Hey everyone,
I was doing some miscellaneous maintenance earlier today, and while slightly lifting the back end of the fuel tank to get at the air filter, the On and Reserve fuel lines decided to tear and start spraying gasoline all over the garage. Annoying, I thought, but no big deal since I can just replace them.
I also noticed that the hose end that attaches to the tank's petcock is much smaller than the end that attaches to the frame petcock; I'm assuming this just underwent some ridiculous stretching? Anyway, after poking around the boards to find what size works, I figured that if I could get a hold of 7mm or 5/16" hoses I'd be set. Well I picked up some 5/16" hoses, but they absolutely will not fit onto the frame-mounted petcock no matter what I do. I've tried stretching it, pounding the ends lightly with a hammer (as recommended by another member), and heating it up to try and reshape it. I just can't get this thing to fit! I'm not too keen on wasting more money on more hoses that won't work, so I figure that the OEM replacements on bike bandit will work. Are there any other options that will for sure work, or any tricks to get these mofos the heck on there? Any input would be greatly appreciated  

I use 1/4 inch which is smaller than 5/16.All I do is lay mine in the sun while I work and then slide them on.A hair dryer will help soften them a little.I sometimes use a pair of needle nose pliers to help push them all the way on.Just make sure there are no sharp edges or burrs on the pliers.

I ripped mine too the other day (i was able to cut it short and make it work temporarily, but i don't like it that way)  (i had the same problem with 5/16 fuel hose.... and 1/4... and.... hose i found laying around dad's garage....)

I don't see both fuel hoses listed at bike bandit for 95'.

(and just found out that my fuel hoses, 2001, are $25 a piece.... lol..., must be the platinum lined hoses)  (i think i will get 06' petcock, and hoses instead, and hope it all bolts up)

ehhhh... I think i will do the dirtbike petcock instead though.

I've used clear tubing from home depot 5/16" ID.

To fit the frame mounted petcock I made three tiny snips at the end about 1/16" in length so that the tube will fit around the frame petcock and then just use some lube (spit!) and push them in.

go to Advanced Auto, I bought 2 2.99 Lawnmower gas lines from there and they worked GREAT
(this was a hasty repair as my lines actually broke in the parking lot of Advanced Auto and I had to rush inside and borrow a fire extinguisher a 12mm ratchet and a long flat head... I had just filled up too I was so sad)

Anyway i think they are 1/4 inch and they fit perfect, stretch the petcock end with a pair of needle nose pliers first to slip them easily over the petcock fittings.

then slap on either the stock clamps or buy some cheap hose clamps and put on for security, I have read some members don't even clamp theres but thats a bit too trusting for me.

Also as a bonus they are clear and look pretty cool.

Quote from: gs500e on June 11, 2011, 08:54:39 PM
I ripped mine too the other day (i was able to cut it short and make it work temporarily, but i don't like it that way)  (i had the same problem with 5/16 fuel hose.... and 1/4... and.... hose i found laying around dad's garage....)

I don't see both fuel hoses listed at bike bandit for 95'.

(and just found out that my fuel hoses, 2001, are $25 a piece.... lol..., must be the platinum lined hoses)  (i think i will get 06' petcock, and hoses instead, and hope it all bolts up)

ehhhh... I think i will do the dirtbike petcock instead though.

The factory lines are molded to fit the bike,that's why they cost so much.They still aren't worth it,especially if you have a petcock upgrade,lunch box air filter,or both.I can't use them because of this.

Quote from: franke3c on June 11, 2011, 10:58:55 PM
I've used clear tubing from home depot 5/16" ID.

To fit the frame mounted petcock I made three tiny snips at the end about 1/16" in length so that the tube will fit around the frame petcock and then just use some lube (spit!) and push them in.

isn't Spit always the best lube.....

was gonna buy some 1/4 inch tygon fuel line to replace mine, does anyone know if the the vacuum line fits the same diameter? 
Does it matter if it's tygon or not?

Quote from: Toner on October 13, 2017, 11:59:33 AM
was gonna buy some 1/4 inch tygon fuel line to replace mine, does anyone know if the the vacuum line fits the same diameter? 
Does it matter if it's tygon or not?

I believe they are 3/16 and yes because they will get some fuel vapor in them.

Quote from: ben2go on October 13, 2017, 12:37:10 PM

Quote from: Toner on October 13, 2017, 11:59:33 AM
was gonna buy some 1/4 inch tygon fuel line to replace mine, does anyone know if the the vacuum line fits the same diameter? 
Does it matter if it's tygon or not?

I believe they are 3/16 and yes because they will get some fuel vapor in them.

Thanks. So you would recommend Tygon lines?

Quote from: Toner on October 13, 2017, 01:04:12 PM

Quote from: ben2go on October 13, 2017, 12:37:10 PM

Quote from: Toner on October 13, 2017, 11:59:33 AM
was gonna buy some 1/4 inch tygon fuel line to replace mine, does anyone know if the the vacuum line fits the same diameter? 
Does it matter if it's tygon or not?

