSP.eu until the 4th (today), then when I checked today and they're now on backorder until the 10th, so I might just cancel it and order some of the hose you posted.

What year is your F for reference? Also did you go for the 7.2mm ID hose?

2007, and yeah, the 7.2mm one. It was weirdly difficult to find a supplier for such small hoses without any braiding or such, but AFS shipped it out pretty quick.

Thanks, ordered 2m from AFS and cancelled the MSP one.

Gonna order 2x quick disconnects and a fuel filter too, all for way less than the OEM hoses alone were costing!

[tobyd]

I used 6.4mm and its a bit tight, 7.2mm ( didn't see that when i was replacing mine ) should be a good fit.

I doubt 6.4mm needs any clamps though. i used this sort but they are still a hog to remove and fit over the tank joins.