Although modern motorcycle fuel lines are crafted with dual-layer construction to prevent the interior hose from minor damage the outer layer sustains, many dirt bike operators face damaged hoses following wrecks. Work on carburetors and fuel tanks can also damage a dirt bike’s gas line. Repairing a leaky gas line is one of the easiest motorcycle maintenance jobs and routine hose replacement is often included in an annual maintenance schedule, so most dirt bike riders should be comfortable replacing their gas line in order to save on shop fees.
1) Turn the motorcycle’s petcock to the off position. The petcock is the valve between the tank and the fuel line; shutting it off prevents gas spillage when you remove the fuel line.
2) Kick start the bike and allow it to run until it burns all the fuel left in the line and the engine. While this will eliminate most fuel spills, a small amount of gas may remain in the line and the carburetor, so be prepared for a small amount of leakage when you remove the hose.
3) Remove the air cleaner between the fuel line and carburetor using a slotted screwdriver and a pair of pliers. Using a slotted screwdriver, loosen the hose clamps at either end of the fuel line.
4) Work the hose clamps toward the ends of the fuel line. While you may be able to shift the clamps with your bare hands, it might be necessary to use pliers to work the clamp off the line. If the clamps are particularly stuck, use a utility knife to split the fuel line lengthwise at the connection point. When the lines are past the mooring bump inside the hose and move freely, you’ve moved them far enough to remove the hose.
5) Remove the fuel hose from the carburetor first, catching any fuel drips using a shop rag. Remove the hose from the petcock.
6) Cut the new fuel line to the correct length using a utility knife. Use the fuel line you removed from the dirt bike as a template to measure the correct length. Remove the hose clamps from the old piece of gas line and place them on the replacement.
7) Slide the ends of the replacement hose over the connections on the carburetor and the petcock. Use pliers to slide the hose clamps over the bump near the end of the hose. Tighten both clamps using a slotted screwdriver.
8) Turn the petcock valve back to the open position.
* It’s standard practice to replace a motorcycle’s fuel filter each time you replace a fuel line as part of a routine maintenance schedule. When replacing a damaged one, it’s usually not necessary.
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