I believe they are 3/16 and yes because they will get some fuel vapor in them.

Thanks. So you would recommend Tygon lines?

Yes, or motion pro line if you have a dealer close by that sales it.

I have to say though, there is nothing as good as a set of new OEM lines with the protective mesh. They are the perfect length and slip right on like they are supposed to.

Quote from: Bluesmudge on October 13, 2017, 03:22:26 PM
I have to say though, there is nothing as good as a set of new OEM lines with the protective mesh. They are the perfect length and slip right on like they are supposed to.

Seems to be impossible to find any. I'm in Europe but I can't even find them in US or anywhere. 
I have a 2000 GS500E. 
You think all the models share the same lines?

+1 to the OEM lines.

Toner, are you looking at OEM parts websites like bikebandit, motosport, partzilla etc? My favorite is motosport and I know they have international shipping... dunno how much it would be though....

AFAIK all the GS's have the same lines. When I got my OEM lines this past summer, they weren't exact length... not sure why... and I had to trim them a bit to my liking. No biggie tho!!

Checking on Bike Bandit for my 2006 GS500F the reserve hose is $8.72 and the main fuel hose is $7.21.

I can't imagine saving enough money off the $16 for real Suzuki hoses that it would ever be worth it the extra trouble. I believe the tank petcock and the main petcock may have slightly different diameters. Couple that with how close the lines mount together on the tank petcock and you don't have much margin for difference in internal/external diameter compared to what Suzuki designed. I have been watching people discuss GS500 fuel hoses on this site for ~10 years and there has never been a consensus on an easy aftermarket option. Just spend the 16 bucks. The E model hoses are a little more expensive at $13.10 each but still worth it in my opinion.

Quote from: ShowBizWolf on October 13, 2017, 04:38:59 PM
+1 to the OEM lines.

Toner, are you looking at OEM parts websites like bikebandit, motosport, partzilla etc? My favorite is motosport and I know they have international shipping... dunno how much it would be though....

AFAIK all the GS's have the same lines. When I got my OEM lines this past summer, they weren't exact length... not sure why... and I had to trim them a bit to my liking. No biggie tho!!

Quote from: Bluesmudge on October 13, 2017, 05:01:32 PM
Checking on Bike Bandit for my 2006 GS500F the reserve hose is $8.72 and the main fuel hose is $7.21.

I can't imagine saving enough money off the $16 for real Suzuki hoses that it would ever be worth it the extra trouble. I believe the tank petcock and the main petcock may have slightly different diameters. Couple that with how close the lines mount together on the tank petcock and you don't have much margin for difference in internal/external diameter compared to what Suzuki designed. I have been watching people discuss GS500 fuel hoses on this site for ~10 years and there has never been a consensus on an easy aftermarket option. Just spend the 16 bucks. The E model hoses are a little more expensive at $13.10 each but still worth it in my opinion.

Found some OEM fuel hose in the UK here but they don't have the reserve hose. I'll check out those US sites, thans:
https://www.discountbikespares.co.uk/ourshop/prod_5781140-HOSE-FUEL-GS500-T-Y-GSF650-GSF600-RGV250.html

yeah, nobody seems to have the conclusive answer for non OEM hoses but this guy is persuading me to try Tygon 1/4 inch.
http://gstwins.com/gsboard/index.php?topic=51643.msg848711#msg848711

Then I could get some 3/16 Tygon for the vacuum line. 

Guys, I'm confused now. You see this hose here: 
https://www.discountbikespares.co.uk/ourshop/prod_5781140-HOSE-FUEL-GS500-T-Y-GSF650-GSF600-RGV250.html

Is that hose 6 going from the tank to the petcock or is hose 3 going from the petcock to the carbs?

Quote from: Bluesmudge on October 13, 2017, 03:22:26 PM
I have to say though, there is nothing as good as a set of new OEM lines with the protective mesh. They are the perfect length and slip right on like they are supposed to.

boy  that's  the truth 

Quote from: Toner on October 13, 2017, 06:42:55 PM
Guys, I'm confused now. You see this hose here: 
https://www.discountbikespares.co.uk/ourshop/prod_5781140-HOSE-FUEL-GS500-T-Y-GSF650-GSF600-RGV250.html

Is that hose 6 going from the tank to the petcock or is hose 3 going from the petcock to the carbs?

3 is petcock to carb and 6 is tank petcock to petcock.

Quote from: ben2go on October 14, 2017, 07:57:57 AM

Quote from: Toner on October 13, 2017, 06:42:55 PM
Guys, I'm confused now. You see this hose here: 
https://www.discountbikespares.co.uk/ourshop/prod_5781140-HOSE-FUEL-GS500-T-Y-GSF650-GSF600-RGV250.html

Is that hose 6 going from the tank to the petcock or is hose 3 going from the petcock to the carbs?

3 is petcock to carb and 6 is tank petcock to petcock.

I know but which is the hose in the link?