ski
New member
Yamaha replacement fuel lines
After a 6 or so season hiatus I recently got back into sledding. I picked up a used (and slightly abused) 2003 Viper. Doing some routine maintenance I decided to replace the hard and crusty factory fuel lines from the pump to the carbs. I wasn't able to find the correct size immediately and found little info on the web (at least none that was correct)
People kept telling me the line from pump to carb was 1/4", but it was obviously too loose, and leaked like a sieve. I finally was able to track down the correct sizing and get some actual Yamaha bulk replacement lines from my local dealer. It comes in a 26 foot roll from Yamaha, but they sold it to me by the foot @ $2.59/foot (Canadian funds). 2 feet was enough to do the 3 carbs. Note that the O.D. of the Yamaha line is about the same as good quality 1/4" line, so the spring clamps fit about the same.
The hose size from pump to carb is 5MM I.D. (7MM O.D.) Yamaha Part # IQG-00002-60-20
The hose size from tank to Pump is 7MM I.D. (11MM O.D.) Yamaha Part # IQG-00003-60-20
I can't stress enough the importance of using the correct size of line. The 1/4" stuff leaked unless it was double clamped and even then was sketchy at best... huge fire hazard. The Yamaha replacement line won't leak even without being clamped at all (use clamps regardless). The best part is the wall thickness. When compared to Polaris replacement line it is noticeably heavier and won't kink on tight bends. See the pics below for a comparison.
Here you can see the wall is about 15% thicker than "other" brand's line...
Yamaha line can take a much tighter bend without kinking...
Finished lines on the Viper...
Hopefully this helps someone else get the right lines and not burn their sled down on the trail.
After a 6 or so season hiatus I recently got back into sledding. I picked up a used (and slightly abused) 2003 Viper. Doing some routine maintenance I decided to replace the hard and crusty factory fuel lines from the pump to the carbs. I wasn't able to find the correct size immediately and found little info on the web (at least none that was correct)
People kept telling me the line from pump to carb was 1/4", but it was obviously too loose, and leaked like a sieve. I finally was able to track down the correct sizing and get some actual Yamaha bulk replacement lines from my local dealer. It comes in a 26 foot roll from Yamaha, but they sold it to me by the foot @ $2.59/foot (Canadian funds). 2 feet was enough to do the 3 carbs. Note that the O.D. of the Yamaha line is about the same as good quality 1/4" line, so the spring clamps fit about the same.
The hose size from pump to carb is 5MM I.D. (7MM O.D.) Yamaha Part # IQG-00002-60-20
The hose size from tank to Pump is 7MM I.D. (11MM O.D.) Yamaha Part # IQG-00003-60-20
I can't stress enough the importance of using the correct size of line. The 1/4" stuff leaked unless it was double clamped and even then was sketchy at best... huge fire hazard. The Yamaha replacement line won't leak even without being clamped at all (use clamps regardless). The best part is the wall thickness. When compared to Polaris replacement line it is noticeably heavier and won't kink on tight bends. See the pics below for a comparison.
Here you can see the wall is about 15% thicker than "other" brand's line...
Yamaha line can take a much tighter bend without kinking...
Finished lines on the Viper...
Hopefully this helps someone else get the right lines and not burn their sled down on the trail.
Last edited:
Youllbe2nd
New member
Great info.
Sent from my E6560C using Tapatalk
Sent from my E6560C using Tapatalk
Good info.
Not that it matters, but I don't think that is OEM line. However it does look like a high quality PVC line. It would be good to know exactly what line that really is, as it might be a good replacement. The OEM stuff is grey and not at all transparent. I do not think Yamaha offers it anymore, but not sure. It lasts much longer than any of the replacement line (many) I have used since including the stuff from Motion Pro that looks similar. I do think the thickness is a key to longevity especially when you take them off and on as many times as I do.
I wonder if you can get a pic of the box it came out of some time.
Not that it matters, but I don't think that is OEM line. However it does look like a high quality PVC line. It would be good to know exactly what line that really is, as it might be a good replacement. The OEM stuff is grey and not at all transparent. I do not think Yamaha offers it anymore, but not sure. It lasts much longer than any of the replacement line (many) I have used since including the stuff from Motion Pro that looks similar. I do think the thickness is a key to longevity especially when you take them off and on as many times as I do.
I wonder if you can get a pic of the box it came out of some time.
ski
New member
Fair point... I edited to reflect that and added Yamaha part numbers.
shaggyzr2
Active member
I tried those numbers on a yamaha parts site and nothing came up. I found a ton of 5 and 7mm fuel line on ebay though.
A lot of the fuel line you can get for sleds just doesn't last very long. The stuff "ski" shows above looks like good quality stuff. I would try to find something like that.
http://blog.hemmings.com/index.php/...line-hose-what-you-should-and-should-not-use/
I would say 3/16 tygon, but I did read one guy had it collapse when he used it inside the tank for pickup.
I would say 3/16 tygon, but I did read one guy had it collapse when he used it inside the tank for pickup.
I have tried all of them that your typical Snowmobile stores carry (JR Graham, Dennis Kirk, ShadeTree, Western Powersports, etc.) including Tygon. None of them last nearly as long as the stock ones. The stuff in the pics above looks like a much thicker wall which is likely to last a lot longer,
Just orde OEM, pricey but worth it.
ski
New member
I'm not sure why, but maybe it is Canada only on that number? Try a dealer directly. I only found 5mm marked as 3/16" line on ebay (didn't really look that hard though) and it also seemed like thinned wall stuff. 3/16" is actualy 4.7MM not 5MM so while it may be forced on to the fitting, the flow rate may not be the same.