Rajan Wilcox
There are many different opinions on what generic fuel lines work best for the Suzuki GS500F. The stock size appears to use a 7mm ID hose, which is more difficult to source. The proximity of the main and reserve fuel pick-ups in the tank can make it tight to get both hoses attached. The reserve hose runs from outlet 1 on the fuel tank petcock to inlet 5 on the frame-mounted petcock, while the main hose runs from outlet 2 on the fuel tank petcock to inlet 4 on the frame-mounted petcock. When in doubt, OEM lines and clamps are the way to go. They are a bit more expensive but they fit as they should.
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What You'll Learn
Using a single Pingel petcock to replace both fuel valves
The stock petcock on the GS500 is not ideal, and a Pingel petcock is a good alternative. Pingel will make a valve to fit your needs. For example, one user with a 2001 GS500 ended up with a "3/8-inch 6290-A valve with a down nipple and no reserve, and an A1602-C adaptor plate". This costs around $75 and is easy to install.
The Pingel petcock provides a better-flowing valve that can be turned off at the tank. These valves are made from high-quality brass and stainless steel. However, there is no specific application for a GS 500, and it can be rather hard to get to tucked away under the frame rail.
There are a lot of different opinions and information on what generic fuel lines work best. When in doubt, OEM lines and clamps are recommended. They are more expensive but they fit as they should. The stock size uses a 7mm ID hose, which is harder to source. A 1/4" ID hose is 6.35mm and a 5/16" ID hose is 7.94mm. Either size should work. It is preferable to use tubing that is specifically made for fuel. Standard hose available at hardware stores will work but may get hard and turn yellow over time.
One user on GSTwin.com replaced the three fuel hoses from the petcock on a 2006 GS500F. They couldn't source the OEM hoses and used a 6mm ID, 11mm OD hose with cotton braiding. You'll need a little over 1 metre to match the OEM length. They added 10cm to the tank hoses to give a little more play next time they need to lift the tank.
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The right size for fuel lines
Another user has found that an 8mm or 5/16" fuel line fits the tank petcock perfectly, but does not fit the frame petcock. They found that the frame petcock input lines are a 10mm or 3/8" connection. It is important to note that soft rubber fuel lines are too thick to fit side by side on the fuel tank barbs.
When in doubt, OEM lines and clamps are the way to go, as they are designed to fit your specific motorcycle model. While they may be more expensive, they will fit without any issues, and you can be sure that the tubing is specifically made for fuel. Standard hoses from a hardware store will also work but may degrade and discolour over time.
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Using oil to lube the nipples
When replacing the fuel lines on a GS500F, you may encounter issues with the proximity of the main and reserve fuel pick-ups in the tank, making it challenging to attach both hoses securely. It is recommended to use a 7mm ID hose, which is the stock size, but it can be challenging to source. As an alternative, you can opt for a 1/4" ID hose (6.35mm) or a 5/16" ID hose (7.94mm), both of which have been reported to work by other GS500F owners.
Now, let's focus on the topic of using oil to lube the nipples:
When dealing with the fuel lines on your GS500F, you may encounter difficulties in fully inserting the nipples into the lines. To address this issue, a little oil can be used to lube the nipples, ensuring a smooth and secure connection. By applying a small amount of oil to the nipples on the tank and vacuum petcock, you can achieve a full insertion. This technique is particularly useful if you're reusing your existing fuel filter and dealing with tight spaces.
It is important to note that while oil can aid in the insertion process, it is not a substitute for proper clamping. If you feel that additional clamps are necessary to secure the lines, don't hesitate to use them. Additionally, when sourcing fuel lines, it is recommended to use tubing specifically made for fuel whenever possible. While standard hose from a hardware store may work, it tends to harden and turn yellow over time.
To ensure a proper fit, it is essential to consider the measurements of the existing stock hose. For a 2006 GS500F, the actual measurement of the stock hose was found to be 6.5mm ID x 11mm OD using digital calipers. However, keep in mind that the ends of the OEM hoses may be pre-stretched to accommodate the required size on the tank barbs. As a result, they need to be stretched quite a bit during installation.
