I cut my old fuel hose to make faster work of disassembly.  I went to replace the fuel hose with 1/4-inch fuel hose, but it looks smaller inside (and thicker outside! no clearance between the two tank nipples):



The larger inner-diameter hose on the right is the stock hose, cut about 1/8-inch below the fuel tank nipple.  It looks like I need something about 5/16 inner diameter and a thinner hose?

Same thing happened to me-  Let us know what size you used.  I bought 1/4 inch to "replace" my old line but it was too small.  I reused my old line and want to replace next month when I change the jets agin.

That 1/4" tubing is really for pressurized systems used with fuel injection. Maybe just get some fuel resistant clear tubing in 5/16". Most auto supply places should have it.

Or spend a few dollars at the dealer...they have the correct size....and it's not like you have to buy 100 feet of it.......

Yeah yeah let the dealer bashing begin... (I support my local dealer now and then...yes you pay more...but sometimes you need them for stuff....)

Dealer bashing and thread hijack begins here...
OK the dealers around here are quite well supported by sport bike weenies, Harley whores and cruiser chrome deckers... So my $2 of fuel hose, or $2.95 jets that I ordered last week doesn't even make them answer the phone... of course I get even less respect in person... So in conclusion if you find a dealer that helps you and actually cares regardless of the total amount you spent there... then support them. Else well no other choice in most towns... but screw the dealer.
Cool.
Srinath.

Don't sugar coat it ,Srinath, tell us how you really feel....



My dealership overall is pretty cool. I know all the mechs and half the parts guys .... I don't spend a fortune there but they are pretty cool on the phone and in person (Must be my charm...).... Hehehehe

Anyway.... do whatcha gotta do....

I've got a good mech shop (not a dealer).  Guess I'll try that next.

I'll hijack my thread back, with a twist:

I put the old hoses back on so I could ride to the shop.  The rear hose (short nipple) went on the tank just fine, but I couldn't get the hose on the longer, front nipple all way.  Do you lubricate the brass with gasoline or something, or stretch the hose before installing?  It was a real pain.

Also, the back hose (which went on OK) was leaking like crazy whenever I pushed the tank up to insert the tank screws.  If I let the tank slide back an inch towards the battery, it stopped.  Grrr. :guns:  It was very frustrating.   What tricks do you have to get the hoses seated on the tank nipples?

Welll you can take a larger Phillips head screwdriver to open the hose end a little....but if it's too old and stiff..(Much like my back feels like tonight) you can split the hose pretty easily....

Look at the  fuel nipple closely..sometime a small chunck of old hose gets stuck on it......makes it hard to seal...

Quote from: seshadri_srinathDealer bashing and thread hijack begins here...
OK the dealers around here are quite well supported by sport bike weenies, Harley whores and cruiser chrome deckers... So my $2 of fuel hose, or $2.95 jets that I ordered last week doesn't even make them answer the phone... of course I get even less respect in person... So in conclusion if you find a dealer that helps you and actually cares regardless of the total amount you spent there... then support them. Else well no other choice in most towns... but screw the dealer.
Cool.
Srinath.

Srinith,
have you ever considered it might be you?
or
you live in downtown REDNECKVILLE.....and you don't look or sound like you grew up in the hills of NC

Nope... They cant tell a redneck if one peed on their bike in the showroom... They are from Florida and new york. Anyway unless you are bleeding money they wont come to squeeze the blood out.
Cool.
Srinath.

I just bought some fuel line from Cycle Gear that seems to match perfectly to the original line.  I bought Polyurethane Fuel Line 5/16 I.D. x 7/16 O.D.  I will let you know if it works.