Jet Ski Fuel Line Replacement: A Step-By-Step Guide

If you're looking to replace the fuel lines on your jet ski, there are a few things you'll need to keep in mind. Firstly, it's important to read the service manual for your specific jet ski model, as oil injection systems can vary. You'll also want to invest in high-quality fuel lines that are compatible with your jet ski – consider purchasing marine-grade fuel hose (Type A1) to ensure safety and durability. The process of replacing fuel lines typically involves draining the fuel reservoir, removing the old lines, and installing the new ones, ensuring that all connections are secure and there are no leaks. It's a task that can be done at home with the right tools and knowledge, but if you're unsure, it's always best to consult a professional.

How to Replace Jet Ski Fuel Lines

Buy Tygon fuel line or marine-grade fuel hose

When looking to buy fuel lines for your jet ski, you'll want to consider Tygon fuel line or marine-grade fuel hose. These options offer distinct advantages and disadvantages that are important to understand before making a purchase.

Tygon fuel lines are a popular choice for jet ski owners due to their transparency, which allows for visual confirmation of fuel flow. This type of fuel line is made from PVC or a PVC-like material and is known for its flexibility, even in cold weather. Tygon fuel lines are also ethanol-resistant, making them suitable for use with fuel that contains ethanol. However, it's important to note that Tygon is not fire-resistant. In the event of a fire, the Tygon fuel line will melt, potentially dumping fuel onto the fire. As such, it may be safer to opt for a fire-resistant marine-grade fuel hose.

When purchasing Tygon fuel lines, it's important to buy from a reputable source to ensure the quality of the product. Knock-off Tygon lines may not perform as expected and could fail prematurely. Additionally, it's a good idea to confirm the size of the fuel line required for your specific jet ski model before making a purchase.

On the other hand, marine-grade fuel hose is designed to meet higher safety standards and is a better option for those seeking fire resistance. This type of fuel hose is typically made from materials that are more resistant to heat and flames, reducing the risk of fuel leakage in the event of a fire. Marine-grade fuel hose is often more expensive than Tygon, but it offers greater peace of mind, especially when riding in areas where a fire could have catastrophic consequences.

When purchasing marine-grade fuel hose, look for Type A1 hose, which is specifically designed for use in marine applications. This type of hose will be marked with "A1" on the tubing. Again, ensure that you purchase the correct size of fuel hose for your jet ski and only buy from reputable sellers to guarantee the quality of the product.

Both Tygon fuel line and marine-grade fuel hose are readily available online and can be purchased in various lengths and sizes to suit your needs. It's important to carefully consider the advantages and disadvantages of each option before making a decision, as the safety of you and your jet ski may depend on it.

Use stainless steel clamps

When replacing jet ski fuel lines, it is important to ensure that the clamps you use are made of stainless steel. Stainless steel clamps are superior to plastic or nylon cable ties, which can become useless if handled and are more prone to failure. Stainless steel clamps are also better at withstanding higher temperatures, which can be important if your jet ski is stored in a hot garage.

There are a few types of stainless steel clamps to choose from. One option is the standard stainless steel worm-screw-tightening clamp, which can be purchased at most hardware stores, such as Home Depot or Lowe's. These clamps are adjustable and reusable, but care must be taken not to over-tighten them, as this can lead to hose failure and leaks. Another option is a one-time-use stainless steel band, such as the Oetiker clamp. Oetiker clamps are often used in OEM assembly and are known for their small size, light weight, fast assembly, and uniform pressure distribution. They require a specialized tool for installation and must be correctly sized, as they have a limited amount of size change. A third option is a nylon ratcheting hose clamp, which can also be released if needed.

When selecting clamps, it is important to choose the correct size for your fuel lines and to ensure that they do not interfere with the operation of the jet ski or its linkages. It is also worth noting that, according to US federal regulations, hose clamps used on fuel lines must be made of corrosion-resistant material and must not cut or abrade the fuel line.

Clean the fuel selector valve

To clean the fuel selector valve of a jet ski, you will need to disassemble the valve and clean it with a suitable cleaning agent. Here is a step-by-step guide:

Step 1: Gather Tools and Materials

Before starting, ensure you have the necessary tools and materials, such as a fuel injector cleaning kit, soft-bristle brush, cleaning solvent, and protective gear (e.g., eye protection).

Step 2: Remove the Fuel Selector Valve

Locate the fuel selector valve on your jet ski, referring to your jet ski's manual if needed. Once located, carefully remove the valve by loosening any retaining nuts or bolts and disconnecting any fuel lines attached to it. Place the valve in a well-ventilated area or outdoors to avoid inhaling fumes during cleaning.

Step 3: Disassemble the Valve

Gently disassemble the fuel selector valve into its individual components, being careful not to damage any parts. This step may vary depending on the make and model of your jet ski, so refer to a repair manual or seek advice if needed.

