Fuel line quick disconnect repair for 2003 1150RT

[DETOUR]

Hello to all,
I am a new member to this site. Unfortunately, I am short on time today to do a proper hello, but I have a dilemma that I was hoping to get some responses on today. I have a 2003 1150RT that has the infamous cheesy quick disconnects. They are now leaking and was wondering if anyone knows of an auto parts store that would carry a suitable, much better replacement. Also, if not, would a direct fuel line replacement be a suitable temporary fix or a permanent fix? The bike is in a bit of an inconvenient location so waiting on parts isn't a convenient option right now. I apologize because I am sure there have been many previous posts with this question, but all seemed to be older posts and thought there might be some new information. Thanks for any and all help. Will check back later.

[TomBarnhart]

QUICK FIX

Go to Home Depot or Lowes or any other well equipped hardware store. Buy some barb connectors and stainless band clamps. I think I got 3/8 brass fittings. Then head to the discount auto parts store and buy 1 foot or pressure rated fuel line, be prepared to spend about $12 or so a foot. (you only need 3 or 4 inches if you can get them to sell this amount). I think 5/16 most closely matches the 8mm line on the bike. Pull (a real bear of a job) or cut the factory crap out, instert the barb fittings, tighten the band clamps and live happily ever after. I seem to remember that the total cost for this fix came to about $7.00 for each by-pass I made. Do your friends a favor and make up a few spares for when their's fail on the road.

[Mika]

Welcome!

BeemerBoneYard ( http://beemerboneyard.com/fuliqudise.html) is where you will find them online. It is a good place for a variety of things.

A direct connect may be an emergency repair road side but I don’t think you would like it at all for the long term.

[selyab]

QUICK FIX

Go to Home Depot or Lowes or any other well equipped hardware store. Buy some barb connectors and stainless band clamps. I think I got 3/8 brass fittings. Then head to the discount auto parts store and buy 1 foot or pressure rated fuel line, be prepared to spend about $12 or so a foot. (you only need 3 or 4 inches if you can get them to sell this amount). I think 5/16 most closely matches the 8mm line on the bike. Pull (a real bear of a job) or cut the factory crap out, instert the barb fittings, tighten the band clamps and live happily ever after. I seem to remember that the total cost for this fix came to about $7.00 for each by-pass I made. Do your friends a favor and make up a few spares for when their's fail on the road.

Try to get everything at the auto parts store since there are hose clamps for instance that are made for use on pressurized fuel lines. Home Depot/Lowes never a first choice for hardware in my opinion. A decent auto parts store might have everything you need.

[DADODIRT]

It's probably just the little O rings that are getting worn.
You might be able to find some in local auto store.

[TomBarnhart]

Try to find an auto parts store that sells barb connectors!!!!!! Good Luck. While down on the road I had a friend take me to 4 chain parts stores. They all sent me to the Home Depot just across the road from where I broke down.
My fix was as permanent as it needed to be--2 years till I traded the bike.

[kenk]

Do yourself a big favor by removing both quick disconnects and simply replacing with high pressure fuel lines. There is ABSOLUTELY NO REASON for an R1150RT to have quick disconnects.

You're simply increasing your chance of part failure since its not if they will leak again, but when. Every time you disconnect one of these connectors, you run the risk of chipping the delicate o-ring seals or cracking the male end of the plastic connector. With the steel connectors, you won't crack the male ends. However, they increase the chance of chipping the o-ring. I use the steel disconnects on my GS. However, not my RT or LT. In order to remove your fuel tank on your RT, you have to first remove all the plastic that covers it anyway. There nothing quick about this process and there's no reason for quick disconnects.

[DETOUR]

I want to thank everyone for responding,I got my bike to a safer location and went ahead and ordered the metal connnectors from the Beemer Boneyard.Due to the somewhat mixed reviews from the posts I am not sure if I am doing the right thing by even putting them back on or going straight fuel line.Its not like I am removing the fuel tank every other day.I guess I would be more concerned about the continual flow of fuel if I got a leak riding with no way of shutting it off.Again thanks for the replies and any additional feedback is welcomed.

