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Old 02-07-2015, 10:03 AM   #1
Riteris OP
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need help replacing a fuel hose on DL-650

Hi all,

I need to replace a fuel hose on my 2005 DL-650.

It is the ~3" fuel hose on the right side of the motor near the throttle body.

The frame blocks most of the access from the right. There is little access from below.

I do not see any easy way of undoing the pinch type (Oeticker?) clamps.

I cannot see an easy way of accessing the hose short of taking the air box out.

So, if you have ever replaced this hose, how did you do it?

Thanks very much for any time saving advice!
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Old 02-07-2015, 09:33 PM   #2
Flashmo
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Pull the tank and the air box so you can get to it.
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Old 02-08-2015, 09:40 AM   #3
Riteris OP
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Quote:
Originally Posted by Flashmo View Post
Pull the tank and the air box so you can get to it.

I was hoping there was a less involved way of getting to the hose without pulling the airbox.

You confirmed what I suspected.

Thank you.
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Old 02-08-2015, 01:32 PM   #4
Zapp22
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but...

in case you don't know [and there are a lot of resources on the Stromtrooper forum]: the entire front end, the "nose cone" as I call it, can be removed as a unit if you like. Or you can try unfastening the upper collar and the side cowls and try to extract the tank that way, but my guess is you'll end up taking every piece off anyway, hence the first remark. its a tad unwieldy for one person to extricate the nose cone but it can be done - only weighs about 35lbs or so.
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Old 02-08-2015, 01:37 PM   #5
PiJiL
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Remove the fairings permanately, you get more wind in you hair and Maintence is easy

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Old 02-10-2015, 03:13 PM   #6
Riteris OP
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Quote:
Originally Posted by PiJiL View Post
Remove the fairings permanately, you get more wind in you hair and Maintence is easy



Uh, I did remove the fairings. It still does not give easy access to the hose. That is why I asked if anyone ever did it. Thanks for playing.
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Old 02-11-2015, 10:21 AM   #7
robberst
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It's been a while since I had mine apart.......




But as I recall the only fuel line on the right side of the bike is on the fuel rail. I don't think there would be any way to replace it other than to remove the entire fuel rail. Even were it easily accessible it would be difficult since the line is so short and the gap between the nipples would be very small.

Removing the fuel tank and air box is not difficult or even very involved. Replacing that hose is getting into the realm of involved.
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Old 02-11-2015, 04:24 PM   #8
Bigger Al
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Quote:
Originally Posted by robberst View Post
It's been a while since I had mine apart.......




But as I recall the only fuel line on the right side of the bike is on the fuel rail. I don't think there would be any way to replace it other than to remove the entire fuel rail. Even were it easily accessible it would be difficult since the line is so short and the gap between the nipples would be very small.

Removing the fuel tank and air box is not difficult or even very involved. Replacing that hose is getting into the realm of involved.
This.

Removing the airbox is involved the first time that you do it. Having a good manual will help things, as will taking some digital images as you go along. On my DL1000 the hose that I think that you're talking about is indeed for the injector rail, which means that you'll likely need to pull the injectors themselves. If so, pay attention to the o-rings that live between the injectors themselves and the throttle bodies. They can slip off the end of the injectors and disappear. DAMHIK.

Also be certain that you have hose that rated for the pressures that exist in the system. Good FI hose should do the job.
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Old 02-11-2015, 06:05 PM   #9
squish
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My bike is a few thousand miles away, so I can't help you with the hose swap.

but here's something to chew on. If that hose is bad, is there a chance other hoses in the same area are bad?
If you you might want to plan on doing them at the same time as a kind of preventive deal, you would hate to go through the hassle of all of this to replace one hose and have a second hose go south a few months later...

I've found with suzuki lots of parts go bad around the same time when it comes to the rubber hoses.
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Old 02-12-2015, 09:02 AM   #10
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The reason I was looking at the hose that it was leaking on startup in cold weather.

Once the motor gets warm, it stops leaking.

I tapped it with a small chisel and it seems to have re-seated itself.

As I don't usually ride in the winter, it is not a big deal.

The bike is a 2005 so it will need replacement of the hoses at some point.

I just hope to delay the inevitable until the last minute.

Otherwise, I should plan on a major disassemble and do a lot of work at one time.
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Old 02-12-2015, 09:10 AM   #11
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It's been mentioned , but there is alot of info over on Stromtrooper.com that can help you along , should you need it.
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Old 02-12-2015, 09:26 PM   #12
greywolf
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http://www.stromtrooper.com/general-...as-leak-3.html is right on point.
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Old 02-13-2015, 12:47 PM   #13
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Quite helpful! Thank you.
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Old 02-13-2015, 10:48 PM   #14
PeterW
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Quote:
Originally Posted by squish View Post
My bike is a few thousand miles away, so I can't help you with the hose swap.

but here's something to chew on. If that hose is bad, is there a chance other hoses in the same area are bad?
If you you might want to plan on doing them at the same time as a kind of preventive deal, you would hate to go through the hassle of all of this to replace one hose and have a second hose go south a few months later...

I've found with suzuki lots of parts go bad around the same time when it comes to the rubber hoses.
Not in this case, that short length of hose is a known problem, possibly a bitch to crimp even in the factory ;), and some just leak.

Replacing it and using screw down FI clamps seems to work just fine.

Pete
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