Motorcycle Maintenance: Replacing Fuel Lines, When Is It Necessary?

A leaky fuel line can be a frustrating setback for motorcycle owners, but with proper maintenance and care, it can be easily managed. The fuel line is a critical component that connects the gas tank to the engine, ensuring the smooth flow of fuel. While it is designed to withstand various conditions, several factors can lead to its deterioration, including old age, improper storage, and poor maintenance. Recognizing the signs of a faulty fuel line, such as fuel leaks, unusual bike behaviour, or the distinct smell of gasoline, is crucial for timely replacement. Taking preventive measures, such as using high-quality fuel, adding a stabilizer during storage, and storing the bike appropriately, can help extend the lifespan of the fuel line and enhance the overall performance of your motorcycle.

The importance of regular maintenance

Motorcycle fuel lines are essential for delivering fuel from the tank to the engine, and proper maintenance is critical to ensure the bike's performance and safety. Regular maintenance can help prevent leaks, which can cause delays in riding and potentially hazardous situations.

One of the key aspects of fuel line maintenance is addressing the effects of ageing. Over time, fuel lines can become brittle and cracked, especially when exposed to extreme temperatures or improper storage conditions. For example, leaving a motorcycle in direct sunlight or in a dry environment can accelerate the ageing process, leading to leaks. Therefore, it is crucial to follow proper storage practices, such as keeping the bike out of direct sunlight and using fuel stabilizers during winter storage.

Another factor that underscores the importance of regular maintenance is the potential impact on engine performance. A faulty fuel line can cause the bike to operate abnormally, such as running out of gas or "bogging out." This can affect the overall performance and riding experience. Additionally, improper maintenance can lead to clogged fuel systems, which can be caused by using grease or lubrication on the fuel line.

Furthermore, the type of fuel line used is an important consideration. Using the wrong type of fuel line, such as a fibre-core automotive fuel line in a carbureted motorcycle, can lead to issues. It is essential to use the correct type of tubing that is specifically designed for gasoline/fuel systems. This includes using ethanol-proof lines if the fuel contains ethanol, as ethanol can dissolve certain types of plastics.

By conducting regular maintenance and inspections, riders can identify potential issues with their fuel lines before they become more significant problems. This includes checking for leaks, inspecting the condition of the fuel line, and ensuring that the correct type of fuel line is being used. In some cases, it may be necessary to replace the fuel line, which is a relatively straightforward process that can be done by the rider with the help of proper tools and instructions.

Signs of a bad fuel line

A damaged fuel line can be caused by a bad wreck, but usually, it's a combination of old age, improper storage, and poor maintenance. For example, if you live in a hot and dry place, your fuel line can shrink and crack if you don't follow the proper storage methods.

• Leaks: The most obvious sign of a bad fuel line is a fuel leak. If you notice a thin puddle of fuel under your motorcycle, it's definitely time for a replacement.
• Abnormal operation: Your motorcycle may start acting up if the fuel line is damaged. This can manifest as the bike running out of gas or "bogging out" unexpectedly.
• Hard-starting/Rough idle: If your motorcycle takes more cranking than usual to start, or if the engine is not idling consistently, it could be a sign of a restricted fuel flow due to a clogged fuel filter.
• Repeated stalling: Stalling throughout the rev range, especially during idle or when accelerating or decelerating, could indicate that your engine is starving for fuel due to a faulty fuel line.
• Throttle hesitation/Performance loss: Blockages in the fuel filter may prevent enough fuel from reaching the engine when you open the throttle, resulting in hesitation and reduced performance.
• Engine issues: If your engine is struggling to start, sounding rough, or stalling frequently, it could be due to a faulty fuel line restricting the fuel flow.

It's important to address these issues promptly and consider replacing the fuel line to ensure the optimal performance and longevity of your motorcycle.

Common causes of fuel line damage

There are several reasons why a motorcycle fuel line may need to be replaced. Fuel lines are usually made of rubber, which can dry out and crack over time, leading to leaks. Small leaks will cause the vehicle to emit fuel vapors, noticeable by a gasoline odor. These small leaks will eventually turn into larger leaks, compromising the operation of the fuel system and causing engine misfires and stalling. Therefore, any sort of fuel leak should be addressed as soon as possible due to the high flammability of gasoline.

One of the first symptoms of a potential issue with a fuel line is visible cracks along the exterior of the hose. These cracks will not be able to hold the fuel system pressure as reliably as hoses that are in good condition and will be more prone to leaks.

Another common cause of fuel line damage is improper storage. For example, leaving a motorcycle out in the sun can cause the fuel line to age prematurely, leading to shrinkage and cracking. Similarly, storing a motorcycle in a dry environment can cause the rubber to dry out and crack.

Not adding a fuel stabilizer to the gas tank during winter storage can also damage the fuel line. This can cause the gas line to become gummed up, leading to similar issues as a cracked fuel line.

