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September 18th, 2019, 09:39 AM   #1
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I Ride: 2008 FE 550
Wiring and hoses near exhaust on FE550

Hello all,

As the rebuild is almost done, I noticed as I was running the motor for a minute or so that I had melted the carb vent hoses, as shown below.

Those hoses are just PVC or polyurethane (I can't recall which) to replace the old ones. I think the temp rating is only around 70C.

I might play with routing to get a bit further away from the exhaust, but I'm concerned about the starter relay wiring even more so, as that's harder to replace.

So my questions are:

1) How to pull that wiring away (the cable is a fixed length, not much I can do with it)

2) What hose material would folks recommend for those hoses? I can readily source 1/4" OD // 1/8"ID fuel hose, that is rated to 120C. But that's black, and I'd rather have something clear or at least translucent so see blockages and general dirt.

Thanks very much, everyone.

c
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Wiring and hoses near exhaust on FE550-img_0286.jpg  

Last edited by canadius; September 18th, 2019 at 09:47 AM.
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September 18th, 2019, 11:40 AM   #2
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You have the start relay mounted backwards
There is a bracket that holds the carburetor drain lines out of the way have a look for it in the parts book
Wiring and hoses near exhaust on FE550-pc070001.jpg

Wiring and hoses near exhaust on FE550-pc070002.jpg
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September 18th, 2019, 11:58 AM   #3
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Feed the lines thru this bracket and pull them tight and they will be away from your exhaust

Frank
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Wiring and hoses near exhaust on FE550-hberg.jpg  
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September 19th, 2019, 11:08 PM   #4
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Thanks all.

Yes, I have that bottom retaining bracket by the swingarm - but hadn’t noticed the relay was backwards.

Found a supplier for the correct hoses, and since they’re softer, they bend more readily and are less bulky than the PVC hoses.

Looks like I’m sorted now. Thanks!

C
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September 20th, 2019, 04:37 PM   #5
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Those carb hoses are expensive .......I burnt mine like you as I did not thread them through the wire protector. I cut the burnt bit out and joined them up again with small cheap reticulation joiners.
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September 20th, 2019, 04:48 PM   #6
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Originally Posted by fe600racer View Post
Those carb hoses are expensive .......I burnt mine like you as I did not thread them through the wire protector. I cut the burnt bit out and joined them up again with small cheap reticulation joiners.
Interesting. I just measured the total linear length of the five hoses, went my to my local KTM dealership, and bought 10 of the pink carb hose they sell in bulk.

Cut them to match the old ones, and put them on, with carb on bike. Each took about a min to flare the end with a heat gun and wriggle them on. Job done in half an hour, with all my usual fussing, heat shrink in certain areas, etc.

Was easy, and cost me about $1.40 a foot.
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September 21st, 2019, 07:35 AM   #7
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That's good I was quoted ten dollars a foot from carb distributor so it shows you what happens.....your price sounds what it should be!
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