Replacing Fuel Hose On 2007 Suzuki Boulevard C50: A Step-By-Step Guide

The Suzuki Boulevard C50 is a popular motorcycle, but like any vehicle, it requires regular maintenance and occasional repairs. One common issue that owners of this bike may encounter is the need to replace the fuel hose. This process can be complex and time-consuming, but with patience and careful attention to detail, it is possible to do it yourself. Before beginning this task, it is important to gather the necessary tools and parts, including a new fuel hose that is compatible with the 2007 Suzuki Boulevard C50. It is also advisable to consult a repair manual or seek guidance from experienced mechanics or online forums to ensure that the job is done correctly and safely.

Removing the fuel tank

To remove the fuel tank from a 2007 Suzuki Boulevard C50, you will need to first remove the seat. There is one bolt to remove the rear seat and two bolts to remove the front seat. All of these bolts are 6mm allen head bolts.

Next, you will need to remove the three 3mm allen bolts that hold the dash in place. Once these bolts are removed, flip the dash over and pull back the dust boot to access the wiring harness. Squeeze the clip to unplug the wiring harness and set the dash aside.

Now, you will need to locate the 12mm bolt at the end of the fuel tank. Loosen this bolt and carefully lift the tank up and back, freeing it from the mounts. It is important to place a rag or towel over the frame where the seat was to protect the paint from the sharp edge of the tank.

Once the tank is removed, you can proceed with replacing the fuel hose or performing any other necessary maintenance. Keep in mind that you will need to drain the fuel from the tank before reinstalling it.

When you are ready to reinstall the fuel tank, simply follow the above steps in reverse. Ensure that all bolts are tightened securely and that the wiring harness is properly connected before starting the motorcycle.

Locating the fuel hose

To locate the fuel hose on your 2007 Suzuki Boulevard C50, you'll need to access the fuel pump assembly, which is located inside the fuel tank. Here's a step-by-step guide to help you locate the fuel hose:

Step 1: Remove the Seats

Start by removing the rear seat, which is secured with a single bolt. Use a 6mm Allen head to remove this bolt. Next, remove the two bolts holding the front seat in place, also using a 6mm Allen head.

Step 2: Access the Fuel Tank

With the seats removed, you'll now have access to the fuel tank. Before proceeding, place a rag or towel over the frame where the seat was to protect the paint from any sharp edges on the tank.

Step 3: Remove the Dash

To access the fuel tank more easily, you'll need to remove the dash. Locate the three 3mm Allen bolts securing the dash and remove them. Once removed, flip the dash over and pull back the dust boot to access the wiring harness. Gently squeeze the clip to unplug the wiring harness.

Step 4: Loosen the Fuel Tank

Now, focus on the end of the fuel tank closest to the rear of the motorcycle. You'll find a single 12mm bolt securing the tank in place. Loosen this bolt and carefully lift the rear of the tank a few inches to free it from the mounts.

Step 5: Disconnect the Wiring Harness and Fuel Line

With the tank slightly lifted, you can now access the wiring harness and fuel line connected to the fuel pump. Squeeze the clip on the brown connector to unplug the wiring harness. Then, squeeze the gray prongs to release the quick-connect on the fuel line, which is the fuel hose you're looking for.

Step 6: Remove the Fuel Tank

At this point, you can now completely remove the fuel tank by lifting it out of the motorcycle. Place it on a stable surface, preferably upside down, to access the fuel pump assembly.

Step 7: Locate the Fuel Hose

With the fuel tank removed and flipped upside down, you should now have a clear view of the fuel pump assembly. The fuel hose is connected to the fuel pump, and it's the rubber or plastic tube that carries fuel from the tank to the engine. It's usually black or dark in color and has a flexible or corrugated surface.

Remember to exercise caution when working with fuel systems and refer to a qualified mechanic or a repair manual for detailed instructions on replacing the fuel hose in your 2007 Suzuki Boulevard C50.

Disconnecting the fuel hose

Step 1: Remove the Seats

Start by removing the rear seat with a 6mm allen wrench. Then, remove the front seat with two bolts, also using a 6mm allen wrench.

Step 2: Disconnect the Wiring Harness

Locate the dash and remove three 3mm allen bolts to free it. Flip the dash over, pull back the dust boot, and then squeeze the clip to unplug the wiring harness.

Step 3: Loosen the Fuel Tank

Using a 12mm bolt, loosen the fuel tank at the end nearest the seat. Gently pull the tank up and back to free it from the mounts. Place a rag or towel over the frame to protect the paint from any sharp edges on the tank.

