Whats the best way to route the fuel line??

I'm having trouble routing the fuel line on my "78 KZ650sr without having it kinking or bending, thus restricting the fuel flow. Its not the easiest place to get into with hands or pliers. Can't find anything in the Hayens manual about the fuel line specifically.

Use enough fuel line to make a loop and put your filter in it.
Steve

When I added an in line filter I had the same problem. Either I kinked the cable or the loop was so long it went up under the tank creating a fuel trap. So I added an elbow like this one. Problem solved.



www.zoro.com/parker-union-elbow-90-deg-0...V8P8HAQ&gclsrc=aw.ds

Use a longer section of fuel line. Your bike probably uses 5/16" tubing & fuel filter (not 1/4" ).

Note: some plastic fuel filters are unsuitable for ethanol blended gasoline, as the ethanol attacks the plastic. I've experienced the phenomenon firsthand & I'm darn lucky the thing didn't catch fire. :ohmy:

The clear plastic ones seem unaffected. Don't buy CHINESE.
Steve

It was a clear filter from Z1Enterprises.com & the same as the one in the photo, or at least very similar to it.

Mine are 2 years old. No problems.
Steve

Here's what I found to be the absolute best on my KZ650:

The original hoses were metric, but here’s what I use and it works perfectly. Goodyear 5/16" Fuel Hose SAE 30R7 (required 8") Part # 65123. Here is a link describing it - www.goodyearrubberproducts.com/2012pdfs/...wnloads/page0031.pdf . I bought it at www.applied.com/apps/directory/storelocator?r=US&a=20853 Applied Industrial Technologies is nationwide, so there may be an office near you.

For clamping the hoses I use 5/16" spring clamps (see 1st image below). They are a million times easier and quicker to use than the screw type. Some auto stores sell them or they can be easily found on eBay.

I use a Golan Super Mini 5/16" fuel filter; see "70-312G 5/16 Barbed Fittings” at www.golanproducts.com/filters.html#filters-mini for specs. (See 2nd image below). They are not cheap, but one will last a lifetime; I got mine from ronayers.com. They use a stainless steel filter element that can be cleaned. They filter out very small 10 micron particles but still pass fuel at a rate of 6 gallons per minutes – MORE than enough for any bike. They are very small so they fit well under the tank. Also, I used a 5/16” stainless steel elbow to make the bend from the tank to the carbs so there is zero chance of the fuel line pinching (see 3rd image). I got it at a place that specializes in propane supplies.

I suspect all this seems like a lot of fuss over fuel delivery, but it works great, makes removing the fuel tank a 30 second task, and it will last for decades.

One word of warning – having tried numerous fuel delivery setups over the past 38 years the absolute worst product I found is Gates Barricade fuel line. Do not waste your time and money on it as it has an inner sleeve that rolls up like a loose sock and clogs the line when you install it. Ed

I use the yellow Tygon fuel line. It stays supple, tolerates ethanol well, and is much easier to route. I have used it successfully without clamps. For safety I usually use a plastic zip tie once everything is dialed in.
The problem is the carb fitting is 5/16 and the petcock is more like 1/4. I would love to find a filter that has 1/4 going in and 5/16 coming out.

ThatGPzGuy wrote: I use the yellow Tygon fuel line. It stays supple, tolerates ethanol well, and is much easier to route. I have used it successfully without clamps. For safety I usually use a plastic zip tie once everything is dialed in.
The problem is the carb fitting is 5/16 and the petcock is more like 1/4. I would love to find a filter that has 1/4 going in and 5/16 coming out.

1/4" ??? Maybe someone installed an aftermarket petcock on your bike? The stock petcock outlet on my KZ650-C1 has a bulge that is used to ensure the fuel line doesn't leak. That bugle is considerably larger that 1/4" (0.250") In fact, the bulge is 0.353" which is larger than 5/16" (see 1st image below). The Goodyear 5/16" fuel line fits it tight enough to let you hang the petcock from the fuel line and it won't slip out of the fuel line (see 2nd image below), but I use the spring clips shown in my posting above to be safe. In the past I used 1/4" fuel line on my bike, but I found it was far too difficult to install and remove because it was too tight. Ed

Right. 5/16 rubber fuel line fits well on the petcock but the 5/16 Tygon is a little loose and will leak. Probably because it is a thinner wall. But it is much easier to route and seems to last forever without getting hard.
You can see how it is a little loose on the petcock. I don't have a picture but it is a perfect fit on the carb tee.

Huge 2nd on Eds 5/16ths lines and clamps ........... they go on so fast and easy with the a pair of nettle nose or reg plyer's and have never leaked.