Sylvie Willis
Installing a fuel line on a motorcycle can be a tricky process, but with the right tools and knowledge, it can be a rewarding experience. The process can vary depending on the make and model of the motorcycle, but there are some general guidelines that can be followed. It is important to take the necessary safety precautions when working with fuel lines, such as wearing protective gear and ensuring proper ventilation. The first step is to identify the type of fuel line and determine if any modifications are needed. Once the fuel line is disconnected, it can be cut and fitted to the motorcycle, ensuring all connections are secure to prevent leaks. Learning how to install a fuel line can be a great skill for any motorcycle enthusiast, allowing for customisation and quick repairs.
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What You'll Learn
How to make a custom fuel line assembly
Installing a fuel line on a motorcycle is a relatively simple task, but it requires careful attention to avoid leaks. Before you begin, make sure you are wearing rubber gloves to protect your hands from gasoline.
To make a custom fuel line assembly, you will need to start by removing the old fuel line from your motorcycle. Disconnect the fuel line and remove all the fittings attached to it. You can reuse most of the fittings, but you will need to replace the ferrules and the fuel line itself. Heat the line to soften it and make it easier to remove the fittings. Ensure that the line is free of any fuel residue.
Use the old fuel line as a template to measure and cut your new fuel line to the exact size. You can then install the new fittings, following the same order as the original line. If you are using a ferrule, install it over the PTFE liner, trim a small portion of the liner with a sharp razor knife, and then install the fitting into the socket and tighten it.
Once your new fuel line assembly is complete, you can install it back onto your motorcycle. Check for any kinks or tight bends that could cause issues, and tighten everything securely. Turn on the fuel and check for any leaks. If you notice any leaks, you may need to adjust the fittings or clamps to ensure a proper seal.
It is important to use high-quality fuel line materials that are compatible with your motorcycle's fuel system. Options include nylon, brass, rubber, or braided stainless steel. You can also choose from clear or coloured fuel lines to match your preferences. Additionally, consider using a fuel stabilizer during winter storage to prevent fuel line damage.
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How to replace a fuel line
To replace a fuel line on a motorcycle, you will need to first wear rubber gloves for protection from gasoline. The next steps will depend on the type of motorcycle you have.
For petcock valve-equipped bikes, close the float bowl drain plug and replace the vent hose, then turn on the fuel. For fuel-injected bikes, prime the system by cranking the bike.
If your bike has a fuel filter, you will need to clamp either side of the filter to cut off the fuel. The filter is attached to the fuel line using clamps. On fuel-injected models, the filter is installed inside the tank.
Once you have accessed the fuel line, you can begin to remove it. Remove all existing fittings attached to the line and set them aside, as you will be reusing them. To remove the fittings from the existing fuel line, heat the line to soften it first. Ensure the line is free of any fuel residue.
Use the original fuel line to measure the total length, then cut your new fuel line to the exact size. Slip a ferrule onto each end of the new line. Before crimping, ensure the new fuel line is pushed all the way onto the fittings.
Finally, verify that you have correctly installed the new fuel line. If there is a leak, you will need to repeat the steps above to fix it. You likely did not fit the line correctly to the inlet or outlet extension and/or put the clamp on incorrectly.
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How to identify a bad fuel line
A bad fuel line can cause a range of issues with your motorcycle, and it is important to identify these issues early on to prevent further problems. Here are some detailed instructions on how to identify a bad fuel line in your motorcycle:
Firstly, it is important to understand the function of a fuel line and the fuel filter. The fuel filter is attached to the fuel line and is responsible for keeping contaminants away from the engine. Over time, the fuel filter can become clogged with debris and dirt, which restricts the fuel flow to the engine. This can lead to issues such as hard-starting, where the vehicle takes more cranking than usual to start, or repeated stalling throughout the rev range, indicating that your engine is not receiving enough fuel.
One of the most common signs of a bad fuel line is leakage. While a leaky fuel line may not completely ruin your riding day, it will certainly cause delays and inconvenience. Leaks can be caused by improper fitting of the fuel line, incorrect clamping, or damage to the fuel line due to various factors. These factors include old age, improper storage, and exposure to extreme temperatures without proper maintenance. For example, leaving your motorcycle in the sun or in a dry environment can cause the fuel line to age prematurely, leading to shrinkage and cracks, resulting in leaks.
Another sign of a bad fuel line is when the motorcycle operates abnormally, such as running out of gas or "bogging out". This could be an indication that the fuel line is clogged or restricted, preventing an adequate amount of fuel from reaching the engine. Additionally, not adding a fuel stabilizer to the gas tank during winter storage can cause the fuel line to become gummed up, leading to similar issues.