Step 4: Clean the Valve Components

Using a suitable cleaning agent, such as Sea Foam Spray or a carburetor cleaner, carefully clean each component of the fuel selector valve. Pay close attention to any areas where fuel passes through, such as orifices or passageways, as these areas may be clogged with salt, sand, or other debris. Use a soft-bristle brush to gently remove any stubborn deposits.

Step 5: Rinse and Dry the Components

Rinse the valve components with clean solvent to remove any remaining cleaner or debris. Ensure that all parts are thoroughly dried before reassembly.

Step 6: Reassemble the Valve

Carefully reassemble the fuel selector valve, ensuring that all components are properly aligned and secured. Refer to a repair manual or seek advice if needed to ensure correct reassembly.

Step 7: Reinstall the Valve

Reinstall the cleaned and reassembled fuel selector valve onto your jet ski, connecting any fuel lines and tightening any retaining nuts or bolts.

Step 8: Test the Valve

Once the valve is reinstalled, test the jet ski to ensure proper fuel flow and engine performance. If issues persist, consult a qualified mechanic for further diagnosis and repair.

It is important to note that cleaning the fuel selector valve is just one aspect of jet ski maintenance. Regular maintenance of your jet ski's entire fuel system, including the fuel injectors, fuel lines, and other components, is crucial to ensure optimal performance and prolong the life of your watercraft.

Rebuild carbs

To rebuild a jet ski carburetor, you will need a complete jet ski carburetor rebuild kit. These kits are available for many jet ski models and contain all of the parts you will need. These are typically rubber parts like gaskets and the diaphragm, but sometimes the needle valve and seat are also included.

Rebuilding a jet ski carburetor means removing it from the engine, cleaning the internals, and replacing all the necessary parts. Keep in mind that a separate kit is usually required for each carburetor, but you can also find dual carb rebuild kits on the market.

It is also recommended that you carefully check the diagram that comes with the kit. Every kit is unique and can only be used for a certain type of carburetor. These kits often contain the hardware needed to disassemble and rebuild the carburetor.

If you are considering rebuilding your jet ski's carburetor, these step-by-step tutorials may be helpful:

• JetDrift's video guide
• JetSki Solutions' carburetor remanufacture/rebuild services

The cost of rebuilding a jet ski carburetor is around $15-$100 if you do the work yourself. The prices of the rebuild kits vary depending on the model and the contents of the kit. If you get it done by a mechanic, it will likely cost you around $200-$400.

It is recommended to stick to OEM rebuild kits, as aftermarket kits can lead to malfunctions or even engine damage. The simplest kits contain just the internal gaskets and diaphragm(s) and cost around $15-$25 per carb. If you have a dual carburetor or want to replace more parts, be prepared to pay up to $100 for an extended rebuild kit, which may include the following:

• Internal gaskets
• Diaphragm
• Needle valve and seat
• Other hardware

Check fuel line size

Checking the fuel line size is crucial before replacing your jet ski fuel lines. The fuel line size is determined by the inner diameter (ID) and outer diameter (OD) of the hose. Here are some steps and tips to help you check the fuel line size:

• Identify the Fuel Line Size: The fuel line size for jet skis typically ranges from 1/4" to 3/8" in inner diameter. The most common size is 1/4" ID, which is mentioned in several product descriptions for fuel lines compatible with jet skis.
• Check the Current Fuel Line: If you have access to the existing fuel line on your jet ski, carefully remove it and measure both the inner and outer diameters. This will give you an exact match for the replacement fuel line.
• Consult the Owner's Manual: Refer to the owner's manual or the manufacturer's website for your specific jet ski model. They usually provide detailed specifications, including the recommended fuel line size.
• Consider the Engine and Application: Different jet ski engines and applications may require specific fuel line sizes. For example, some high-performance jet skis might need larger fuel lines to accommodate higher fuel flow rates.
• Compatibility with Other Components: Ensure that the fuel line size is compatible with other components in the fuel system, such as the fuel pump, fuel filter, and carburetor.
• Standard Sizes: It's worth noting that fuel lines are typically available in standard sizes. So, even if you don't have the exact measurements, you should be able to find a suitable replacement based on the common sizes available.
• Fuel Line Kits: If you're unsure about the exact fuel line size, you can opt for fuel line kits that come with various sizes and adapters, ensuring a proper fit for your jet ski.
• Seek Expert Advice: If you're still uncertain, don't hesitate to consult a marine mechanic or a jet ski specialist. They can provide guidance based on their experience and knowledge of different jet ski models.

Remember, it's essential to get the fuel line size right to ensure proper fuel flow, prevent leaks, and maintain the performance and safety of your jet ski.

Frequently asked questions