Replacing Bassa fuel lines

[nwguy]

I plan to replace the fuel filter and fuel pump on my 99 Bassa. Someone advised replacing the fuel lines too. I suppose at 66k miles and 26 years that makes sense, and since I have the tank and body parts off. Maybe someone could help me determine what parts to buy for this. Parts diagram shown below. Besides the filter and pump I'm guessing I'd need these too.

#  Qty Guzzi #   Cost   Desc
------------------------------
22 1   30108770  $128  Fuel pipe https://cadrecycle.com/product/fuel-hose-3/
7  1   03106500  $27   Per 5' fuel pipe, replace with SAE30R10 in braided steel
18 2   12157900  $4    Clamp
9  1   30106170  $24   Fuel pipe  (cheaper alternative?)
8  6   93305017  $1    Clamp
11 1   18161150  $3    14.5mm crush washer
24 2   12006400  $1    Aluminum seal washer, 12mm ID
15 1   30108270  $26   Fuel pipe
21 2   12154200  $1    8mm alu washer
19 1   30108070  $?    Fuel pipe, can't find info on this, what ID?
25 3   28157950  $3    Clamp 12.25mm

Is this overkill or could some hoses, clamps or washers be reused? Anything cheaper for the $128 fuel pipe or other parts? What are the IDs of the fuel pipes? Buy generic fuel lines and clamps from NAPA?

[marcmorrison]

Don't have any experience with the fuel pipe hose, but since it's 25 y.o. rubber, it deserves an examination (and maybe I should do the same thing).  That price for a new fuel pipe would prompt me to look at some alternatives (perhaps taking the metal fittings to a hydraulic hose shop and have something made up).  As far as the braided steel fuel line, I've found cutting/working with this stuff is a PITA....I just went with ethanol resistant fuel hose (nylon braided)...about 7/16" or 11 mm I.D.  Good luck!!

[John A]

You can get the lines at Napa, I don’t remember the sizes but get fuel injection rated hose and clamps if you need them

[guzzisteve]

SAE30R14 is what I used in both sizes 5/16-8mm and 11mm same grade, used the metal mesh on stock line on the new one.

[John A]

If I remember right, the hose from the fuel filter has a crimped banjo fitting. I cut it off and use a hose clamp on the fitting.

[nwguy]

If I remember right, the hose from the fuel filter has a crimped banjo fitting. I cut it off and use a hose clamp on the fitting.

You can do that? It's safe?

[guzzisteve]

I cut hoses off the fitting on fuel pressure regulator & took fitting to hydraulic hose maker with the hose to install & they crimped on the new hose, 3 cents for each band crimped on. CHEAP  I gave them a $20 bill for the job, they didn't want to charge anything to do it.

[John A]

You can do that? It's safe?

It depends on the skill and judgment of the person doing the work. If there is any question, don’t do it. Do what Steve suggested. My hose shop didn’t have a crimper small enough so it’s what I did .

[Antietam Classic Cycle]

Use good quality clamps, and you'll have no problems. For the 5/16" hose, I use these "fuel injection clamps": https://www.mcmaster.com/53175K86/ and on the larger hose I use "Norma" s.s. clamps: https://www.mcmaster.com/5076K13/

[kingoffleece]

Not to dish anyone, but why would you not use clamps designed for the job.  What's the upside and downside on using/not using the proper item?
For me at least, that's the very definition of needless risk.

But then again, as a former professional SCUBA instructor trainer I've seen people do all kinds of stuff.  Sometimes you get away with it.

[DoubleGuzzi]

These days, I've finally got around to using single-ear clamps, rather than Jubilee (worm drive) clips, for fuel lines. In the past, I've found bolt clamps better for a fuel tight seal, than Jubilees.

[pehayes]

I own two 98EV and found this issue on both of them.  This applies to '98, but might extend to '99.  YMMV.  Most of the hoses involved are assembled to the frame before it gets an engine installed.  Those hoses all come from one roll supply.  The engine is assembled at a different location and the final three hoses are attached to the engine at that assembly. Thus, when the engine is married into the frame those final three hoses come from a different supply roll (maybe different manufacture?).  The fuel hoses on my bikes seem to be good for life.  Except the final three short pieces which all come together in the "Y" splitter #27 in your diagram.  Those three pieces had quite numerous surface cracks and eventually burst through to piss fuel.  Inspect carefully.  You may not need everything replaced.

Patrick Hayes
Fremont CA

[nwguy]

Interesting info Pehayes.

Looks like you need a special tool for those single-ear clamps.

[DoubleGuzzi]

Interesting info Pehayes.

Looks like you need a special tool for those single-ear clamps.

