Replacing Fuel Lines On A Suzuki: 1982 Motorcycle Guide

If you're looking to replace the fuel line on your 1982 Suzuki motorcycle, there are a few things you should know. First, it's important to determine the size of the fuel line you need. The fuel line size for your Suzuki motorcycle may vary depending on the specific model you have. It's always a good idea to consult the owner's manual or a trusted mechanic to ensure you get the correct size. Additionally, you'll need to gather the necessary tools and materials, such as fuel injector hose, hose clamps, and gloves to protect your hands from gasoline. When it comes to the replacement process, you'll need to turn off the petcock or clamp the line, unplug the fuel drain screw or plug, remove the old fuel line, and carefully install the new one. It's important to take your time and follow the correct steps to ensure a safe and proper fuel line replacement.

Disconnect the fuel line from the throttle bodies and tank

Disconnecting the fuel line from the throttle bodies and tank is a crucial step in replacing a Suzuki motorcycle fuel line. Here is a detailed guide to help you through the process:

Firstly, locate the fuel line and identify the type of hose clamps securing it in place. There are typically two clamps, one near the petcock or fuel outlet at the tank, and the other near the carburettor or throttle body. The fuel line is usually a small, black rubber hose, but it can vary in colour.

If your Suzuki has screw clamps, use the appropriate screwdriver to loosen the screws and free the clamps. Be sure to have a bucket nearby to catch any remaining fuel. If you encounter pinch clamps, you may need pliers to un-pinch the clamp and remove the hose. Alternatively, if your bike has crimped-on hose clamps, you will need to cut them off using a clamp kit or a special tool specified in your owner's manual.

When removing the clamps, exercise caution not to lose any plastic clips that may be present. Gently twist and pull the connector off the hose with your hands. Avoid using pliers or any tools that could compress the connector. Once the fuel line is disconnected from both the throttle bodies and the tank, you can proceed to the next step of acquiring a new fuel injector hose.

It is important to wear rubber gloves throughout this process to protect your hands from gasoline. Remember to refer to your Suzuki's owner's manual for specific instructions and variations that may apply to your motorcycle model.

Remove old fuel line

To remove the old fuel line from your 1982 Suzuki motorcycle, you will need to first disconnect the fuel line from both the throttle bodies and the tank, ensuring you don't lose any plastic clips. Then, pull and twist the connector off the hose with your hands—do not use pliers as they can compress the connector.

Next, locate the fuel line hose clamps that attach the fuel line from the gas tank to the engine. These are usually found near the petcock or fuel outlet at the tank and on the other end near the carburettor or throttle body. If you have screw clamps, use a screwdriver to loosen the screws and free the clamps. If you have pinch clamps, you may need pliers to un-pinch the clamp and remove the hose. For crimped-on hose clamps, you will need to cut them off with a special tool.

Once all the clamps are removed, twist the fuel line and work it back and forth to free it from the inlet and outlet extensions. Repeat this process for the other side. Be prepared for the hose to be tight and require some force to remove.

Install new fuel line

To install a new fuel line, you will need to cut the new fuel line to the appropriate length unless you have a fuel injection model which is sized to fit. Work the fuel line over the inlet and outlet extensions (or nipples) in the same way that you removed the old line. Once in place, clamp the line unless you have a fuel injection model that snaps into place without the need for clamps. Do not use any grease or lubrication, as this can clog your fuel system and cause the line to come undone. Repeat the process on the opposite end.

Note: Don't forget to place the clamp over the hose before you slide it on the extensions. For petcock valve-equipped bikes, close the float bowl drain plug and replace the vent hose, then turn on the fuel. For fuel injection bikes, prime the system by cranking the bike. Check both ends of the fuel hose, including the connectors, fitting, and the extensions the new line is attached to.

Measure and cut new fuel line to size

When measuring and cutting a new fuel line for your 1982 Suzuki motorcycle, there are a few key steps to follow. First, make sure you have the correct type of fuel line. It should be fuel line hose, not just a generic rubber hose. You can purchase this at an auto parts store or online. The diameter of the fuel hose will depend on the specific model of your Suzuki motorcycle. Common sizes include 3/8", 8mm, and 5/16". You may need to refer to your motorcycle's service manual or consult a mechanic to determine the exact size required.

Once you have the correct fuel line, it's time to measure and cut it to size. Start by measuring the distance between the gas tank and the throttle bodies or carburetor. The new fuel line should be long enough to provide some slack between these two points. As a reference, a fuel line of about 5-6" should be sufficient. It is important to measure twice to ensure accuracy before cutting the hose.

When cutting the fuel line, use a sharp blade or hose cutter to ensure a clean cut. You may also need to trim the ends of the fuel line at an angle to facilitate a secure connection. Be cautious not to cut the hose too short, as it may need some extra length to accommodate bends and connections.

After cutting the fuel line to the measured length, it's a good idea to test-fit the hose before proceeding with the installation. This will help ensure that the line is the correct length and that all the necessary bends and connections are accounted for.

Now that you have measured, cut, and test-fitted the new fuel line, you can proceed with the next steps of the fuel line replacement process for your 1982 Suzuki motorcycle. Remember to wear rubber gloves and take the necessary safety precautions when working with gasoline and fuel lines.

Identify the correct fuel line size

Identifying the correct fuel line size for your Suzuki motorcycle is crucial to ensure a proper fit and optimal performance. Here are some detailed instructions to help you determine the correct fuel line size:

Consult the Owner's Manual: The first step is to refer to your Suzuki motorcycle's owner's manual. This manual should provide detailed specifications for your specific model, including the recommended fuel line size. It is essential to refer to the manual for your 1982 model as specifications may vary across different years and models.

Measure the Existing Fuel Line: If you still have the original fuel line or a portion of it, carefully measure its inner diameter. This measurement will give you the exact size you need to replace it with. Use a digital or manual caliper to get an accurate measurement in millimetres or inches.

Reference Part Numbers: If you have the part number for your Suzuki motorcycle's fuel line, you can use that information to cross-reference the correct fuel line size. Look for the part number in your owner's manual or on the manufacturer's website. Then, you can search for that part number online or at your local motorcycle parts store to find the corresponding fuel line size.

Standard Fuel Line Sizes: For Suzuki motorcycles, the most common fuel line sizes are often 1/4 inch or 5/16 inch (approximately 6.35 mm or 7.94 mm, respectively). These sizes are typically compatible with various models, but it's important to confirm before purchasing.

Fuel Line Compatibility: When identifying the correct fuel line size, it's crucial to consider the compatibility with your motorcycle's fuel system. Ensure that the fuel line you choose is designed for your motorcycle's specific fuel type and pressure requirements.

Seek Expert Advice: If you're unsure or need further assistance, don't hesitate to consult a motorcycle mechanic or a trusted local dealership. They will have the expertise and resources to help you identify the correct fuel line size for your 1982 Suzuki motorcycle.

Frequently asked questions