[kantuckid]

Try to find an auto parts store that sells barb connectors!!!!!! Good Luck. While down on the road I had a friend take me to 4 chain parts stores. They all sent me to the Home Depot just across the road from where I broke down.
My fix was as permanent as it needed to be--2 years till I traded the bike.


O'Reillys for barbs :thumb

[2BikeMike]

I want to thank everyone for responding,I got my bike to a safer location and went ahead and ordered the metal connnectors from the Beemer Boneyard.Due to the somewhat mixed reviews from the posts I am not sure if I am doing the right thing by even putting them back on or going straight fuel line.Its not like I am removing the fuel tank every other day.I guess I would be more concerned about the continual flow of fuel if I got a leak riding with no way of shutting it off.Again thanks for the replies and any additional feedback is welcomed.

Doing the right thing as you say, is doing what YOU think is best. Quick disconnects were made I assume, to aid in removing the fuel tank.

[Mika]

Doing the right thing as you say, is doing what YOU think is best. Quick disconnects were made I assume, to aid in removing the fuel tank.

+1

My opinion is just that my opinion based on my experience. I like quick disconnects and have used them in several different applications. My current BMW is a Roadster and we seem to have to take the tank off for all sorts of things. Doing the right thing is doing what you think is best with the best and most appropriate parts available to you.

[DETOUR]

Will all of the fuel in the tank leak out once the quick disconnect piece closest to the tank is removed or ?

[DrPaul]

Will all of the fuel in the tank leak out once the quick disconnect piece closest to the tank is removed or ?No. In addition to providing an easy way to disconnect both fuel lines (supply and return) they shut off all flow as soon as they separate. This feature is, in my opinion, the most compelling reason to keep them on the bike. Otherwise, one would have to either drain the tank (a major PITA) or rush around trying to plug each hose end with something to keep gasoline from gushing everywhere.

[DETOUR]

Dr. Paul,
Thanks for the response but I was actually asking about when I remove the quick disconnect to install a new one would all the fuel flow from the tank and based on what you are saying the answer is yes.Looks as though extra caution will be needed near the area that attatches to the hard hoses so as not to break them as well.

[John Brase]

You may get a dribble of fuel when you remove the QD fitting but it won't let the whole tank drain out. As long as you don't turn the key on and run the fuel pump. Don't do dat!

John

[DrPaul]

Dr. Paul,
Thanks for the response but I was actually asking about when I remove the quick disconnect to install a new one would all the fuel flow from the tank and based on what you are saying the answer is yes.Looks as though extra caution will be needed near the area that attatches to the hard hoses so as not to break them as well.Oh, sorry! You might not have a lot of fuel leakage but I would have something handy to plug the line (I have a large Craftsman Phillips head screwdriver that works well for this).

[Lee]

Oh, sorry! You might not have a lot of fuel leakage but I would have something handy to plug the line (I have a large Craftsman Phillips head screwdriver that works well for this).
You can also use a foam ear plug or pinch the fuel line somehow. Vice grips with something on the jaws to protect the fuel line. On one of our K1200RS I used a cheap plastic pump to suck the gas out of the gas tank. On one bike I let the fuel run out of the tank through the fuel line into a 5 gallon gas can. I guess the R1150 is different than a K1200 because I had 4 to 5 gallons that was more than a dribble.
For future use save the male end from one of the plastic disconnects. Attach this to a short section of fuel line, then you can snap this into your new metal disconnect and have a clean easy way to drain your gas into a gas can if you need to. This is nice if you need to change your fuel filter or just want to make the tank lighter when you lift it off for service.

[Lee]

I forgot the picture.

[JimMoore]

They sell fuel line clamps at the local Pep Boys.

[DETOUR]

This is just a quick update to my quick connect issue.Got it done yesterday and appreciate all the advice.I went ahead and disconnected from where it attatches to the hard fuel line.I loosened the clamp and then very carefully used a exacto knife to cut the line off. I then made a new short fuel line with the disconnect already clamped to it.I beleive it made it much easier to get it all put back on as its not easy getting them on and I did not want to stress the hard fuel line anymore than I had to.Its quite the pain getting them of without ruining part of the fuel line or torquing on that hard line.Overall fairly simple simon stuff but a pain in arse due to big hands in small spaces.Anyways thought the concept of having it somewhat put together and connecting to the hard line might help someone out in the future.I feel quite sure it made it easier for me.Thanks again for all the advice.

