Sylvie Willis
Setting up a motorcycle fuel line can be a tricky task. There are many ways to do it, and it depends on the type of motorcycle you have. For example, if you have a vintage Triumph, BSA, or Norton motorcycle, you can cut, crimp, and make your own custom fuel line assembly. You can also purchase a ready-to-install fuel line assembly, or even a fuel line tee connector, which is applicable for 1970-1995 Airheads for the 7mm fuel line between petcocks. If you're unsure about how to set up your fuel lines, it's best to consult an expert or a motorcycle forum for advice.
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What You'll Learn
Making a custom fuel line assembly
First, remove the existing fuel line from your motorcycle. Ensure that you disconnect the fuel line from the bike. It is important to remove all existing fittings attached to the line, as you will be reusing them. Heat the line to soften it and make the removal of fittings easier. Make sure that the line is free of any fuel residue.
Next, take the bare fuel line and measure its total length. You can use this measurement as a reference for your new fuel line. Cut your new fuel line to the desired length. It is recommended to use the original fuel line as a template, especially if it is a vintage motorcycle.
Now, you can start assembling your new fuel line. If you are using a PTFE (polytetrafluoroethylene) hose, which is similar to Teflon®, ensure that you follow the specific assembly procedure. PTFE hoses require fittings that use a sealing ferrule. You may need to trim the liner using a sharp razor knife to ensure a flush fit with the ferrule. Then, install the fitting into the socket and tighten it.
Other options for hoses include the TechAFX carbon-impregnated PTFE hose, which is stiffer and requires a larger bend radius. Earl's Vapor Guard hose is another alternative, a multi-layer rubber hose that offers protection against additives and prevents fuel evaporation. This hose is more affordable, with simple slip-on fittings that use a hose clamp to seal.
Finally, once you have assembled your custom fuel line, it's time to install it back onto your motorcycle. Ensure that the fuel line is free of any kinks or tight bends. Tighten everything securely and your custom fuel line assembly is complete!
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Disconnecting the fuel line
Firstly, remove the fuel line from your motorcycle. This is an important first step as it allows you access to the line and its fittings. Once removed, take a close look at the existing fittings attached to the line. It is recommended to remove and set aside all of these fittings as they can be reused, with the exception of the ferrules and the fuel line itself. Removing the fittings can be challenging, so it is advised to heat the line to soften it before attempting to take them off. Ensure that the line is free of any fuel or gas residue before proceeding.
Next, measure the length of the original bare fuel line. This will give you the exact length you need for your new fuel line. Cut your new fuel line to match this length. After cutting, slip a ferrule onto each end of the new line. It is important to ensure that your fuel line is properly secured and bottomed out on the fittings before moving on to the next step.
At this stage, you can begin cutting and making your own fuel line. This process involves crimping, so make sure your new fuel line is correctly positioned and secured before proceeding. Once you have finished crimping, it is time to install the new fuel line assembly back onto your motorcycle. Check that there are no kinks or tight bends in the line, as these could cause issues down the line.
Finally, tighten everything up and your job is done! You should now have a functional and aesthetically pleasing fuel line assembly. Remember, with ethanol in the fuel, the clear fuel line will eventually turn yellow and harden. If this happens and you need to replace it, you only need to purchase a new fuel line hose and ferrules; you can reuse the rest of the assembly.
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Cutting and measuring a new fuel line
To cut and measure a new fuel line for a motorcycle, you will need to first remove the old fuel line from the motorcycle. Once the fuel line is disconnected, you can start cutting and making your new line.
It is recommended to remove all existing fittings attached to the line and put them aside, as you will be reusing them. Removing the fittings from the existing fuel line may be difficult, so it is suggested to heat the line to allow it to soften and then proceed with the removal. Ensure that the line is free of any fuel or gas residue.
