Fuel Line Broken

[Russ]

I need to replace my fuel line.

This junky fuel line I installed this year pulled apart when I tugged on the end. Closer inspection shows it had a lot of cracks. I'm glad it pulled off when I was winterizing and not out on the water.

This was a premade fuel line I got off Amazon. Had good ratings, but it didn't last ONE stinking season.
So now I'm thinking I shouldn't buy a premade fuel line and just buy some better grade fuel line hose and make my own.

Can I use automotive-grade fuel line or do I need something else? What do you smart folks recommend?
I believe the UV from the sun did this hose in.

[NiceAft]

Or, you can replace it, and carry a spare to be kept below with all of the other duplicate stuff.

[Gotro]

On my I replaced my fuel line with automotive fuel line and it works fine . The problem I am having this time is my squeeze ball I purchased from Tohatsu Macanic . It locks up and does not let fuel pass to the motor to start or run. The one before this squeeze ball I purchased from academy it only later a year.

[Russ]

Or, you can replace it, and carry a spare to be kept below with all of the other duplicate stuff.

I have a spare. The original came with the boat, and it is in fair condition. I keep it handy and ready to install if I need to.

The "NEW" fuel line I cut to install the Raycor filter/water separate in the middle. Didn't last a season.

[Russ]

On my I replaced my fuel line with automotive fuel line and it works fine . The problem I am having this time is my squeeze ball I purchased from Tohatsu Macanic . It locks up and does not let fuel pass to the motor to start or run. The one before this squeeze ball I purchased from academy it only later a year.

That was my thought. I replaced my Seadoo fuel lines with nice heavy automotive fuel lines. Much thicker than the flexible one that broke. However, it was not subject to UV light which I think destroyed this one.

My original (came with the boat) fuel line has a very hard squeeze bulb. Hard to get it started. The "NEW" line has a nice squeeze bulb. So I may keep that and replace the hose bits with actual fuel line from an auto parts store.

[socalmacer]

On my 1996 , I am on only my second fuel line with fittings and bulb since new. There wasn't a problem with the original I was just a little concerned with the age 16+ years when I replaced. The only difference is I purchased from the outboard manufacturer - Honda when I replaced. I am still using the original six gallon Honda fuel tanks which show now sign of leaks or cracks. I am definitely going to keep this in mind when I purchase these parts in the future and replace the outboard at some point. I have kept the boat covered since new which I'm sure has helped extend the life. From an engineer perspective, this is NOT the part I would be looking to save money on.

[Russ]

From an engineer perspective, this is NOT the part I would be looking to save money on.

No doubt that was my problem. Buying from a sketchy seller on Amazon. Same thing happened with a fuel filter leak. I should learn.

[Starscream]

Agree, no doubt. I also once purchased fuel hose from Amazon and it was a disaster, leading to a long engine-less sail home. I also bought a fuel valve off of Amazon that I had to return because of $#iTTY quality. Lesson learned: no fuel accessories from Amazon, period.

Buy a quality product like this: https://www.entrepotmarinemart.com/en/f ... pi315-0380 from a marine store. It's super-easy to make your own lines and fittings.

You can buy a PEX tube-cutter from Amazon: this one works fine: https://www.amazon.ca/Pex-Tubing-Cutter ... hdGY&psc=1

You can also buy fuel line crimping tool and crimps like this: https://www.amazon.ca/BeiLan-Stainless- ... C85&sr=8-6

but I recommend using normal stainless pipe clamps with the hex-head screw tightening mechanism.

[LordElsinore]

Same experience. The original from my 2012 is still going strong. The 'pre-made' one I bought off Amazon last year to add a fuel filter fell apart over the winter even while covered up from the sun.

[Russ]

Agree, no doubt. I also once purchased fuel hose from Amazon and it was a disaster, leading to a long engine-less sail home. I also bought a fuel valve off of Amazon that I had to return because of $#iTTY quality. Lesson learned: no fuel accessories from Amazon, period.

Buy a quality product like this: https://www.entrepotmarinemart.com/en/f ... pi315-0380 from a marine store. It's super-easy to make your own lines and fittings.

You can buy a PEX tube-cutter from Amazon: this one works fine: https://www.amazon.ca/Pex-Tubing-Cutter ... hdGY&psc=1

You can also buy fuel line crimping tool and crimps like this: https://www.amazon.ca/BeiLan-Stainless- ... C85&sr=8-6

but I recommend using normal stainless pipe clamps with the hex-head screw tightening mechanism.

Thanks for the links. I will order a proper fuel line from them. It makes no sense to cheap out on such a critical piece of hardware.


I have that Pex cutter tool.
I also have that crimper tool and clamps leftover from a lawn sprinkler project.
However, I agree that I much prefer old school hex head screw hose clamps.

Interesting that I'm not alone in poor-quality Amazon fuel lines.
In fact, this is my SECOND Amazon fuel line. The first one (Seachoice branded) disintegrated from the inside out and I NEVER use ethanol gas.
The hose crumbled and had some icky stuff inside that no doubt flowed into my fuel filter.

[OverEasy]

Hi Russ!

Sheeze! You weren’t kidding about the fuel line splitting!!!

Haven’t had that happen as yet…a crack and leak yes but not a split like that.
That could have been a real disaster!

When we modded our fuel system we got our fuel hose from the local West Marine store.
We’re on our third year now and I’m a little concerned. It was the best they had from a limited selection choice. It looks a lot like yours from the outside appearances……

My neighbor in SC is retired a Retired Chief Petty Officer who specialized in watercraft.
He mentioned that I’d be prudent to change out from the grey jacket lines to something more robust.
Black marine fuel grade flex lines are what we’ve been aiming at except that the black rubber tends to mar onto white surfaces with sun exposure and foot traffic. To mitigate that I’m thinking about oversleeping with white Teflon heat shrink and/or braided nylon anti chafe socking. It’s one of the Spring 2025 Projects on the list.

Thanks for sharing this as I doubt you’re alone with this problem.

Best Regards,
Over Easy