fuel line under seat keeps rupturing on my 03 250

NinjaDucky · January 3rd, 2014, 03:48 AM

So my left-side fuel line keeps getting pinched and breaking right at the tank under the seat. Has anyone found a solution to this? Or am I the only one who has a leg that smells like a gas station?

Foxrider64 · January 3rd, 2014, 06:47 AM

Is the line an actual fuel line or did someone at some point put another kind of hose on there?

Does the hose feel flexible or is it stiff?

What kind of clamp do you have holding the hose to the petcock?

It is not a common problem AFIK though.

DaBlue1 · January 3rd, 2014, 07:02 AM

If you still have any OEM rubber hoses that carry fuel or fuel vapors, they should have been replaced a long time ago, given the age of your bike.

Good grade fuel line is hard to pinch and rupture. You should get some 1/4" fuel line (at any auto parts store) and replace all your fuel lines and make sure they are routed properly and not being pinched anywhere. If it is being pinched, it's improperly installed or your seat is the problem.

Motofool · January 3rd, 2014, 09:57 AM

Quote:

Originally Posted by NinjaDucky

So my left-side fuel line keeps getting pinched and breaking right at the tank under the seat. ..........

Which one?

alex.s · January 3rd, 2014, 10:03 AM

i wonder how long ducttape would hold gasoline before the plastic disolved

TnNinjaGirl · January 3rd, 2014, 10:18 AM

/\ about 8 hours and the sticky dissolves, not the fiber/plastic/miracle tape

csmith12 · January 3rd, 2014, 10:21 AM

Quote:

Originally Posted by alex.s

i wonder how long ducttape would hold gasoline before the plastic disolved

It will get you through a track day.

alex.s · January 3rd, 2014, 10:30 AM

thats a good thing to know in case you bust a fuel line in the middle of nowhere

NinjaDucky · January 3rd, 2014, 05:11 PM

Quote:

Originally Posted by Motofool

Which one?

The far left or #1 line, oddly (and this worries me now) i dont have one in that #2 spot as in your photo...

what i guess keeps happening is if i sit too far forward on the seat it puts pressure against the line and pinches it between the nipple and the body of the seat and rips it.. i have an extra long line there so i usually just check it from time to time and when i smell gas i stop, pull off the hose, clip an inch off and re-attach it. works for now but id like to find a way to maybe protect it from being ripped at all. maybe carve out that part of the seat body? or some sort of hard protector/bumper/bushing thing that keeps the pressure from the seat body off of it?

NinjaDucky · January 3rd, 2014, 05:22 PM

Quote:

Originally Posted by Foxrider64

Is the line an actual fuel line or did someone at some point put another kind of hose on there?

Does the hose feel flexible or is it stiff?

What kind of clamp do you have holding the hose to the petcock?

It is not a common problem AFIK though.

as far as i can tell its actual fuel line, and the hoses were all replaced within the last 6 months if i remember correctly. either way if you look at them they are clearly not original hoses. ill go take some pics and post em.

NinjaDucky · January 3rd, 2014, 05:23 PM

Quote:

Originally Posted by DaBlue1

If you still have any OEM rubber hoses that carry fuel or fuel vapors, they should have been replaced a long time ago, given the age of your bike.

Good grade fuel line is hard to pinch and rupture. You should get some 1/4" fuel line (at any auto parts store) and replace all your fuel lines and make sure they are routed properly and not being pinched anywhere. If it is being pinched, it's improperly installed or your seat is the problem.

this is right at the nipple so its not a routing problem, as i cant reroute that part cause its made of gastank

Motofool · January 3rd, 2014, 05:25 PM

Quote:

Originally Posted by NinjaDucky

The far left or #1 line, oddly (and this worries me now) i dont have one in that #2 spot as in your photo...

..........

Is there anything to connect the non-existing #2 hose to?
If not, your tank cap has no drain for rain water.
That is what the attached picture shows.

Check the forward supports of your seat on the frame, you may be able to lift the seat by building up some those points.

NinjaDucky · January 3rd, 2014, 05:47 PM

Okay so here are the pics of the lines. i didnt know thats what that #2 spot was for, ill check but im sure its fine since ive had the bike out in the rain and it didnt run like it had watered down gas in it after. ill double check still anyway. prolly just doesnt have the hose there.

Motofool · January 3rd, 2014, 06:07 PM

If you don't correct the pressure of the seat on the tank, it could develop a leak from the tank over time.

This article explains the whole CA emissions system:
http://faq.ninja250.org/wiki/Hose_ro...ine_fuel_tanks

burnrich · January 3rd, 2014, 06:12 PM

Quote:

Originally Posted by alex.s

thats a good thing to know in case you bust a fuel line in the middle of nowhere

Yep that's an excellent point and I've now put a small roll in my toolkit just in case.