Finally, physical damage to the fuel line, such as kinking, can result from a bad installation, a crash, or even the track ghost. If the kink is severe enough, it can damage the hose and require replacement.

Choosing the right replacement fuel line

The fuel line is a critical component of your motorcycle's fuel system, ensuring that fuel is delivered from the tank to the engine. When replacing your motorcycle's fuel line, it is essential to select the right type of fuel line to maintain optimal performance and avoid future issues. Here are some detailed instructions to help you choose the correct replacement fuel line for your motorcycle:

Consider the Material:

The material of the fuel line is an important factor in its durability and compatibility with your motorcycle's fuel type. Most fuel lines are made of rubber, specifically designed to withstand the chemicals in fuel and the engine's heat. However, it is crucial to ensure that the rubber material is compatible with the type of fuel your motorcycle uses, such as gasoline or diesel.

Check the Inner Diameter and Length:

Fuel lines come in various inner diameters, typically ranging from 1/8" to 3/8". It is essential to choose a fuel line with the correct inner diameter that matches your motorcycle's fuel system. Using a fuel line with an incorrect inner diameter can restrict fuel flow or cause leaks. Additionally, ensure that the fuel line is long enough to reach between the fuel tank and the engine, with some allowance for bends and routing.

Select the Appropriate Clamping System:

Fuel lines are typically secured using clamps, and it is important to choose a clamping system that provides a secure and leak-proof connection. Common types of clamps include screw clamps, pinch clamps, and crimped-on hose clamps. Consider the ease of installation and the tightness of the connection when selecting the clamping system.

Fuel Type Compatibility:

Different types of fuel, such as gasoline and diesel, have specific requirements for fuel lines. For example, ethanol-blended fuels can be corrosive to certain materials, so it is crucial to choose a fuel line that is compatible with the type of fuel your motorcycle uses. Always refer to your motorcycle's owner's manual or consult a mechanic to determine the correct fuel line for your specific fuel type.

Temperature and Environmental Considerations:

If you ride your motorcycle in extreme temperatures or varied environmental conditions, consider choosing a fuel line that can withstand these conditions. Some fuel lines are designed to handle a wider temperature range, preventing cracking or degradation due to heat or cold. Additionally, if you store your motorcycle outdoors or in varying weather conditions, ensure that the fuel line can resist damage from weather exposure.

Ease of Installation and Maintenance:

When selecting a replacement fuel line, consider the ease of installation and any maintenance requirements. Some fuel lines may be easier to route and secure than others, and some may offer quick-connect fittings for convenience. Additionally, consider the availability of replacement parts and the ease of accessing the fuel line for future maintenance or repairs.

By following these guidelines and consulting your motorcycle's owner's manual, you can make an informed decision when choosing a replacement fuel line. Remember to consider the material, size, compatibility, and ease of installation to ensure a safe and reliable fuel system for your motorcycle.

Steps to replace a fuel line

Step 1: Wear Protective Gear

First, put on protective gloves. Working on the fuel line is bound to get your hands dirty with gasoline, so it's important to wear gloves to protect your skin.

Step 2: Turn Off the Petcock or Clamp the Line

If your bike has a petcock (an on/off valve), simply turn it off. If it doesn't, you'll need line clamping pliers to pinch the fuel line and prevent fuel from spilling out when you remove one side of the line. It's a good idea to keep a bucket nearby to catch any spills.

Step 3: Drain the Fuel

Some people prefer to start the engine and let it idle until the fuel in the line burns off. However, the recommended method is to locate the fuel drain screw or plug (also called a float bowl drain plug) on the carburetor. Snake the attached vent tube into your bucket, then unplug or unscrew the plug to drain the remaining fuel.

Step 4: Remove Fuel Line Hose Clamps

The fuel line hose clamps secure the fuel line from the gas tank to the engine. Locate and remove these clamps using the appropriate tools. The fuel line is typically a small, black rubber hose attached with pinch clamps or screw clamps. If you encounter screw clamps, use a Phillips head or Allen wrench (hex socket) to loosen the screws. For pinch clamps, pliers may be necessary to un-pinch the clamp and remove the hose.

Step 5: Remove Old Fuel Line

The fuel line may be tightly secured, so you'll need to twist and work it back and forth to free it. Repeat this process for both sides of the fuel line.

Step 6: Install New Fuel Line

Cut the new fuel line to the appropriate length, unless you have a fuel injection model which comes sized to fit. Work the line over the inlet and outlet extensions, similar to how you removed the old one. Once in place, secure the line with clamps unless it's a fuel injection model that snaps into place without them. Do not use grease or lubrication, as it can clog your fuel system. Repeat this process for the opposite end of the line.

Step 7: Final Checks

For petcock valve-equipped bikes, close the float bowl drain plug, replace the vent hose, and turn on the fuel. For fuel injection bikes, prime the system by cranking the bike. Check both ends of the new fuel line, including connectors, fittings, and extensions, to ensure it's correctly installed.

Once you've completed these steps, you're ready to get back out on the road!

Frequently asked questions