I just got the 20L tank and I'm planning to set it up with dual petcocks like you did. Thanks for the vid about the filters and the hose setup you've got going! Definitely reconsidered my original idea how to set it up.
I bought an almost new 2018 DR650, just 4500kms on it, just last month and the day after I rode it home the 160 kms from Brisbane Motorcycles (I live in Northern NSW) the fuel system started playing up. It would power-surge like it was running out of fuel and it's been doing it every time I've been on it since then. Anyway I got home from town this arv and got on RUclips and came across this video of Biker Bits' from 2016. And I saw "fuel filter" and thought, this might have something helpful in it. And I watched it and then after dinner I put my head torch on and went up the shed to see if there was a filter on my DR that might need cleaning out. Turns out there isn't a filter on it, but when I pull the hose off the tank to check if the fuel looks clean I fine a tiny pin-hole near the end of the rubber hose, hidden under the metal spring/guard. So I cut the last centimetre off and reconnect it to the tank, get my keys and take it for a spin, and guess what - that completely fixed the problem. It now runs beautifully like you'd expect a new DR to run. So thanks Biker Bits, very grateful to have got it purring again. I have no idea what put the hole in the hose, it had stock Suzuki hose-clips on it, but your mentioning the garden hose-clips being prone to cutting the rubber was what had me looking out for a hole, which I might not have noticed otherwise. Cheers mate.
Nice work. My only comment would be that zip ties are great for a field repair but spring type clamps like the oem ones are best for fuel hose. Any rigid type of clamp that can't move with the vibes will eventually wear a hole into the rubber (not a big deal at the fuel tee and filters since they're free to flop around).
Hey mate I had the very same problem a few years ago just found your page I will be watching them with great interest I am in the u.k. and currently rebuilding a 1978 Yamaha xs 250 but making it into a bobber into my own design welding bending tubing etc I am trying to do the wiring at the moment installing new plugs that's easy I am try to workout what wire goes where and I am installing twin four and three quarter inch bates headlights how to wire them in and an ignition switch tinkering around with bits I have years of experience in the engineering aerospace industry composite materials made a lot of parts over the years from carbon fibre great and cheaper keep up the good work best regard kevin, Plymouth u.k. p.s. love your little dog
Thanks for the video. I am working on my husbands Harley-Davidson. He's not ridden in over a year because of starting issues. It starts just fine with starting fluid but not with regular gas from the tank. I took the petcock off and noticed a lot of rust so I'm coating the tank cleaning the carburetor install an inline gas filter and going to replace all the fuel lines while I'm at it. His bike is a 2003 Harley-Davidson 883 XL Custom Sport. Its the 100th Anniversary Edition I bought for him for Valentine's Day before our son was born. I've done some looking and found fuel line pinch clamps so I'm going to use those instead of zip ties. I really appreciate all the explanation I'm good at fixing stuff but I like to know what does what.
As you know I love a zip tie solution. In regards to concerns of others. I have been using them for years in this way and no dramas. No vibration induced freting or cracks, nor UV issues. After all none of these areas is expsosed to direct UV, and most of them you have covered with foam and a gotcha strap. I reckon you should replace the zip ties when you start to see cracks in your fuel cap, seat cover, front fender, headlight shroud or mirror housings. Or when ever you change your fuel filter. Also I never did see you install the steering damper, wasup with that?
Just use proper Fuel Line Spring Clips, you can get a pack of 60 of ebay for less than ten bucks. Zip ties are ok for a field repair but they are notoriously NOT uv stabilised and will drop off one day. Use the correct part and you will have no trouble.
There should be no prroblem with fuel lines going above the height of the petcock, provided the end of the line, is below. That's how you siphon fuel out of cans. If that's not working for you... is the flow through the petcock restricted somehow? Has the petcock got a blocked screen?
I don't think the hose clamp would be an issue unless you are tightening and loosening it a bunch. You should replace your fuel hosing every 4 years anyways so shouldn't be a big issue. Those spring clamps are much better though, wouldn't recommend zipties as a permanent fix
Hey mark, good video but unfortunately not quite correct. The screw hose clamps you were using are fine, just don't over tighten them , you only have to have a firm fit on the end of the filter .I've been using them on motorcycle fuel lines for years and had a problem.
Probably one for main and one for reserve, reserve would be at a lower elevation to allow an emergency amount of fuel while being one hell of a reminder to fuel up ASAP
How often should this type of filter be replaced? Live in USA and ride all the time so assuming fuel quality or sitting still won't really cause problems. They're cheap but I don't want to overdo the maintenance interval.
I like the size of those small filters, except they are plastic. I will never use another plastic fuel filter. I found they fail, in a very short time...