Step 4: Disconnect the Fuel Line

With the tank removed, you will now have access to the fuel line. Squeeze the gray prongs on the quick-connect coupling to release the fuel line from the tank. You may need to wiggle the coupling gently to fully release it.

Step 5: Remove the Fuel Pump

If you are replacing the fuel pump, follow these additional steps:

• Drain the gasoline from the fuel tank.
• Flip the tank over and remove the bolts holding the fuel pump in a cross-hatch pattern, taking care not to warp the baseplate.
• Install a new O-ring on the new fuel pump, greasing the O-ring channel.
• Reinstall the new fuel pump, tightening the bolts in a cross-hatch pattern and using a torque wrench to achieve the specified torque (88-inch/pounds).

Step 6: Reassembly

Finally, reverse the above steps to reassemble the motorcycle. Ensure all connections are secure, especially the fuel line, to prevent leaks. Refill the fuel tank and start the engine to verify that there are no leaks and that the fuel system is functioning properly.

Replacing the fuel hose

Step 1: Remove the seats

Use a 6mm allen head to remove the bolts for the rear and front seats.

Step 2: Remove the dash

Remove the dash by unscrewing the 3mm allen bolts.

Step 3: Disconnect the wiring harness

Flip the dash over and pull back the dust boot to reveal the wiring harness. Squeeze the clip and unplug the wiring harness.

Step 4: Loosen the fuel tank

Loosen the fuel tank by removing the 12mm bolt at the end of the tank. Pull the tank up and back to free it from the mounts.

Step 5: Protect the frame

Place a rag or towel over the frame where the seat was to prevent the sharp edge of the tank from scratching the paint.

Step 6: Disconnect the fuel tank

Flip the tank upright and squeeze the clip on the brown connector to unplug the wiring harness. Squeeze the grey prongs to remove the quick-connect on the fuel line.

Step 7: Remove the fuel tank

Remove the fuel tank from the bike.

Step 8: Drain the fuel

Drain the gas from the tank.

Step 9: Remove the fuel pump

Flip the tank over and remove the bolts that hold the fuel pump in place.

Step 10: Install the new fuel pump

Install a new fuel pump, ensuring you use a new O-ring and grease in the O-ring channel. Use threadlocker on the pump mounting bolts and tighten the bolts in a cross-hatch pattern, tightening them in three steps to 88 inch-pounds using a torque wrench.

Step 11: Reattach the fuel tank

Reattach the fuel tank to the bike, ensuring the back edge is resting where the seat goes.

Step 12: Reconnect the fuel line and wiring harness

Plug in the quick-connect and the brown wiring plug.

Step 13: Reinstall the tank

Lower the tank back into place and secure it with the bolt.

Step 14: Reinstall the seats and dash

Reinstall the driver and passenger seats, as well as the dash. Push the dust cover back into place.

Step 15: Refuel and reset the clock

Refill the tank and reset the clock.

Troubleshooting:

If your Suzuki Boulevard C50 is spitting, sputtering, and surging, there could be a vacuum leak in the fuel hose. To resolve this, you can try cleaning the fuel injectors, replacing the fuel pump, or checking for a vacuum leak. If there is a vacuum leak, you may need to replace the intake boots under the throttle body.

You can also try using a product like Berrymans B12 Chemtool in the gas tank to help flush out any remaining sludge or gunk in the fuel system.

Reattaching the fuel tank

To reattach the fuel tank of a 2007 Suzuki Boulevard C50, follow these steps:

Firstly, ensure the fuel tank is clean and free of any residue or dirt. This includes ensuring that the fuel pump has been cleaned and that any necessary replacements have been made. It is also important to note that the fuel tank should be handled with care to avoid any scratches or dents. Place a clean cloth or towel over the frame where the seat was to protect the paintwork.

Next, you will need to reattach the fuel hose to the fuel tank. This involves securing the fuel hose with a small grey clip that fits inside the black end piece of the hose. This clip is essential to ensure a snug and secure connection to the fuel tank. Without this clip, the hose may wiggle loose and cause fuel to leak. If you have misplaced this clip, you may need to purchase a new fuel hose that includes this piece.

Once the fuel hose is securely attached to the fuel tank, you can proceed to reattach the fuel tank to the bike. Ensure the tab on the end of the fuel tank with the mounting hole is sitting flush on the frame. Carefully tighten the bolt, being mindful not to over-tighten as this can cause damage.

After the fuel tank is securely mounted, you can proceed to reconnect the necessary fuel and electrical connections. Ensure the fuel line is properly connected and secured with the appropriate clamps. Reconnect the wiring harness by squeezing the clip on the brown connector.

Finally, you can reattach the seat by securing it with the appropriate bolts. Ensure all connections are secure before operating the bike.

Frequently asked questions