So I have been running out of gas lately... No reserve nothing.

I go and grab a gas can thinking that I have a small gas leak and will deal with it later.

As I pour the gas I notice a splash and look down and gas is shooting out of my bike from my petcock.

The reserve line has hardened and gotten so brittle that apparently it's almost broken in half...

as I pull the gas line away from my bike to get it into the gas can to save what I can, the entire hose snaps off at the tank pet chicken.

I have already had some slight issues with the tank petcock leaking. Now I am fed up and about to replace nearly all of the fuel system with new hoses and petcocks.

Does anyone have any good suggestions for good looking hoses that are ethanol rated and can stand up to the abuse. I had almost the same thing happen to me with the stock hoses and I am about to give up on fuel lines.

If I did get new petcocks and hoses. I would like to go with AN fittings instead of the stupid nipples.

FYI: Not sure what year your bike is, but the recommendation from Suzuki is to change the fuel lines every 4 years as standard practice.

Sorry for some reason I thought I had that in my signature.

2004 GS500F (non CA)

I also have an '04 and my fuel lines were original until I pulled the tank off Sunday night.  Even though its been garage kept its entire life, the ends of the fuel line were pretty brittle.  They got replaced.  Although I don't think I'm happy with the looks or quality of the new ones right now, so I'm still in the market for some good fuel lines.  But I would imagine they would be much worse if it was outdoors in the elements.

- Bboy

MotionPro has excellent fuel lines. I use them on all m bikes now.

When you replace the fuel lines, make them a few inches longer. It gives you more room for removing the tank and other  work you may need to do. If you find you make them too long, then shorten them. If too short - you need to start all over. Some might think mine are too long, but they look fine to me. I have plenty of room to work if I lift the tank. Hoses are not stretched so tight that they bend and pinch.

You can get gray, black and clear from MotionPro. Different inside diameters too.

Shattered fuel line?

Probably had been replaced with hardware-store vinyl (non-fuel rated) by a Clever Previous Owner. That is a common problem.

If you don't mind mail-order, the best price I found for fuel-rated polyurethane lines was at CycleRecycle Part II (and that has remained true when I've checked again, though I'm not comparison shopping tonight, so it might or might not still be true tonight.) Nice thick-walled tubing (which makes it harder to kink.)

Tygon is a brand name for a brand of polyurethane. Without the brand name it is still PU, but cheaper...

I always suggest getting a couple feet of 1/8" when buying line so you have an easy way to drain and check float levels from the carb drains.

For my 1990, 5/16" ID line was the right stuff (I ordered 5 feet of that, 5 feet of 1/4" and 2 feet of 1/8" - the 1/4" has since helped out a few lawnmowers, being far too snug for my taste on the GS.)

This happened to me to. It was suggested to me that the use of cheap fuel corroded the line. Not sure if that was the true cause or not but ether way I ordered 2 replacements hoses from Suzuki for 22 bucks

Quote from: DoD#i on October 03, 2012, 04:50:11 PM
Shattered fuel line?

Probably had been replaced with hardware-store vinyl (non-fuel rated) by a Clever Previous Owner. That is a common problem.

If you don't mind mail-order, the best price I found for fuel-rated polyurethane lines was at CycleRecycle Part II (and that has remained true when I've checked again, though I'm not comparison shopping tonight, so it might or might not still be true tonight.) Nice thick-walled tubing (which makes it harder to kink.)

Tygon is a brand name for a brand of polyurethane. Without the brand name it is still PU, but cheaper...

I always suggest getting a couple feet of 1/8" when buying line so you have an easy way to drain and check float levels from the carb drains.

For my 1990, 5/16" ID line was the right stuff (I ordered 5 feet of that, 5 feet of 1/4" and 2 feet of 1/8" - the 1/4" has since helped out a few lawnmowers, being far too snug for my taste on the GS.)

i use tygon on my gopeds. ( before theft lol) now the motovox scooter. as ell as my power equipment. its cheap and lasts damn near forever. and avail. nearly everywhere

Decided to go back to 100% stock. The lines were put on by me and purchased from cycle gear. The guy said they were ethanol rated (hopefully that meant they were also gas rated lol). I am doing a big overhaul on my fuel system soon. Replacing everything from the tank petcock gaskets to lines from tank to petcock to carbs, also doing a rejet for the lunchbox, and V&H I have on the way. I figure I should be good until I decide to move to a 600F4I.