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How to Diagnose and Repair a Broken Lawnmower Fuel Line – Part 3

Bob Jackson
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by Bob Jackson

How to Diagnose and Repair a Broken Lawnmower Fuel Line – the new Tygon fuel lines are installed in the gas tank. This repair is continued from How to Diagnose and Repair a Broken Lawnmower Fuel Line – Part 2.

Tygon® Lawn Mower Fuel Lines

My local Gravely dealer said he’s seen a lot of deteriorated intake fuel lines and had just gotten this new fuel line kit, Mfg. Part #59207200 for about $30. The new fuel lines are Tygon® F-4040-A that are designed to resist swelling and hardening in gasoline and other fuels. Gravely is obviously is aware of the problem with the original fuel lines is offering this repair kit with everything you need – fittings, Tygon tubing and grommets.

Tygon Fuel Line Kit 59207200 - Gravely ZT1640 Lawn Mower
Tygon Fuel Line Kit 59207200 – Gravely ZT1640 Lawn Mower

Here’s the new Tygon F-4040-A fuel lines compared to the original deteriorated and cracked fuel line:

Tygon® F-4040-A Fuel Lines vs Original Fuel Line
Tygon® F-4040-A Fuel Lines vs Original Fuel Line

A closeup of the Tygon brand marking on the new fuel line.

Tygon® F-4040-A Fuel Tubing
Tygon® F-4040-A Fuel Tubing

Lawn Mower Gas Tank Fuel Line Installation

Insert the fuel line into the tank – the end with the brass fitting and filter screen goes in first. Look inside the gas tank to see that the line is guided to the “deep” or “far end” of the tank and doesn’t coil up.

Installing the New Tygon Fuel Line - Gravely ZT1640 Lawn Mower
Installing the New Tygon Fuel Line – Gravely ZT1640 Lawn Mower

Slide the orange rubber grommet up the fuel tube until it almost meets the brass band as shown:

Adjust the Rubber Grommet
Adjust the Rubber Grommet

Press and seat the orange grommet into the fuel tank hole. Use only your fingers – do not use a screwdriver or other tools to avoid damaging the grommet.

Insert the Rubber Grommet into the Fuel Tank Sidewall
Insert the Rubber Grommet into the Fuel Tank Sidewall

Push/press the fuel fitting into the grommet until seated as shown. Be extra careful to press straight in on the square head of the fitting. You risk breaking the 90 degree nipple if you press on it.

It took a bit of effort to press in the fitting, don’t be in a hurry. Consider wearing gloves if it digs into your palm.

Fuel Line Fitting Fully Seated in the Grommet
Fuel Line Fitting Fully Seated in the Grommet

Push the black exterior fuel line onto the fuel fitting and secure with the wire hose clamp. Inspect the yellow Tygon fuel line inside the tank with a flashlight to verify it’s laying in the deep end of the gas tank.

Tygon F-4040-A Fuel Line inside the Gas Tank
Tygon F-4040-A Fuel Line inside the Gas Tank

Screw on the gas cap and reinspect your work.

Finished Job - New Tygon Fuel Lines - Gravely ZT1640 Lawnmower
Finished Job – New Tygon Fuel Lines – Gravely ZT1640 Lawnmower

Repeat the procedure for the other fuel tank.

This repair is continued in How to Diagnose and Repair a Broken Lawnmower Fuel Line – Part 4.

Take care,

Bob Jackson

59207200air cleanerBriggs & Strattonbroken fuel lineclogged fuel line
Bob Jackson
Bob Jackson
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