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1997 GS - Fuel line replacement

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dte33

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I just purchased a 1997 GS with Grey fuel lines and I need to replace them. We just returned from vacation in Michigan with it last week and it ran all week long with no issues. We ran it pretty much everyday, all day.
Now that I am back home, I wanted to replace the fuel lines. I keep reading in these posts that people are replacing them pretty easily. I want to know if I can just start disconnecting the fuel lines and replacing them or do I need to do them in a certain order? I am new to this, I am certain I can do it, I just want to be certain I do it right to avoid damage by doing something wrong.
Thanks
dte
 
Replace them one by one so you don't get confused on where they go... I would take one off, cut a new one to match the length, then install it and repeat... Piece of cake!!
 
Thanks for the quick reply. Do I need to worry about bleeding the lines afterwards like you do with the oil lines? Also, can i just remove the housing for the fuel filter to replace the the filter too without worrying about it?
 
what kind of black fuel line you guys recommend? where are you guys buying it from?

Just bought my first jet ski ever (97 xp) and looking to replace the gray lines
 
you can use standard 1/4" automotive rubber fuel line from your local auto parts and stainless steel hose clamps
 
perfect...ill see how the clams are and get to it sooner or later....just got this thing and looking forward to it
 
does anyone know how to take off the stock hose clamps on the tempo lines ? ive heard of a few people dremmeling them out but im not a big fan of sparking right next to fuel lines and a semi filled gas tank
 
I just replaced my hoses this past weekend. I agree about sparks near the gas tank.
I used a small vise grip and pulled it along the line. If you twist it, it takes a little longer to remove. Sometimes you can just pull the line off the fitting, but it if doesn't come loose easily then don't tug too hard.

You don't need to replace the vent lines from the gas tank to the hull or fuel selector valve. Take apart the selector and clean it. (Res/off/on). Squirt carb cleaner and then blow air thru it.
 
mattydipps said:
does anyone know how to take off the stock hose clamps on the tempo lines ? ive heard of a few people dremmeling them out but im not a big fan of sparking right next to fuel lines and a semi filled gas tank
Click to expand...

i usually get them off fairly easily twisting them open with a screwdriver, but I had a couple last week that I tried the screwdriver on for like 10 minutes then I discovered you can pry them open pretty fast with a hooked pick. I was able to get them off in like 15 seconds by sticking the point of the pick between the clamp where it overlaps and prying it up enough to then stick the pick in thru the little slots in the clamp and then pry it right open. The picks I have are STANLEY, got em at Walmart but the one I was using is pretty much the same as the 3rd one in this set:

http://www.harborfreight.com/4-piece-pick-and-hook-set-66836.html
 
bigJake said:
i usually get them off fairly easily twisting them open with a screwdriver, but I had a couple last week that I tried the screwdriver on for like 10 minutes then I discovered you can pry them open pretty fast with a hooked pick. I was able to get them off in like 15 seconds by sticking the point of the pick between the clamp where it overlaps and prying it up enough to then stick the pick in thru the little slots in the clamp and then pry it right open. The picks I have are STANLEY, got em at Walmart but the one I was using is pretty much the same as the 3rd one in this set:

http://www.harborfreight.com/4-piece-pick-and-hook-set-66836.html
Click to expand...

here's the set I got at walmart, for like $4

http://www.walmart.com/ip/Stanley-4pc-Hook-and-Pick-Set/16913722
 
I also took a few photos of mine before I touched anything.But I still changed the lines,one at a time.
 
I used a pair of side cutters on the factory clamps, squeezed the clamp together where it met and twisted, then it popped loose, and I did change my vent lines, they were gooed up like the rest and neither ther check valve or the pressure relief valve worked so replaced them too
 
flowmasterman said:
I used a pair of side cutters on the factory clamps, squeezed the clamp together where it met and twisted, then it popped loose, and I did change my vent lines, they were gooed up like the rest and neither ther check valve or the pressure relief valve worked so replaced them too
Click to expand...

I tried side cutters on those stubborn ones I had too but they didn't work either. I've probably remove about 40 of these clamps and these 2 were the first to give me any trouble. Might have been because they seemed to be super tight.
 
Anyone have pics of the lines to be replaced? i am going to chase the gray lines around and replace them, just dont want to miss any....i know some go under the seat area (seadoo xp) and some run and hide....
 
Smokymance said:
what kind of black fuel line you guys recommend? where are you guys buying it from?

Just bought my first jet ski ever (97 xp) and looking to replace the gray lines
Click to expand...


Smokymance, for your particular ski, you have two sizes of stock fuel lines. You will need 5/16 hose for the hoses running from the tank to the carbs. This includes from tank to fuel selector, to water trap filter, and then off to the carbs.

For the return lines, you will buy 1/4 hose. Check the gray fuel lines you have and you will see 8mm and 6mm written on the sides of them. This will let you know which size to use when you take one off to replace.

I am not sure what affect it would have (if any) on your ski if you used all of one size hose. My ski is like yours and has the two sizes, so I replaced them as close to spec as I could.
 
i will replace them accordingly...what components are you guys removing to make this easier? i know some are very hard to get to, like the ones going to the carbs and the y splitter that is right there by the intake. also, what size clams are to be used? as i read somewhere, i think i will need about 30 of them

dont recall, but i think a few run in some spots by under the seat that will take a few tricks to remove.
 
Smokymance said:
what components are you guys removing to make this easier?
Click to expand...

What you have to remove largely depends on the particular ski, as you will find, there are big differences in the component layouts from ski to ski. You just got to dig in to the task and remove what you have to in order to get the job done.

On my machine, I removed the large 2" vent hoses under the hood and the steering system although, I was doing much more than just replacing the fuel lines at the time.
 
Last edited by a moderator:
I found two kinds of clamps in mine

151.jpg
 
the oetiker clamps are factory installed. those are the ones that were suggested to get off with side cutters or a pick. the standard hose clamps i would think indicate some prior work done on the ski.
 
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