fuel hoses

[Ghetto Garage]

I think for the most part I figured out the two petcocks. the one in the tank is just reserve and main. The other has places for them. The one on the front is for the foam. The one behind that, Im pretty sure is for expresso. So Im pretty clued in on that. What I am having issue is hose size. I noticed two sizes. Im pretty sure the smaller size is 6mm. What is the other size one (metric) I want to get a proper fit. Cant have leaks in my expresso/GS500 machine.

[herennow]

from my notes,

I had good luck with Motion pro hoses but most folks like the OEM ones as there is not much space..

"Fuel hose = (tank water drain is the same) 8mm (5/16) id. - 11.5mm (7/16) od.  Need 1.5m for whole bike"

[ShowBizWolf]

Speaking from personal experience I highly recommend getting OEM Suzuki lines and clamps if you can get them in your part of the world. IMO they are worth the price to avoid headaches that generic hoses can give us with fitment.

This picture can be found elsewhere on the forum as well:
You cannot view this attachment.

[herennow]

Hey SBF, how do we read that picture?

[Ghetto Garage]

ShowBizWolf, Thanks. That was just what I am looking for.
Im the same way, I will try to get the OEM if I am able.

[ShowBizWolf]

Ghetto Garage, you're very welcome! I hope you are able to get the OEM ones.

Hi herennow. I'm not sure what you mean. Is the image not showing up for you or is it something else?

[Bluesmudge]

The most important take away from that picture is that the lines have to be different diameters on each end. You can't buy that as a generic option AFAIK, so get the OEM Suzuki lines. They are very high quality (should last at least 10 years but probably more like 20) and they fit perfectly. That's worth the extra $10 if you ask me. I've had aftermarket lines harden up and go brittle after just a couple years.

It also shows that if you MUST buy aftermarket lines, get something around 7.5mm ID because it will sort of work everywhere. A little small here, a little big there, but can work with both petcocks and the carbs. But again...just get the real deal Suzuki lines because they fit better and last longer.

[herennow]

no, I mean, what are the two 6.5 mm ID pipes to petcocks shown for? they are not standard right, which ines are correct , the top , or the bottom ones (whch are wrong for 2003 at least).

Cheers

[Bluesmudge]

The image shows OEM lines: Top two on the right are main and reserve line to the frame petcock. Bottom two on the right are the same main and reserve line to the tank petcock (8.5mm ID on one end and 6.5mm ID on the other end). Left side two are the one line from frame petcock to carburetors (also different sizes on either end).

The image looks correct/OEM to me for a 2004+ GS500. I'm not familiar enough with the '01-'02 and pre-2000 bikes to know if the diameters changed. I'm pretty sure the petcocks and fuel lines were different on the '89 - '00 bikes so this image may not be correct for everyone.

Long story short: The image shows why there was so much back and forth over the years on the forum picking the right size aftermarket fuel line: there is no correct size because each line needs to be different IDs on each end. Buy OEM Suzuki lines. If you must buy aftermarket lines, split the difference of everything in the picture and get lines around 7.5mm ID and they should work good enough.

[herennow]

It's been a few years, But Im sure that on my 2003 the nipples for the hosres on both ends were identical... Am I going crazy?

[gruntle]

Erratically sized nipples are two of the many GS500's alluring attractions...