Swapping Fuel Lines

[ctburke]

Alright...so I decided I would do what everyone suggested and swap out the gray fuel lines with new fuel lines. For some reason I was under the impression this would be a fairly easy thing to do. It isn't...for me, anyway.

I have a 1998 GSX Limited. I am having the carbs rebuilt, and while they're out I figured I might as well take care of the fuel line. I was able to change out about half of it, but I could not get to the lines coming from the gas tank to the selector. (I could get to the lines coming from the tank, but could not get to the selector).

There was also a fuel line that went to the right side of the jetski and into styrophome. I could not locate where it came out so I couldn't change that line.

Anyway, I guess my question is: is there an easier way to get to these lines? I tried taking the handle bars off but that didn't help. I feel like the only way to do it is to completely remove the entire handlebar/steering assembly.

The good news is I successfully cleaned the rave valves!:coolgleam:

At this point I am inclined to just leave it the way it is...all new fuel line except that which comes from the tank to the selector (and that sneaky line that disappears into the styrophome).

 

[SabrToothSqrl]

I did this on my 1999 GTX (someone else did on my 02 XP). the vent line (your styrofoam line) most likely isn't a big deal. what I did was take the 12' roll (or about?) of hose and undid the end of ONE gray line. used electrical tape to tape the two butt to butt (NOT across), as that would make it too wide to fit through. Next I gently pulled the other end of the gray line, so the new black one followed where the old one perfectly. then i'd remove the grey one from the other end, and attach the black one at both ends. whatever you do, don't detach all of them at once, u will have no idea where anything goes!

Also, VENT THE GAS TANK (pop the cap) before pulling the line(s) off of it. else u will shoot gasoline 10' in the air and in your eyes and up your nose.

Don't ask me how I know that last part...

 

[ctburke]

I did this on my 1999 GTX (someone else did on my 02 XP). the vent line (your styrofoam line) most likely isn't a big deal. what I did was take the 12' roll (or about?) of hose and undid the end of ONE gray line. used electrical tape to tape the two butt to butt (NOT across), as that would make it too wide to fit through. Next I gently pulled the other end of the gray line, so the new black one followed where the old one perfectly. then i'd remove the grey one from the other end, and attach the black one at both ends. whatever you do, don't detach all of them at once, u will have no idea where anything goes!

Also, VENT THE GAS TANK (pop the cap) before pulling the line(s) off of it. else u will shoot gasoline 10' in the air and in your eyes and up your nose.

Don't ask me how I know that last part...

Yeah, that's pretty much exactly how I did it (with the tape...luckly no gasoline up my nose!). So I got the hose from the filter back to the carb and I got the hose from the tank to the carb. And the one from the carb to the motor. But I could not get to the selector valve. So there is still gray hose going from the tank to the selector.

It was getting late, and there were a few more cuss words flying than usual...so I might have given up a little too early. But the selector is really tucked in there, and without the steering assembly completely removed, plus the bow vent hoses, I have no idea how to get up in there to swap out the lines.

Whatever though. Hopefully they will be ok. Like I said, most of the line is replaced...just gray line going from tank to selector. Everything else was replaced.

Fingers crossed X

 

[FritoB]

You should probably remove the selector switch and clean it as it gets gunked up. There is a small black rubber cap on the top of the switch that covers a screw. Remove the cap and the screw so you can get the selector dial off and then you can use a wrench to remove the whole piece and clean or replace. You can also remove the lid and inside of the glove box for easy access to the lines on top of the fuel tank. The line between the fuel tank and selector valve needs to be replaced as this is one of the main fuel lines. Don't give up.... it's pretty easy.

 

[Minnetonka4me]

I would def. agree you want to pull the selector out and clean it.

I pull the whole mess of hose out in one piece, clean the valve and the fuel/water seperator...then replace one hose at a time. I mark the hose ends with a R and O so I know which one is which when I put it back in. I also put zipties on loose b/c the are a biatch to get around the hoses inside the machine.

 

[ctburke]

You should probably remove the selector switch and clean it as it gets gunked up. There is a small black rubber cap on the top of the switch that covers a screw. Remove the cap and the screw so you can get the selector dial off and then you can use a wrench to remove the whole piece and clean or replace. You can also remove the lid and inside of the glove box for easy access to the lines on top of the fuel tank. The line between the fuel tank and selector valve needs to be replaced as this is one of the main fuel lines. Don't give up.... it's pretty easy.

Oh, alright. I started to pry that rubber piece out figuring that had to be how to get the knob off, but wasn't sure and eventually decided not to. I will try that and hopefully that will make it easier to get to the remaining lines.

Thanks!

 

[seadooya]

Its debated, but i dont replace the return line, nor the vent line/s. If anything, bypass the selector switch. Run a line from "ret" off tank, to the inline filter, then filter to carb. Leave your selector switch to "Off".

Does your fuel gauge work? if not, then whats the point, right. Still need to lift the hatch to check fuel.

 

[SabrToothSqrl]

yes, pull the selector switch out of the hull, much easier to access.

I like the switch, it kind of forces you to get back to shore...

 

[ctburke]

Its debated, but i dont replace the return line, nor the vent line/s. If anything, bypass the selector switch. Run a line from "ret" off tank, to the inline filter, then filter to carb. Leave your selector switch to "Off".

Does your fuel gauge work? if not, then whats the point, right. Still need to lift the hatch to check fuel.

No, my fuel gauge doesn't work (hoping it's just the sending unit...I'd like to fix it). So that is why i'd like to keep the selector switch...for the reserve function.

 

[Minnetonka4me]

No, my fuel gauge doesn't work (hoping it's just the sending unit...I'd like to fix it). So that is why i'd like to keep the selector switch...for the reserve function.

FYI the fuel pickup is a NIGHTMARE to get out on the GSXs.