Installing GS650 fuel line--stupid airbox!

[PhamNuwen]

I should have known better, but it turned out that my new fuel line was dripping a bit, so I want to put a clamp on there. The trouble is, I can't reach in well enough to get it on!

It's a 1982 GS650GL. There's a metal plate on the frame DIRECTLY above the fuel intake on the carb. I was able to kind of wiggle the fuel line on there without a clamp, but so far I haven't found any way to get a pair of pliers in there to get the clamp on.

I tried taking the airbox off, but it's held in place pretty good by the carbs in front, the frame on top, bottom, and sides, and the air filter/battery boxes in the back. I can't do more than wiggle it a little up and down.

Any recommendations? I'm tearing my hair out here.

[Steve]

The only recommendation that I can offer is to remove the carbs and install some OEM fuel line, not the stuff you find at Auto Zone.

Yeah, it's going to be a bit of work and you will have to wait for the fuel line to get there after you order it, but it's worth the wait.

Stock fuel line is 7mm diameter. What you can get at Auto Zone is either going to be 1/4" or 5/16". 1/4" is only 6.25mm, which means that it likely won't stretch over the fitting. 5/16" is 8mm, which means that you HAVE to use a clamp. The stuff you get at Auto Zone is also much thicker, as it's reinforced for pressurized systems. OEM line is thinner, more flexible, fits right, and is so much easier to work with.

Don't be put off by the fact that the price is about $10, as you get about 6 feet of line for the price and you only need about a foot of that, so you have plenty of spare hose for later.

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[PhamNuwen]

The only recommendation that I can offer is to remove the carbs and install some OEM fuel line, not the stuff you find at Auto Zone.

Yeah, it's going to be a bit of work and you will have to wait for the fuel line to get there after you order it, but it's worth the wait.

Stock fuel line is 7mm diameter. What you can get at Auto Zone is either going to be 1/4" or 5/16". 1/4" is only 6.25mm, which means that it likely won't stretch over the fitting. 5/16" is 8mm, which means that you HAVE to use a clamp. The stuff you get at Auto Zone is also much thicker, as it's reinforced for pressurized systems. OEM line is thinner, more flexible, fits right, and is so much easier to work with.

Don't be put off by the fact that the price is about $10, as you get about 6 feet of line for the price and you only need about a foot of that, so you have plenty of spare hose for later.

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If it's going to require removing the carbs, I might as well get new boots and such for my carbs while I'm at it. It'll also have to wait until I've actually started work in a month or two, because with moving across country and getting a new apartment, I should be saving my money for a bit.

The service manual says to replace the fuel line every 2 years, I just can't comprehend why they'd make you pull the carbs out to do it.

[Steve]

Yeah, read the manual again. It says to replace the brake lines every two years, too.

Trust me, virtually nobody does that.

The fuel lines that I put on my wife's bike almost 6 years ago still look, feel and work just fine. Personally, I think the "2-year rule" is a bit of overkill.

When is the last time the carbs had a good cleaning? If you can't remember (or simply don't know), it's probably past time. While you have the carbs out, strip them and dip them, treat them to a new set of o-rings from cycleorings.com. While you are ordering from them, also get the intake boot o-rings and stainless bolts for the boots. Your bike will thank you for it and will reward you with smooth, consistent performance.

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[tom203]

Yeah, it's nasty! Do what Steve said- get correct size hose and it probably won't need clamp. After all, there's little pressure on it when it runs and hopefully even less when the petcock blocks flow.
Pull carbs to replace fuel line?- no thanks!

[cowboyup3371]

+1 on what Steve says - I only paid about $1.50 for a foot of line at my local stealership.

[PhamNuwen]

Yeah, it's nasty! Do what Steve said- get correct size hose and it probably won't need clamp. After all, there's little pressure on it when it runs and hopefully even less when the petcock blocks flow.
Pull carbs to replace fuel line?- no thanks!

Looking in there, I see what looks like a hose clamp already attached at the base of the fuel intake. However, no tool or manual dexterity I possess will be able to get that clamp out of there, being thoroughly surrounded by the carbs, airbox, and frame.

I also had a hard enough time just pressing the too-big Autozone line onto the intake, I'm not sure I could manage to get a slightly smaller one on! It'll probably have to be a carb-pulling job.

[cowboyup3371]

It does take a bit of work but it is possible to slide it on while the carbs are still on the bike. But like someone else said in another thread, get a thesaurus as you'll want to learn new "words". Course, if you are going to clean the carbs then you'll be taking that hose off anyway.

[tom203]

Looking in there, I see what looks like a hose clamp already attached at the base of the fuel intake. However, no tool or manual dexterity I possess will be able to get that clamp out of there, being thoroughly surrounded by the carbs, airbox, and frame.

I also had a hard enough time just pressing the too-big Autozone line onto the intake, I'm not sure I could manage to get a slightly smaller one on! It'll probably have to be a carb-pulling job.

With seat and tank off, pull hose straight up- it will come off- use safety goggles! But if you want to clean carbs now, this is the time!