When choosing replacement fuel lines, it is important to consider both the inner diameter (ID) and outer diameter (OD) of the tubing. For the GS500F, a combination of 6mm ID and 11mm OD hose with cotton braiding has been found to work well. Additionally, adding a few extra centimetres to the tank hoses can provide more play and make it easier for future adjustments or maintenance.
In conclusion, when replacing the fuel lines on your GS500F, using oil to lube the nipples can be a helpful technique to ensure a smooth and secure connection. However, it is important to consider the specific measurements and choose the appropriate tubing size for your motorcycle. Always refer to the experiences of other GS500F owners and follow recommended practices for a safe and successful fuel line replacement.
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The reserve hose and the ON (main) hose
The GS500F has four hoses connected to the petcock: the red hose, the blue hose, the green hose, and the yellow hose. The red hose is for the reserve, and the blue hose is for the ON or main. The red hose goes from the front, longer hose of the upper petcock to the rear hose of the lower petcock. The blue hose goes from the rear, shorter hose of the lower petcock to the outer frontal hose of the lower petcock.
The stock size of the hoses appears to be a 7mm ID hose, which is challenging to source. The OEM hoses are even more difficult to find. The actual measurement of the existing stock hose is 6.5mm ID x 11mm OD. Some people have used 6mm ID, 11mm OD hose with cotton braiding, but stretching it over the nipples/barbs was difficult. Others have used 8mm or 5/16" fuel line, which fits the tank petcock but not the frame petcock. The frame petcock input lines are 10mm or 3/8" connection.
To make the hoses fit more easily, you can try lubricating the nipples on the tank and vacuum petcock with oil or grease. Softening the end in boiling water and using needlenose pliers to stretch the opening can also help. It is recommended to use tubing specifically made for fuel, as standard hoses can harden and turn yellow over time.
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Using generic fuel lines
There are varying opinions on which generic fuel lines work best for the GS500F. When in doubt, OEM lines and clamps are recommended, as they are designed to fit properly. The stock size for the GS500F appears to use a 7mm ID hose, which can be difficult to source. As a result, some people opt for a 1/4" ID hose (6.35mm) or a 5/16" ID hose (7.94mm), both of which are reported to work.
Some riders have used soft rubber fuel lines, but have encountered issues with the thickness preventing them from fitting side by side on the fuel tank barbs. It is recommended to use tubing that is specifically designed for fuel. Standard hoses from hardware stores can work, but may harden and turn yellow over time.
One rider reported success with using 8mm or 5/16" fuel line, which fit the tank petcock but not the frame petcock. The frame petcock input lines require a 10mm or 3/8" connection.
Another rider used thick, reinforced black fuel line from Home Depot (1/4" ID, 1/2" OD) for over a year without issues, before switching to yellow Tygon lines (1/4" ID, 3/8").
When replacing the fuel lines on a GS500F, it is recommended to use a little oil to lube the nipples on the tank and vacuum petcock, allowing them to fully insert into the lines. You may also choose to reuse your existing fuel filter. Approximately 5 feet of tubing should be enough to replace all the lines. The actual measurement of the stock hose is approximately 6.5mm ID x 11mm OD, but it may need to be stretched to fit properly. To allow for future adjustments, it is recommended to add an extra 10cm to the tank hoses over the standard OEM length.
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Frequently asked questions
The stock size of the fuel lines for a 2006 Suzuki GS500F is 7mm ID hose. The actual measurement of the existing stock hose is 6.5mm ID x 11mm OD.
It is preferable to use tubing that is specifically made for fuel. Standard hose available at hardware stores will also work but may get hard and turn yellow over time.
You will need approximately 5 feet of tubing to replace all the fuel lines on your Suzuki GS500F.
The longer hose stem is the regular fuel feed and the shorter one is the reserve. The reserve hose runs from outlet 1 on the fuel tank petcock to inlet 5 on the frame-mounted petcock. The ON (main) hose runs from outlet 2 on the fuel tank petcock to inlet 4 on the frame-mounted petcock.