Hey mark. Not trying to be a smartar$e but.....are you sure the shop you bought the pipe from had not accidentally sold you normal pipe intended for water, as pipe used for fuel is a special rubber which is resistant to petrol. Many years ago on my first bike (think I was around 11) I was sold normal radiator reserve tank hose and had exactly the same problem with the petrol breaking down the hose. Here in the uk if the rubber pipe is intented for petrol it has white lettering printed all along the side of the pipe/hose, cant remember what the printed lettering says, but something along the lines of for fuel use or something like that ?.
stupid gustion why do you have two small fuel filters then its an T line too the carb . Cloud you just went from the tank to the T vale and just had one huge Fuel filter that was see tho
Appreciate the video! Unfortunately my line twisted a little. I think it is still usable, and I am happy with the final outcome. Here are some pictures. My goal was to get all the lines as horizontal as possible with no uphill. Yours in this video has a pretty good uphill to the carb line that you turned down... I did have to sacrifice one filter, but there is still one in the tank and one in the inlet to the carb, so I feel OK about it... :) Check these pics out: drive.google.com/drive/folders/1a22LDkoJXplPK3_MVLZ0DVPBr-k-Oya2?usp=sharing
I just got the 20L tank and I'm planning to set it up with dual petcocks like you did. Thanks for the vid about the filters and the hose setup you've got going! Definitely reconsidered my original idea how to set it up.
The reason I love your vids is that you make the mistakes we all make and learn from - down to earth and entertaining with it :)
Other than having filtered fuel for your bunker idea, why not just use one filter on the hose to the carb after the t fitting?
Yeah, this would have made more sense, but to each his own.
Nice one mark we all learn by our mistakes. Keep up the good work.
+Toby Duke Thanks Toby :-)
good video mark that hose filter and clamp system looks so much cleaner
+Wes Buhr Thanks Wes and yeah should work nicely now! :-)
Thanks for the advice on the hose clamps
I bought an almost new 2018 DR650, just 4500kms on it, just last month and the day after I rode it home the 160 kms from Brisbane Motorcycles (I live in Northern NSW) the fuel system started playing up. It would power-surge like it was running out of fuel and it's been doing it every time I've been on it since then.
Anyway I got home from town this arv and got on RUclips and came across this video of Biker Bits' from 2016. And I saw "fuel filter" and thought, this might have something helpful in it. And I watched it and then after dinner I put my head torch on and went up the shed to see if there was a filter on my DR that might need cleaning out.
Turns out there isn't a filter on it, but when I pull the hose off the tank to check if the fuel looks clean I fine a tiny pin-hole near the end of the rubber hose, hidden under the metal spring/guard. So I cut the last centimetre off and reconnect it to the tank, get my keys and take it for a spin, and guess what - that completely fixed the problem. It now runs beautifully like you'd expect a new DR to run.
So thanks Biker Bits, very grateful to have got it purring again. I have no idea what put the hole in the hose, it had stock Suzuki hose-clips on it, but your mentioning the garden hose-clips being prone to cutting the rubber was what had me looking out for a hole, which I might not have noticed otherwise. Cheers mate.
BRILLIANT! :-)
Nice work. My only comment would be that zip ties are great for a field repair but spring type clamps like the oem ones are best for fuel hose. Any rigid type of clamp that can't move with the vibes will eventually wear a hole into the rubber (not a big deal at the fuel tee and filters since they're free to flop around).
Hey mate I had the very same problem a few years ago just found your page I will be watching them with great interest I am in the u.k. and currently rebuilding a 1978 Yamaha xs 250 but making it into a bobber into my own design welding bending tubing etc I am trying to do the wiring at the moment installing new plugs that's easy I am try to workout what wire goes where and I am installing twin four and three quarter inch bates headlights how to wire them in and an ignition switch tinkering around with bits I have years of experience in the engineering aerospace industry composite materials made a lot of parts over the years from carbon fibre great and cheaper keep up the good work best regard kevin, Plymouth u.k. p.s. love your little dog
Doesn't come loose with them plastic zipties ?
Thanks for the video. I am working on my husbands Harley-Davidson. He's not ridden in over a year because of starting issues. It starts just fine with starting fluid but not with regular gas from the tank. I took the petcock off and noticed a lot of rust so I'm coating the tank cleaning the carburetor install an inline gas filter and going to replace all the fuel lines while I'm at it. His bike is a 2003 Harley-Davidson 883 XL Custom Sport. Its the 100th Anniversary Edition I bought for him for Valentine's Day before our son was born. I've done some looking and found fuel line pinch clamps so I'm going to use those instead of zip ties. I really appreciate all the explanation I'm good at fixing stuff but I like to know what does what.
poemranger Lucky man!
Why 2 filters?
