The manual says I should replace the fuel lines every four years.  The bike I just bought is an '06, so I guess that means it's due.  I opened up exploded parts diagrams, and got the part numbers for the CA canister, but then opened up the diagram for the carbs and almost immediately got a headache.

Anyone have part numbers/SKUs for the fuel lines?  Do they even really need to be replaced if there are no obvious leaks/deterioration?

i bought some oem honda hose at a honda dealership by the FOOT instead of random pieces, it was like $1.85 a foot i think. they had two sizes, dont remember which one i bought but it fit pretty well.

stock is 7mm.

they dont need* to be replaced, but I have some super thick checker/kragen fuel line that has softened up a little in a year.

I don't mind buying the precut stuff, but I'm not sure what needs to be replaced.  I'm looking at the carb diagram and there're about a million hoses.  Is it just the main fuel line from the petcock to the carbs that needs to be replaced, or is there other stuff in there that needs removal/replacement?

There are 2 hoses from the tank to the petcock, and a hose from the petcock to the carbs. I think that's all of the fuel lines. The rest are vacuum lines.

It's probably way cheaper and just as easy to get low pressure fuel line by the foot instead of paying whatever suzuki wants for the shaped ones.  Most motorcycle stores and probably all small engine places will have 1/4" low pressure fuel line. It is a smidge tighter than 7mm, but nobody has 7mm. Use a blow dryer to warm the hose before putting it on, and you're golden.

Quote from: PachmanP on October 22, 2010, 05:09:39 PM
There are 2 hoses from the tank to the petcock, and a hose from the petcock to the carbs. I think that's all of the fuel lines. The rest are vacuum lines.

It's probably way cheaper and just as easy to get low pressure fuel line by the foot instead of paying whatever suzuki wants for the shaped ones.  Most motorcycle stores and probably all small engine places will have 1/4" low pressure fuel line. It is a smidge tighter than 7mm, but nobody has 7mm. Use a blow dryer to warm the hose before putting it on, and you're golden.

eBay has 10' Tygon lengths 1/4" I.D. for about $17...10' should be plenty and then some, correct?

Should I order new clips, or just use the ones that came off the old line?

Bike Bandit is where to get the numbers and also the parts if you want OEM. Or Oneida Suzuki. Read the diagram and click "buy".

I would not preemptively replace simply due to 4 years old.

If you take it apart, say to rejet carbs, which you should definitely do, then its nice to have spares, cause the original OEM stuff is kind of flimsy. Its tends to break first time broken free from its grip on spigots. Don't grab with pliers and twist. Try lever down by pushing on edge.

I replaced mine with OEM, can't say exactly why. It was about $40. I was not worrying about the cash. 

If I were to do it again I would use aftermarket blue polyurethane in 8mm, with OEM clamps,  because OEM lengths are too short, in my view.

One OEM piece is 10mm on one side, 8mm on the other if I am right. Swaged fuel line. F'ing weird, this is British stupid.

The 8mm can stretch over the 10mm spigot if you buy straight 8 in a roll and maybe warm it up before installing. Maybe its 8mm and 6. I think 10 and 8. Not 7 which will work though.

Recommend a few extra workable OEM clamps on hand. Extras belong in tool box along with extra filters (this bike does not come with in-line filters).

A supply of fuel line in different diameters is good to have in a heavy baggie in lower tool box parts drawer, for the long haul. Its good for lawn mowers too. I stock blue polyurethane at home after all that.  

Yeah, I don't think I'm going to give myself any added headaches.  I have enough to do with the 8K service.  I'll just check the lines for leaks, and keep checking them.  I might replace at the next major service, but I think this time around I might let them go...again providing no obvious leaks.

Its good to look at the thing a lot but don't expect it to spring fuel line leaks all by itself, unless you have installed your own fuel lines, at which point you have a slight chance of spontaneous leaks, or messed with OEM and broken them.

It will spring its own oil leaks for no good reason at all. Multiple places. Thats where you spend your serious leak time.

Rubber hoses deteriorate from the inside out - your brake lines should be replaced more often than fuel lines though.

A couple weeks ago i picked up a 71 Honda SL175 that had what i could only guess had the original fuel lines. While they didnt leak a drop, they were a pita to get off when it was time to clean the carbs.

The quality of your fuel lines will depend on the type of clamps needed. Crappy fuel line wants to leak no matter what, great fuel lines can almost be pushed on with no leaks.