Leaking/Stripped Petcock Mounting Bolt

[DAVINCI]

Holy carp, i just checked the the fiche....how stupid is THAT? They already had a design that worked, why did they have to go mess with it?

[cywelchjr]

Holy carp, i just checked the the fiche....how stupid is THAT? They already had a design that worked, why did they have to go mess with it?

For the same reason they put the octy on there when they had working vacuum taps that used only two hoses per tap to do the job the octy uses what? Eight hoses? Tank shape isn't it, my XS400 has the same tank shape and uses the same petcock as my 1100 (well, the same as the left side petcock anyways). And I know you have had lots of trouble with yours so converted them to manual, but my 400 petcock is the original and has still never been rebuilt and still works, 32 years later .

[DAVINCI]

Ok, now you've jinxed it, look for the puddle in the morning

[cywelchjr]

Ok, now you've jinxed it, look for the puddle in the morning

That would be pretty good being that the tank is currently dry. And before I put it back together and on the road I'll be rebuilding them along with everything else, I figure that even though they don't leak yet, at their age it's just a good idea when rebuilding the engine and all the rest as I do the restoration on the bike.

[Prothec]

... the octy uses what? Eight hoses? ...

When I picked up bulk fuel line at O'Reily when I still had the octy hooked up, they said, "this is for one bike??"
I think I picked up something like 7 ft to have a few feet left over. It adds up quick, though. I think I used a ridiculous 4+ ft when I added the inline filters.

Considering how many times I was removing and reinstalling carbs, I gave up on the octy for now. WAY too much fuel line to screw around with..

Some photos from my recent garage time:

[crazy steve]

...They already had a design that worked, why did they have to go mess with it?

Yeah, there's several 'WTF' engineering choices Yamaha made, this is one of them....

[skids]

The thread insert will STILL need some sort of seal against the original threads or it will also leak.

Naw! If the special is anything like the standard, there is an o-ring around the perimeter of the petcock and the bolts are sealed against leakage with fiber washers between the bolt flanges and the housings. (Don't use metal washers).

Oops, too little, too late. My comment was already covered!

[cywelchjr]

Naw! If the special is anything like the standard, there is an o-ring around the perimeter of the petcock and the bolts are sealed against leakage with fiber washers between the bolt flanges and the housings. (Don't use metal washers).

Oops, too little, too late. My comment was already covered!

The standard is not quite an o-ring, it's got a cross piece at both ends that seals the screw area from the fuel portion of the petcock, which the specials don't have, it's just an oval o-ring, so the screw is bathed in gas, so that washer does have to hold back the gas, unlike the standard where it only has to seal what might come down through the threads, so the teflon tape would work for standards, but not for specials.

[Prothec]

I finally got around to pulling that petcock with the leaking mounting bolt...

The following problems:

1. It was a bolt+washer combo, not a bolt with the collar
2. The bolt was stripped, not the hole

I put in a better bolt with collar. That's probably why the bolt was stripped. Someone probably kept tightening it to try to stop an inevitable leak from the wrong bolt.

I did buy a tap and die set and cleaned out the threads. I don't know how I ever lived without it!

http://www.harborfreight.com/60-piec...set-35407.html
Used a 20% off coupon from an Entertainment Book.