Yup, cheap enough from China Ali. I used mine just a few days ago, when bypassing the V7 check valve.
Example from allgedly closer to home: https://www.ebay.com/itm/296797047879?_skw=single+ear+pliers

[Antietam Classic Cycle]

Guzzi themselves used worm-drive stainless steel hose clamps (like I linked to), at least on the '99-'00 Jackal. Later models may have used the Oetiker type clamps.

[twowings]

Oetiker clamps FTW!

[DoubleGuzzi]

Oetiker clamps FTW!

Seems like my posts are being ghosted, again. 

[n3303j]

I use both single ear clamps and worm drive clamps. I sort of look at the bike and try to figure what I might have to disconnect if I have an on road failure. Those locations get clamps that can come and go with a screwdriver.

[nwguy]

Can anyone post a link to a place that sells 7/16" ID fuel hose rated for fuel injection? I've been searching the web for at least a half hour and can only find 7/16" hose hose rated for 35 psi, or higher rated hose at smaller diameters. None of my local or distant auto parts stores stocks it. I understand EV 1100s typically have 3 bar (45 psi) pressure. I've searched for SAE30R14 7/16" fuel hose. Gates makes a Barricade hose rated for 225 psi, but I can't find it in 7/16".  Their Safety Stripe hose is only rated for 35 psi. The original braided stainless steel hose is discontinued, and was $96 at Harper's.

[DoubleGuzzi]

Try searching for 11mm instead.

[n3303j]

Can anyone post a link to a place that sells 7/16" ID fuel hose rated for fuel injection? I've been searching the web for at least a half hour and can only find 7/16" hose hose rated for 35 psi, or higher rated hose at smaller diameters. None of my local or distant auto parts stores stocks it. I understand EV 1100s typically have 3 bar (45 psi) pressure. I've searched for SAE30R14 7/16" fuel hose. Gates makes a Barricade hose rated for 225 psi, but I can't find it in 7/16".  Their Safety Stripe hose is only rated for 35 psi. The original braided stainless steel hose is discontinued, and was $96 at Harper's.

Save your money. The 7/16 line runs from the tank to the pump. It is gravity fed and may be in suction if the tank filter plugs up. It's not under pressure beyond a few ounces due to gravity.
Just replaced mine 3 weeks ago. O'Reilly's had it in stock.

[nwguy]

I should have realized this. Thanks.

[guzzisteve]

I got all my hose from RockAuto and enough to do 2 EV's, mine & another, mine is done. 5/16 line was 10ft per bike & 7/16 was 2' per, I got 5'
I got enough for 2 cause that's what I do, fix & replace for those that can't do.

[n3303j]

I got all my hose from RockAuto and enough to do 2 EV's, mine & another, mine is done. 5/16 line was 10ft per bike & 7/16 was 2' per, I got 5'
I got enough for 2 cause that's what I do, fix & replace for those that can't do.

10 Foot 5/16" per bike! Sounds like you kept all the vapor control system?

Pump to filter, regulator to "Y" connection, "Y" connection to injectors and your 5/16 high pressure lines are done. Filter to regulator is pre-made. Regulator overflow is low pressure pre-made.

[guzzisteve]

Only the tipover valve. I also changed the return line, all of it. The next year I changed all my brake lines to stainless. All good for another 27yrs
My newest bike I'll ever own.

[nwguy]

My fuel injection rated clamps should arrive in the next couple of days. I have all the line material now and have put the braided metal sleeve over the 7/16" diameter line leading from the tank to the fuel pump. I now realize I had the wrong fuel system diagram shown earlier. This is the correct one for my Bassa:





Fortunately the banjo fitting at the fuel filter has two barbed outputs that will take hose clamps. After reading about petcock valves, I'm thinking I should just get a new one even though the existing one may only be a year old.

Have been reading about fuel pressure regulators. Mine's the kind that fits on the underside of the fuel tank, part #29112760 which seems to be no longer available. Wondering if I should worry about it, but I'd like to do everything I can and should do before putting the tank back on again. MG Cycle says this one is applicable:

https://www.mgcycle.com/index.php?main_page=product_info&cPath=30&products_id=5046

Will it? Pricey.

[guzzisteve]

You will like this book it is same as what you have accept the ECU, the rest is what you have--------------------------------------------

https://www.thisoldtractor.com/mg_manuals/workshop_manual_electronic_ignition.pdf

[nwguy]

You will like this book it is same as what you have accept the ECU, the rest is what you have--------------------------------------------

https://www.thisoldtractor.com/mg_manuals/workshop_manual_electronic_ignition.pdf

Thank you!

[nwguy]

A question on the vent lines. See pic 1 below. The Y has a drain tube to lower regions of the frame. I don't remember exactly where the other two tubes coming off the Y go. I'm pretty sure they go to 2 fittings on the under side of my fuel tank (see pics 2 and 3). I don't suppose it matters which branch of the Y goes to what fitting since they both go to the drain line. Can someone verify this before I cut tubing? Thanks in advance.