DaBlue1 · January 4th, 2014, 06:14 AM

Quote:

Originally Posted by NinjaDucky

....i sit too far forward on the seat it puts pressure against the line and pinches it between the nipple and the body of the seat and rips it..
.... id like to find a way to maybe protect it from being ripped at all. maybe carve out that part of the seat body? or some sort of hard protector/bumper/bushing thing that keeps the pressure from the seat body off of it?

Easy fix. Get a couple of super sliders and place them between the tank and seat. it should provide some clearance. Also check to make sure you still have the two rubber bumpers on the frame that sit under the front of the tank.

JohnnyBravo · January 4th, 2014, 11:21 AM

Bugger raby butter jumpers
Rubber baby buggy bumpers

January 3rd, 2014, 10:03 AM	#5
alex.s wat Name: wat Location: tustin/long beach Join Date: Sep 2009 Motorcycle(s): wat Posts: Too much. Blog Entries: 5 MOTM - Oct '12, Feb '14	i wonder how long ducttape would hold gasoline before the plastic disolved __________________________________________________

January 3rd, 2014, 10:18 AM	#6
TnNinjaGirl Ms. Personality Name: CB Location: Murvill, TN Join Date: Jan 2009 Motorcycle(s): Depends on the week you ask Posts: A lot.	/\ about 8 hours and the sticky dissolves, not the fiber/plastic/miracle tape
	2 out of 2 members found this post helpful.

January 3rd, 2014, 10:30 AM	#8
alex.s wat Name: wat Location: tustin/long beach Join Date: Sep 2009 Motorcycle(s): wat Posts: Too much. Blog Entries: 5 MOTM - Oct '12, Feb '14	thats a good thing to know in case you bust a fuel line in the middle of nowhere __________________________________________________

January 3rd, 2014, 06:07 PM	#14
Motofool Daily Ninjette rider Name: Hernan Location: Florida Join Date: Mar 2011 Motorcycle(s): 2007 Ninja 250 Posts: A lot. MOTY - 2016, MOTM - Dec '12, Jan '14, Jan '15, May '16	If you don't correct the pressure of the seat on the tank, it could develop a leak from the tank over time. This article explains the whole CA emissions system: http://faq.ninja250.org/wiki/Hose_ro...ine_fuel_tanks __________________________________________________ *Motofool* *.................................Never ride faster than your guardian angel can fly* "Mankind is composed of two sorts of men — those who love and create, and those who hate and destroy. Love is the bond between men, the way to teach and the center of the world." - José Martí

January 4th, 2014, 11:21 AM	#17
JohnnyBravo Certifiable nontundrum Name: Harper Location: NC Milkshake stand Join Date: Mar 2013 Motorcycle(s): 2013 SE NINJA 300 Posts: Too much. MOTM - Sep '13, Sep '16	Bugger raby butter jumpers Rubber baby buggy bumpers __________________________________________________

January 3rd, 2014, 03:48 AM	#1
NinjaDucky ninjette.org member Name: Sean Location: Buena Park, Ca Join Date: Nov 2013 Motorcycle(s): 2003 Kawasaki Ninja EX250r Posts: 32	fuel line under seat keeps rupturing on my 03 250 So my left-side fuel line keeps getting pinched and breaking right at the tank under the seat. Has anyone found a solution to this? Or am I the only one who has a leg that smells like a gas station?

January 3rd, 2014, 06:47 AM	#2
Foxrider64 Hello Moto Name: Alex Location: Ft. Myers Join Date: Mar 2013 Motorcycle(s): 1975 RD350; 2001 KX125; 2003 Z1000; 2003 KDX50; 2009 ZX6R; 2011 Ninja 250R; 2014 KX250F Posts: 352	Is the line an actual fuel line or did someone at some point put another kind of hose on there? Does the hose feel flexible or is it stiff? What kind of clamp do you have holding the hose to the petcock? It is not a common problem AFIK though.

January 3rd, 2014, 07:02 AM	#3
DaBlue1 Long Time Rider Name: Blue Location: Charlotte, NC Join Date: Sep 2010 Motorcycle(s): 2009 Kawasaki Ninja 250R Posts: A lot.	If you still have any OEM rubber hoses that carry fuel or fuel vapors, they should have been replaced a long time ago, given the age of your bike. Good grade fuel line is hard to pinch and rupture. You should get some 1/4" fuel line (at any auto parts store) and replace all your fuel lines and make sure they are routed properly and not being pinched anywhere. If it is being pinched, it's improperly installed or your seat is the problem.

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