As you know I love a zip tie solution. In regards to concerns of others. I have been using them for years in this way and no dramas. No vibration induced freting or cracks, nor UV issues. After all none of these areas is expsosed to direct UV, and most of them you have covered with foam and a gotcha strap. I reckon you should replace the zip ties when you start to see cracks in your fuel cap, seat cover, front fender, headlight shroud or mirror housings. Or when ever you change your fuel filter. Also I never did see you install the steering damper, wasup with that?
Just use proper Fuel Line Spring Clips, you can get a pack of 60 of ebay for less than ten bucks. Zip ties are ok for a field repair but they are notoriously NOT uv stabilised and will drop off one day. Use the correct part and you will have no trouble.
thanks for the info. Just putting my Acerbis yank on my DR now. I ordered cheapy filters off Amazon but now I think I'll bet better ones.
+John Lanc My pleasure mate! :-)
There should be no prroblem with fuel lines going above the height of the petcock, provided the end of the line, is below. That's how you siphon fuel out of cans. If that's not working for you... is the flow through the petcock restricted somehow? Has the petcock got a blocked screen?
That looks much nicer and cleaner. I'm guessing you carry some extra zip ties in your tool tube just in case of general repairs?
Good points, better than my video. Except zip nylon cable ties get brittle in Arizona. I will look for aircraft style hose clamps and fittings.
5 mil reinforced fuel line works fine on 6 mil connections. Those hose clamps do work fine on the reinforced hose, nothing wrong with zip ties though.
I don't think the hose clamp would be an issue unless you are tightening and loosening it a bunch. You should replace your fuel hosing every 4 years anyways so shouldn't be a big issue. Those spring clamps are much better though, wouldn't recommend zipties as a permanent fix
Helping a brother out, that's realy cool man. great.
Good vid mark looking forward to your video with alistair cheers
I have the same Safari 30lt tank. Do you find the fuel line on the exhaust side gets bloody hot due to its location?
Hey mark, good video but unfortunately not quite correct. The screw hose clamps you were using are fine, just don't over tighten them , you only have to have a firm fit on the end of the filter .I've been using them on motorcycle fuel lines for years and had a problem.
Yep, fuel hose was to big for the connector.
6.5mm hose with 6mm connections.
Does it matter which end is facing towards the carburetor?
I’d use just one filter for gravity feed system..
Haha.........that bloody dog shit!!!!
Another cracking video!
Top stuff. 👍
why does your tank have two separate taps?
Probably one for main and one for reserve, reserve would be at a lower elevation to allow an emergency amount of fuel while being one hell of a reminder to fuel up ASAP
How often should this type of filter be replaced? Live in USA and ride all the time so assuming fuel quality or sitting still won't really cause problems. They're cheap but I don't want to overdo the maintenance interval.
Yeah sorry mate but don’t really know... I’m sure it would depend on how crap was going through!
Always use star tron or techron fuel cleaner in your ATV. Your bike will love u down the road
I like the size of those small filters, except they are plastic. I will never use another plastic fuel filter. I found they fail, in a very short time...
"jeez I'm bloody hopeless" too funny. where can i find these fuel filters? is there a website to order them from?
+lvannes121 You can find them on Ebay!
Hey mark. Not trying to be a smartar$e but.....are you sure the shop you bought the pipe from had not accidentally sold you normal pipe intended for water, as pipe used for fuel is a special rubber which is resistant to petrol. Many years ago on my first bike (think I was around 11) I was sold normal radiator reserve tank hose and had exactly the same problem with the petrol breaking down the hose. Here in the uk if the rubber pipe is intented for petrol it has white lettering printed all along the side of the pipe/hose, cant remember what the printed lettering says, but something along the lines of for fuel use or something like that ?.
Must be the right stuff as it's still holding up! :-)
Would much rather have hose clamps instead of zipties especially on an enduro. If it gets cut loosen it cut split piece reclamp it
good 1
Correction. They are correct
Away u go fab
Looks like you install them backwards
Nah they are good! 👍
stupid gustion why do you have two small fuel filters then its an T line too the carb . Cloud you just went from the tank to the T vale and just had one huge Fuel filter that was see tho
It’s just the way I did it! :-)
What 4 days later and nobody has cracked a joke about, "Blowing into your tank" what gives ? Don't tell me we're losing the larrikin character.
Fuel filter is the wrong way around
C00L
Appreciate the video! Unfortunately my line twisted a little. I think it is still usable, and I am happy with the final outcome. Here are some pictures. My goal was to get all the lines as horizontal as possible with no uphill. Yours in this video has a pretty good uphill to the carb line that you turned down... I did have to sacrifice one filter, but there is still one in the tank and one in the inlet to the carb, so I feel OK about it... :) Check these pics out: drive.google.com/drive/folders/1a22LDkoJXplPK3_MVLZ0DVPBr-k-Oya2?usp=sharing
Great stuff mate!