Replacing Fuel Lines: A Snowmobile Maintenance Guide

Replacing the fuel lines on a snowmobile can be a challenging task. It is important to select the right type and size of fuel line to ensure optimal performance and safety. The most commonly used fuel lines for snowmobiles are Tygon, polyurethane, and rubber fuel lines. Tygon fuel lines are known for their durability and ethanol resistance, while polyurethane fuel lines offer similar benefits and are available in various colours. Rubber fuel lines, such as the Gates Submersible In-Tank Fuel Line, are also widely used. When choosing a fuel line, it is essential to consider factors such as flexibility, compatibility with fuel types, and ease of installation. Some snowmobile owners prefer using non-ethanol gas to prevent fuel line degradation, while others opt for adding oil to the tank for added protection. It is recommended to consult a professional or refer to a repair guide specific to your snowmobile model before attempting any fuel line replacement.

How to remove the old fuel line

To remove the old fuel line from your snowmobile, you will need to first drain the fuel tank. Position the snowmobile in a well-ventilated area and disconnect the spark plug wire. You can then begin to remove the engine shroud by pulling off the choke and throttle knobs, followed by the acorn nuts that secure the carburetor to the engine.

Next, remove the muffler shroud mounting screws and carefully work the engine shroud off the carburetor mounting studs, leaving the primer hose and breather hose connected. Now you can access the fuel line. Release the fuel line clamp and pull the fuel line off the fuel filter. Repeat this process on the other end of the fuel line to release it from the carburetor and remove it completely.

It is important to note that you should take your time and be careful when performing these steps, as some of the parts are fragile and can crack if too much force is applied. Additionally, always make sure to work in a well-ventilated area when working with fuel and engine components.

How to choose the right replacement fuel line

When choosing a replacement fuel line for your snowmobile, there are several factors to consider to ensure you get the right one.

Firstly, it is important to know the specific year, brand, model, and engine size of your snowmobile. This information will help you select a fuel line that is compatible with your particular vehicle. Taking an old piece of the fuel line to an auto parts store can also help you find an exact match.

Secondly, it is recommended to use fuel lines that are specifically designed for snowmobiles and small engine applications. Look for fuel lines made from materials that are compatible with fuel and ethanol, such as Tygon fuel line, polyurethane, or PVC. These materials will ensure the longevity of your fuel line and prevent fuel leakage.

Thirdly, consider the inner diameter (ID) and outer diameter (OD) of the fuel line. The most common sizes for snowmobile fuel lines are 1/4" ID and 3/8" OD, but it is important to measure your existing fuel line or refer to your snowmobile's specifications to ensure an accurate fit.

Finally, decide on the length of the fuel line you need. Fuel lines typically come in rolls of 5 to 10 feet, but you can always cut them to the required length.

When purchasing a replacement fuel line, consider buying clamps or zip ties to secure the fuel line connections. It is also a good idea to check your snowmobile's fuel filter and consider replacing it if necessary.

How to install the new fuel line

To install a new fuel line on a snowmobile, follow these steps:

Firstly, ensure you have sourced a suitable replacement fuel line. There are several types and brands available, but it is important to select one that is compatible with your snowmobile's engine and fuel type. Tygon fuel line is a popular choice, as it is durable and ethanol-safe. It is also worth considering the colour of the fuel line, as some transparent options allow you to see the fuel flowing through, which can be useful for troubleshooting.

Once you have the correct fuel line, you can begin the installation process:

• Connect the new fuel line to the tank and secure it with a fuel line clamp. Ensure that the connection is tight and secure to prevent leaks.
• Repeat the process to connect the other end of the new fuel line to the carburetor. Again, use a fuel line clamp to ensure a secure connection.
• Reinstall the engine shroud by aligning the necessary knobs, shafts, and posts with the openings on the engine shroud. Work the shroud onto the engine, ensuring that any hoses pass through the correct openings and line up with the appropriate fittings.
• Secure any hoses with clamps and reinstall the muffler shroud by sliding the wire control cables into the retainer clip and positioning the shroud onto the engine.
• Reinstall the mounting screws and any other necessary components that were removed during the fuel line replacement process.

By following these steps, you can successfully install a new fuel line on your snowmobile, ensuring a secure and reliable connection for fuel flow.

How to avoid fuel line degradation

To avoid fuel line degradation, it is important to select a suitable material for your fuel line. The fuel lines on older snowmobiles tend to be made of rubber, which can degrade over time, leading to leaks and other issues. It is recommended to replace these with more modern alternatives such as Tygon fuel lines, which are known for their durability and resistance to ethanol in fuel. Tygon fuel lines are widely available at snowmobile dealers, auto parts stores, and online. When purchasing fuel lines, ensure that you get the correct diameter and length to fit your snowmobile's fittings and clamps. It is also important to consider the rigidity of the fuel line, as lines that are too stiff may be difficult to install and may not seal properly, while lines that are too soft may collapse under vacuum pressure.

In addition to choosing the right fuel line material, there are several other measures you can take to avoid degradation and ensure the longevity of your snowmobile's fuel lines:

• Regularly inspect your fuel lines for any signs of wear, cracks, or leaks. Replace the lines if they show any signs of degradation.
• Consider using non-ethanol gasoline in your snowmobile, as ethanol can contribute to fuel line degradation.
• Keep your gas tank full to minimize the amount of air and moisture in the tank, which can accelerate fuel line degradation.
• Drain the fuel tank and fuel lines at the end of the season to prevent corrosion during storage.
• Use fuel stabilizers to help maintain the quality of the fuel and protect the fuel lines.
• Store your snowmobile in a cool, dry place to minimize the effects of temperature and humidity on the fuel lines.

By following these guidelines and selecting a suitable fuel line material, you can effectively avoid fuel line degradation and maintain the performance and safety of your snowmobile.

Tools needed to replace fuel lines

The tools and parts needed to replace the fuel lines on a snowmobile will vary depending on the make and model of the snowmobile, as well as the type of fuel line being used. Here is a list of tools and parts that may be needed:

• A new fuel line: The type of fuel line used is important, as some fuel lines are not compatible with certain types of fuel. Common fuel line types include Tygon, urethane, vinyl, and rubber. It is also important to get the correct size of the fuel line, as some snowmobiles use metric sizes while others use standard sizes.
• Hose clamps: These are used to secure the fuel line in place. There are different types of hose clamps, such as screw-type hose clamps and zip ties.
• Tools to remove and install the hose clamps: This may include a screwdriver or a nut driver.
• Tools to remove and install the fuel line: This may include a socket and ratchet set, as well as a Phillips screwdriver.
• A way to drain the fuel: This may include a shop vac or a fuel pump.
• A way to catch and dispose of the drained fuel: This may include a fuel container and a funnel.
• Safety equipment: It is important to use the proper safety equipment when working with fuel and power equipment. This may include eye protection, gloves, and a respirator.

It is also important to work in a well-ventilated area when replacing the fuel lines on a snowmobile, as fumes can be dangerous. Additionally, it is recommended to consult the snowmobile's owner's manual or a repair guide for specific instructions and tools required for the particular make and model.

Frequently asked questions