Worked a little bit on the bike tonight. After getting some 1/4" fuel line at a local auto parts store, I bought the Oetiker clamps and pliers from McMaster-Carr. We use these guys all the time at work and I cannot recommend them enough. Bought the stuff yesterday morning online, it arrived today, a whopping $6 shipping charges.
Also got Colder Products (CPC) chrome-plated brass quick-disconnect with built-in check valves. The stock plastic one has a hairkine crack that allows it to be continuously wet with gas (although not enough to let it drip). No valve in the stock one either, so when you disconnect it, the entire tank drains out. I wonder how many guys have been caught out by that?
Anyway, part numbers (McMaster) were the following:
5478K419 (Male QD w/valve) $11.51
5478K229 (Female QD w/valve) $17.14
6541K69 (Oetiker pliers) $29.85
5254K73 (20mm clamps for oil change) $10.61 for 25
5254K52 (12.7mm clamps for fuel lines) $8.93 for 25
The downside of haveing the valves is that if I ever do have to drain a tank again, I have to remove a clamp from the throttle body, the upside is I can remove the tank without having to drain it.
1) McMaster parts
2) Old fuel line crusted with gasoline varnish (it used to be white)
3) Draining the tank which took forever as it dribbled out of the return line
4) My new hose and fittings (I just cut the hose to length once the old stuff was off and tank drained)
5) Everything installed and ready to pressure test. No leaks so it appears!