To identify a bad fuel line, it is important to regularly inspect and maintain your motorcycle's fuel system. Refer to your motorcycle's authorized owner's manual for manufacturer-suggested timelines and specific instructions for your model. In general, most manufacturers recommend replacing the fuel filter every two years or every 20,000 miles for street-oriented motorcycles. Off-road motorcycles may require more frequent replacements due to harsher operating conditions.
Additionally, you can use a motorcycle code reader, such as the Ancel MT700, to diagnose issues within the fuel system. This tool connects to your motorcycle and provides specific error codes and their meanings, helping you identify problems without the guesswork. By following these instructions and staying vigilant about maintenance, you can effectively identify a bad fuel line and take appropriate action to ensure a smooth riding experience.
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How to store your bike to avoid damaging the fuel line
Storing your motorcycle in a way that protects the fuel line is important to ensure the bike doesn't get damaged. Fuel lines can be damaged by a bad wreck but also by old age, improper storage, and bad maintenance.
Firstly, avoid leaving your bike outside, even if it's covered. This leaves the motorcycle vulnerable to the elements, which can cause corrosion. Instead, store your bike in a garage or a storage unit. The latter is a great option if you don't have space in your garage, as it will keep your motorcycle out of the elements and protected from corrosion.
Secondly, if you live in a hot and dry place, be mindful that dry air can suck the moisture out of the rubber, causing the fuel line to age prematurely, shrink, and crack. Therefore, store your bike in a climate-controlled unit or garage to protect the fuel line from the effects of dry air.
Thirdly, always add a fuel stabilizer to your tank during the winter storage months. Failing to do so can cause the fuel line to gum up, which is just as bad as a cracked fuel line.
Finally, ensure you use high-quality fuel and store your bike correctly.
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How to identify and fix a leaky petcock
A leaky petcock is a common issue faced by motorcycle owners. The petcock, or "fuel petcock", is a valve on non-fuel-injected 2-stroke and 4-stroke bikes that controls the flow of fuel. If you notice gas leaking onto your garage floor or your bike operating abnormally, you may have a leaky petcock. Here's a step-by-step guide on how to identify and fix this issue:
Identifying a Leaky Petcock:
- Turn the petcock "off": If you notice gas leaking out of the face of the petcock when it's turned off, it's likely a problem with the petcock and not another component of the fuel system.
- Inspect the petcock: Look for any signs of damage, such as cracks or leaks. Pay close attention to the gasket, which is a common source of leaks.
- Check the screws: Ensure that the screws attaching the petcock to the bottom of the tank are tight. Loose screws can cause fuel leaks.
Fixing a Leaky Petcock:
- Drain the fuel: Before beginning any repairs, it's important to drain the fuel from the tank to avoid spills.
- Plug the fuel tank cap vent line: If there is only a small amount of fuel remaining, you can turn the tank over to prevent spills.
- Purchase a repair kit: You can find repair kits specifically designed for fixing leaky petcocks. These kits typically include gaskets, bolts, and screws.
- Remove the petcock: Take out the screws located on the valve (used to switch between "on" and "off" positions) and carefully remove the petcock from the fuel tank.
- Replace the gaskets and screws: Install new gaskets, bolts, and screws from the repair kit. Ensure that all components are securely fitted.
- Reinstall the petcock: Slide the repaired or new petcock into place and attach it using the supplied bolts.
- Test the fuel system: Once the repairs are complete, turn the petcock "on" and carefully inspect for any remaining leaks.
In some cases, a repair kit may not solve the leak problem. If the petcock has been compromised due to a crash, significant damage, or age, you may need to replace it with a new one. Additionally, if your motorcycle has a specific fuel tank brand, you may need to purchase a compatible petcock.
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Frequently asked questions
Installing a fuel line on a motorcycle depends on the type of motorcycle you have. For dirt bikes, you will need to clamp both sides of the filter to cut off the fuel. You can then remove the old fuel line and install a new one, ensuring that it is attached correctly to the inlet and outlet extension. For other motorcycles, you may need to purchase a fuel line assembly or make a custom one.
Some signs that you may need to install a new fuel line include leaks, the bike operating abnormally (e.g. running out of gas or "bogging out"), or the engine not starting.
It is important to wear rubber gloves when installing a new fuel line to avoid getting gasoline on your hands. Additionally, make sure that the line is free of any gas or fuel residue before installation.
