Hi there,

So has anyone done this petcock replacement recently?

I wonder, can you replace the fuel supply hose to the carbs with a longer one WHILE THE CARBS ARE STILL ON THE bike?
The hose needs to be longer to reach the rear-mounted fuel port on the Honda petcock. 
I'm not sure that the old one can be removed and a new one installed without pulling the carbs.
Any advice from someone who has done this replacement?

Also, how did you route the fuel line to the rear port on the Honda petcock?
Is it safely tucked behind a frame tube?

Does anyone who has done this have PHOTOS of the new fuel line routing?

Thanks,
Trwhouse

Trw, if the hose is too short to install the Honda petcock, can you install a barb fitting with a longer fuel line to make up the difference?

I've installed straight in line filters before along with 90° filters as well to help with routing.

Hi there Rich,
I don't want to do that.
It does not seem safe to me to extend a fuel line and add yet another failure point.
Too much chance of leaks and worse if a crash would ever happen.
I really want to know if anyone has ever tried to replace the carb fuel line on the bottom of the carb T-fitting without taking the carbs off the bike.
It would make life easier, but I'm not sure that it can be reached and accomplished.
Buddha, Slack, any of you guys ever done this??

Best wishes,
Trwhouse

If only the airbox is out, can't you reach that t-fitting on the carbs?  or is the airbox also an issue to take out ATM?

No need to pull the carbs to replace the fuel line. I'm eating dinner now, but I'll try to get a few pics of how my lines are routed. They aren't stock. I have no idea if you could stretch stock lines to fit. Suzuki calls for the lines to be replaced every 4 years. How old are your lines?

Hi back, Slack,
Thanks man.
My lines from the fuel tank petcock to the frame petcock are new this spring. I didn't replace the fuel line from the carbs to the frame petcock yet, but I have one to install.
I just ordered the Honda petcock and a new Suzuki GS500E petcock in case I have any hassles with the Honda petcock.
I also ordered a new vacuum hose from the carbs to the frame petcock because the thing is 24 years old. Maybe it is collapsing and causing the problems I am having.
I'll get this sorted out but if you installed a Honda CRF250X petcock and can post some photos of the fuel line routing, especially to the rear port on the petcock, that would be great.
Thanks again, bub.
Yours,
Trwhouse   

Sorry, due to lighting I wasn't able to get a good pic last night. Here are a few I shot real quick this morning. It's hard to get close enough to see details, while being far enough back to get perspective.

Hey Slack,
Thanks man.
That helps a lot.
I ordered the Honda petcock last night as well as new fuel line.
I even ordered a new Suzuki GS500E OEM petcock just in case.
I'm sick of this issue. 

Best wishes,
Trwhouse 

Hi again Slack,

By the way, are you happy with the Honda CRF250X petcock on your bike?
It solved the fuel starvation problems and works well?

Thanks again for the photos.

Yours,
Trwhouse

Works like a top. Just don't forget to turn it "off" when you hop off the bike and "on" before you start it.