[DrPaul]

For future use save the male end from one of the plastic disconnects. Attach this to a short section of fuel line, then you can snap this into your new metal disconnect and have a clean easy way to drain your gas into a gas can if you need to. This is nice if you need to change your fuel filter or just want to make the tank lighter when you lift it off for service.Brilliant! Then again, I'm easily impressed ... ;)

[Acejones]

Thats one of the problems with these well engineered bikes; they are so delicate.

[escondido]

I liked the barbed coupling idea with fuel injector hose clamps. I discovered at Lowe's they had in the plumbing section a full selection of PEX connectors. these are designed for plumber would rather go plastic instead of copper fittings. The brass coupling has flat ridges on the O.D rather that the sharp barbs. My thought was it would facilitate and easier removal of the fuel lines with the ridges rather having the barbs.

[Kaltzg]

Hello to all,
I am a new member to this site. Unfortunately, I am short on time today to do a proper hello, but I have a dilemma that I was hoping to get some responses on today. I have a 2003 1150RT that has the infamous cheesy quick disconnects. They are now leaking and was wondering if anyone knows of an auto parts store that would carry a suitable, much better replacement. Also, if not, would a direct fuel line replacement be a suitable temporary fix or a permanent fix? The bike is in a bit of an inconvenient location so waiting on parts isn't a convenient option right now. I apologize because I am sure there have been many previous posts with this question, but all seemed to be older posts and thought there might be some new information. Thanks for any and all help. Will check back later.

I have used these brass quick disconnects for 5 years with no leaks, no drips, and very rugged. Still, my on bike tool kit contains 2- 5/16” hose barb connectors from a local auto supply just in case.
21375

I just ordered a set of two for a friend. $27.00 total including shipping.

Here’s a link
http://www.smallparts.com/Single-Shut-Off-The-female-side-of-the-coupler-has-a-shut-off-check-valve-to-prevent-fluid-leakage/dp/B0015HQ6V4?ie=UTF8&pf_rd_r=1M9ZWRKEN3WFHXN0PERQ&pf_rd_m=AIUBT5HP6PMAF&pf_rd_t=201&pf_rd_i=B0015HQ6V4&pf_rd_p=449915301&pf_rd_s=left-4

[softshoes]

All,

Thanks for the tips. I just did my first repair on my "new" R1150RT. I started the bike last week and found a fairly rapid fuel leak on the right cylinder head. I tend to like the factory setup, so I ordered the metal quick disconnect units from the Boneyard (http://beemerboneyard.com/cpcqkdiscon1.html). Thank you all very much for the links. Of course I ordered the QDs before I checked for the source of the leak...

Once I got the QDs, I pulled the body panels and found the fuel was leaking from the output line of the fuel pump, not the QDs. Right where the hose was clamped. So I ended up replacing all the fuel line and clamps using parts from Napa: H-205 and 705-1225 (8x13mm FI line and 13-15mm FI clamps). I think the clamps are a bit big as you can see in the photo. They had quite a bit of thread left over once tightened. I managed to make sure that none of the sharp bits or threads on the clamps touched any fuel line. The picture makes it look like the clamp thread is touching the line. The photo is not so good because I was taking it to record the frame number and not the fuel line job. Next time I will take more pictures.

I siphoned the tank and pulled it out. That is a very clever design using the same rubber bumpers as the seat. Fuel QDs, one electrical connector and two vapor lines. Really easy to get the tank off.

The old plastic QDs were ready to be replaced anyway. One of them pretty much came apart in my hands. I managed to save a male plastic QD from which I made a drain hose to drain the tank in the future. The return line (I think it is the return line) to the tank will free drain when open. The supply line will not free drain. Very handy to have a three foot length of hose with a single male QD to drain the tank if needed.

Thanks for all the posts everyone. Made the job easy and most importantly gave the confidence to just do the work. I almost had it hauled off to the dealer.


Best,
Dean