97 gsx

[Prime Target]

Hi all. New to the site. Great info here! I'm pulling the GSX out of a 10 yr hibernation and getting it running again. It ran great when I tucked it away. Im going to replace all the fuel lines, pull/rebuild the carbs, clean the fuel tank(almost empty), change pump oil, inspect wear ring. GSX has ~100 hrs on it. It always had routine maintenance including pump oil. I see Tygon fuel lines are probably the way to go. I did a search but am still confused about the size and length of line needed. It's the 787 and I believe with that motor it's all 1/4, but is that inside diameter or outside diameter? Also, about 25 ft needed? Can't wait to get it back in the water again.

 

[Krispy]

Just get 25' of automotive fuel line 1/4 inch. No need to spend the big bucks on tygon in my opinion. [MENTION=59978]kicker[/MENTION] and [MENTION=31048]LouDoo[/MENTION] have a diagram showing the proper line sizes if you want to go tygon, but personally I would rather have the money I saved to buy a gallon of XPS oil!

Welcome to the site. I too have a 97 gsx and it is a ton of fun!

 

[Prime Target]

Good idea! I'd rather spend the excess $$$ on fuel and oil. Thanks for the response. i'm sure I'll be posting more questions as i start taking things apart.

 

[Krispy]

No problem, let us know if you need any assistance with re plumbing the system.

While you are replacing the fuel line, now is a good time to replace the oil lines that run from the oil pump on the front of the engine to each cylinder.

You will need about 4 feet of 3/32 weed eater fuel line (it is oil and fuel resistant, I get tygon from the local small engine repair shop).

 

[Coastiejoe]

Also clean or replace the fuel selector. It plugs up due to the Grey Tempo lines...

Welcome aboard and thank for joining..

 

[Prime Target]

Trying to figure out where this fuel line goes. Looks like it comes off the fuel selector switch and runs down the side under the right footwell. Is it just a breather line? If so, does it need to be replaced? feels like it's attached to something under the footwell. don't want to pull it off of something I can't get to.

 

[Prime Target]

Here's another pic of it. There's another line that comes out of there that is plugged at the end. The clear(?) line runs all the way back to the battery tray and from what I remember was a battery breather line. Am i correct in assuming these lines are all breather lines?

 

[Krispy]

Only the fuel lines are gray, the amber or clear lines are battery vent, and fuel tank vent lines.

I recomend starting at the carbs and working your way to the fuel selector replacing one piece at a time.

Also, I mentioned the 3/32 tygon lines earlier for your oil injection. I also used these lines to re-plumb my accelerator pump when I was doing fuel lines.

 

[Krispy]

Here's another pic of it. There's another line that comes out of there that is plugged at the end. The clear(?) line runs all the way back to the battery tray and from what I remember was a battery breather line. Am i correct in assuming these lines are all breather lines?

Looking at the pic on my phone I missed something. That other tube is just the inlet to the spray foam bag under the footwell. Nothing to be concerned with. If it isn't grey don't worry about changing it.

 

[AdamXP800]

Those grey "fuel lines" in your last photo are just the vent lines from your gas tank. You do not need to change those grey lines they are fine.

 

[AdamXP800]

If you look right under the rub rail on the outside of the hull you will see the nipple where it vents out. It will not release and vent until the pressure is like 2.5-3psi i believe

 

[Prime Target]

I replaced all of the fuel lines today with new 1/4 inch line. Removed and cleaned the fuel selector switch, which was slightly boogered up with the green slime, but not overwhelming. More in the reserve hole than the main. Pulling the carbs for cleaning/rebuild tomorrow. I want to put a fuel filter on the fuel line coming into the carbs. Is there any specific spot I should put it or can I put it on about 6 inches before the carbs? It's a clear filter. Just want to be able to glance at it instead of hunting for it under the steering head.

 

[Krispy]

I replaced all of the fuel lines today with new 1/4 inch line. Removed and cleaned the fuel selector switch, which was slightly boogered up with the green slime, but not overwhelming. More in the reserve hole than the main. Pulling the carbs for cleaning/rebuild tomorrow. I want to put a fuel filter on the fuel line coming into the carbs. Is there any specific spot I should put it or can I put it on about 6 inches before the carbs? It's a clear filter. Just want to be able to glance at it instead of hunting for it under the steering head.

You can place it just before the carbs. I like to place mine near something I can attach it to, so in this case I would follow the fuel supply line down to near the hull, and place the filter there. When full of fuel it can bounce around a bunch and make noise. If it is zip tied down low this isn't a problem. I have been using the Fram G2 without any trouble on man skis for the past few years.

 

[Krispy]

I replaced all of the fuel lines today with new 1/4 inch line. Removed and cleaned the fuel selector switch, which was slightly boogered up with the green slime, but not overwhelming. More in the reserve hole than the main. Pulling the carbs for cleaning/rebuild tomorrow. I want to put a fuel filter on the fuel line coming into the carbs. Is there any specific spot I should put it or can I put it on about 6 inches before the carbs? It's a clear filter. Just want to be able to glance at it instead of hunting for it under the steering head.

You can place it just before the carbs. I like to place mine near something I can attach it to, so in this case I would follow the fuel supply line down to near the hull, and place the filter there. When full of fuel it can bounce around a bunch and make noise. If it is zip tied down low this isn't a problem. I have been using the Fram G2 without any trouble on man skis for the past few years.