Use the original bare fuel line and measure the total length. Take this measurement and cut your new fuel line to the exact size. If you are creating a custom fuel line assembly, you will need to push the fuel line "all the way home" or bottom it out on the fittings you are using. If the line is not bottomed out, your measurements may be off, and the line may be too long or short.
Once you have finished cutting your fuel line and are happy with the final length, you can slip a ferrule on each end of the line. Then, grab your 1/2" ferrule crimping tool and place it over the ferrule. Begin to screw the plastic knob clockwise until the ferrule is crimped. Once done, unscrew the knob and finish crimping all other ferrules the same way. Always tug on the hose to ensure a tight connection.
If you are not creating a custom fuel line assembly and are instead replacing the 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 and 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.
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Installing a fuel line assembly
First, you need to assess the condition of your current fuel line. If it is brittle or damaged, it should be replaced. Remove the old fuel line from the motorcycle, ensuring that you wear protective gloves as you will be handling fuel. It is important to remove all the fittings attached to the line, which can be softened with heat to make the process easier. Ensure that the line is free of any fuel residue.
Next, you will need to measure the length of the new fuel line. Using the old fuel line as a template, measure the total length and cut the new fuel line to the exact size. This step ensures a proper fit for your new assembly. Once you have the correctly sized fuel line, you can begin to attach the fittings. Reuse the fittings from the previous line, excluding the ferrules, and attach them to the new line.
Now, you can install the new fuel line onto your motorcycle. Ensure that the fuel line is securely connected to the petcock valve and the carb. For petcock valve-equipped bikes, remember to close the float bowl drain plug and replace the vent hose. Turn on the fuel and check for any leaks. If there are no leaks, you have successfully installed your new fuel line assembly.
Finally, test your work by turning on the engine. If the engine runs smoothly and there are no leaks, you have successfully installed your fuel line assembly. If there are any issues, go back and check all connections and fittings, ensuring they are secure and correctly fitted.
By following these steps, you can install a new fuel line assembly, ensuring a safe and reliable fuel system for your motorcycle.
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Troubleshooting fuel line issues
Diagnosing the Issue:
Start by examining the fuel line for any visible signs of degradation. Fuel lines can soften, crack, or collapse internally over time due to exposure to heat, fluids, and the elements. If you notice any abnormalities, it's best to replace the fuel line with a new one compatible with your motorcycle's specifications.
Common Fuel System Problems:
Clogged Fuel Filters:
Clogged fuel filters are a common issue. Fuel filters play a crucial role in keeping contaminants away from your engine, but they can become clogged with debris and dirt over time, leading to restricted fuel flow. This can result in poor acceleration, decreased fuel efficiency, or even the motorcycle refusing to start. Replacing the fuel filter is generally a straightforward and inexpensive fix, but be sure to purchase a compatible replacement.
Carburetor Issues:
The carburetor is responsible for mixing air and fuel correctly for combustion. Problems with the carburetor can lead to symptoms such as difficulty starting the engine, rough idling, and poor fuel economy. Cleaning or adjusting the carburetor may resolve the issue, but it is a more complex process than replacing a fuel filter.
Advanced Diagnostics:
Utilize a motorcycle code reader, such as the Ancel MT700, to accurately diagnose issues within the fuel system. This tool connects to your bike and provides specific error codes, saving you from guesswork. For example, error codes related to limited fuel system flow or mixture control can indicate clogged fuel filters or carburetor issues, respectively.
Preventative Maintenance:
Regular maintenance is key to avoiding fuel system issues. Clean your fuel filter periodically and change it as per the manufacturer's recommendations. Service your carburetor regularly, and don't neglect the importance of using good quality fuel. Additionally, perform periodic checks and adjustments of the entire fuel system, including regular oil changes, spark plug replacements, and inspections of the fuel lines and tank.
Remember, safety should always be a priority when working on your motorcycle. If you're unsure about any aspect of troubleshooting or maintenance, don't hesitate to consult a professional mechanic or a trusted motorcycle specialist.
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