Fuel Line Size

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Dcf1999

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Nov 12, 2012
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43
Location
Dekalb, IL
This should be a pretty easy question to answer. I looked around though and didn't find one. Anyways I have a 97 600xtc and a 97 700sx. I changed all the fuel lines on them. They were getting stiff and i had the carbs off anyways so why not. Anyways, I put 1/4 lines on between the pump and carbs on both sleds. After riding for a bit, I pulled the 700 into the garage and opened the hood. Fuel was spitting out of the lines by the carb. Obviously the 1/4 inch line was too loose. It felt snug when I put them on but I guess I was wrong. Does anyone know the correct size fuel lines for the lines between the pump and carb? Maybe 3/16? I know they are probably a metric size, but good luck finding those. I can't find metric fuel line sizes anywhere.

Thanks for all your help...
 

It is metric. I remember someone on here saying that they used fuel line from an exciter, it's the line that goes along the side of the tank for the fuel guage, supposed to be the correct size.
 
X2 I made a little extension hose so I can pull the hose off the tank fitting and extend it out to run from a quart can of that ethanol free for the first and last time each season. I used 1/4" hose and a 1/4 to 5/16 Pcv nipple and the 5/16 end was too small. I had to put a piece of shrink wrap over it to tighten it up.
 
I figured it would be metric... Now where do I buy metric fuel line besides ordering the factory fuel lines through Yamaha? None of the power sport places around here sell metric line. That makes me think they use non-metric fuel lines when they replace them. Plus, if all these machines take metric line, you would think it would be pretty easily obtainable.

I think I may have some laying around, but I'm not even sure it's fuel line. I ordered it about 8 years ago through the marina I was working at. It's clear line and I'm 90% sure it's fuel line. I wouldn't have ordered plain vinyl line (at a employee discount) that I could have bought at Menards. It's smaller ID than 1/4 but larger than 3/16. I got the lines sitting in a bucket of gasoline right now to see how they stand up to gasoline.

If I can't get metric line, what SAE size would work? Taking the sleds out this week in Northern WI. 3/16 seems snug enough to not leak, but could it be too small to not allow enough fuel through? Seems unlikely but curious.

Thanks.
 
Interesting I was going to get some new lines tomorrow. Now wondering what to get. Maybe I will get some hose clamps to go with.
 
Ok so I talked to 5 different yamaha dealerships and nobody stocks the fuel lines nor do they really use them (except for one). It was recommended to me to use 3/16 because the 1/4" is a tad too big. The 3/16 will not restrict the fuel. If the ID of the nipples on the carbs and fuel pump is less than or equal to 3/16" there would be no restriction at all. The amount of fuel delivered is restricted by the smallest opening... Carb and fuel pump nipple ID in this case. The fuel line ID is larger than those openings. The 3/16 line does slid on the carbs and pump with little effort but you can feel there is enough tension that they won't just come off or leak. Ill also probably use the "fuel line" zip ties to make sure it's secure. There not standard zip ties... These have a round head to contour around the line. Yamaha and other manufactures use these all the time in the marine industry. They probably use them in other lines as well (sleds, quads, etc...) ill have to check my ATV's to see if yamaha used them.
 
Dcf1999 I went to my local sled shop and was told the same thing. Use 3/16 line. They had those squeezable clamps for 3/16 line and I bought those instead of the zip tie thing. 30 cent apiece.
View attachment 53759
 
I opted for the clamps and that's what I used. I also used the tygon yellow line... Seems like a lot of people like that stuff. I had the blue line on there before from parts unlimited and the stuff expanded pretty bad from the gas. When I put it on, it was snug, now it just comes off with no resistance even with the clamp still attached. I compared it with some new "blue" line I had, and you could tell that it really expanded. Origionally I had 1/4 on the between the carbs and pump and 5/16 from fuel filter to tank nipple and also from tank to fuel pump. I replaced the 5/16 blue line with 1/4 yellow tygon. Everything is nice and tight and sled runs awesome. No leaks. In the spring (or maybe this year) I'll replace the line in the tank with the yellow stuff... Depending how much the stuff expands from the gas (if at all), I'll use 5/16 or 1/4.

Devilin - I like that line... it looks tough... I will have to look into it... I search everywhere and couldn't find metric line.
 
Are we sure it is a 7mm line. When I tried the yellow tygon stuff in a 1/4 it fell right off. 7mm is .2755. I know 3/16 is .1875. But I cut a piece off the factory line and the 3/16 looks bigger to me on the inside diameter. I must be missing something
 
I use line from Motion Pro that is very similar to what Yamaha uses. You can get it at most automotive or bike performance shops.
 
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