Failed Fuel System

[jetmechmarty]

I spent most of my last off days getting my bike back together. (along with everything else I had to do) On my last day, I got a little ride in. Everything was fine. Because of a SNAFU at work, I ended up at home on Sunday. I took a nice long ride with my wife. We pretty much rode most of the day.

Now, I am away for work and I won't get home for three weeks. My wife and daughters are home and the house smells like gasoline. I had my daughter check and make sure the cocks were off. They were/are off. I talked her through pulling the drains on the carb bowls. All were full. She said there was a lot of gasoline in them. That was yesterday, and all was fine after draining. Tonight the house stinks again and two of the carburetors are full of gasoline.

I just had the carburetors out and I did not replace the needles & seats because I had the wrong ones. I replaced the "octopus" valve several months ago. So, I apparently have a failed petcock, failed octopus, and failed shutoffs in the carburetors.

I'm fed up with the whole thing! I need to fix it right.

Does one of these adapter plates fit my Special?
Pingel adapter plates

Will this petcock fit with that adapter?
Biker's Choice fuel valve

I didn't think this stuff up myself. I'm not that clever.
Budget XS650 Universal Petcock and Adapter

The biggest problem is how I'm going to cure this temporarily with just the women at home. None of them likely would be able to even remove the seat. It's not a good situation.

I know I need four of these as well:

[bikerphil]

Might want to have them push the bike outside so it doesn't further stink up your house, JAT. Hard to believe that all of those failed at once.

[jetmechmarty]

Might want to have them push the bike outside so it doesn't further stink up your house, JAT. Hard to believe that all of those failed at once.

I don't think they can get it off the centerstand without dropping it. I might have to send the mechanic that works on my cars over there.

It's possible that one of the valves is leaking out the "PRIME" port, therefore, bypassing the "octopus".

[Danny Crawdad]

Can they just clamp the fuel lines right before they enter the carb? You may have to replace some fuel line, but a pair of vice grips on the line going into each fuel inlet would fix it in the interim, wouldn't it?

I haven't had the octy on my bike in a while, so I may be seeing things wrong in the ol' headbone.

[jetmechmarty]

Can they just clamp the fuel lines right before they enter the carb? You may have to replace some fuel line, but a pair of vice grips on the line going into each fuel inlet would fix it in the interim, wouldn't it?

I haven't had the octy on my bike in a while, so I may be seeing things wrong in the ol' headbone.

That will work if we can figure out what line it is and figure out how to operate visegrips. These women are "book smart", but couldn't fix anything if their life depended on it. To be fair, my daughter is interested, and may get us through it. Thank you for the Vise Grip tip!

[jetmechmarty]

For those of you who have had the Special petcocks apart, is the leak more likely the "ON" port, or the "PRIME" port. This is with the valve in the "OFF" position.

[Rasputin]

For those of you who have had the Special petcocks apart, is the leak more likely the "ON" port, or the "PRIME" port. This is with the valve in the "OFF" position.

That makes sense as the petcock would of course reduce the options of where the leak is. Any line after the off position on the petcock could/would be suspect.

[crazy steve]

Does one of these adapter plates fit my Special?
Pingel adapter plates

Will this petcock fit with that adapter?
Biker's Choice fuel valve

I'm sure one of those adaptors will fit, but $27.50 each??? If I were going down that road, I'd make my own. For a bit less, you could make your own (about $35) if you get some 1/2" x 1" stainless bar stock (McMaster-Carr # 8992K861), some 1/16" thick viton rubber for a gasket (86075K22), and a 3/8" NPT tap (2525A114).

That petcock will fit the adaptor, but will it fit your bike? With that 'down' outlet, I'm not too sure that would clear a stock airbox. Pods, no problem, stock I wouldn't try it without getting a measurement. You can get this style in a 'right' outlet, but no left. If you're willing to spend a few more bucks, you can get a lower-profile type in a left/right configuration, look here: http://www.jpcycles.com/product/7200...en=15890050770 ...and here... http://www.jpcycles.com/product/7200769. You might also want to look at this one: http://www.jpcycles.com/product/720-945 . This one will require a custom adpator, as it uses a 1/4" NPT instead of 3/8".

But you've got a Special, why not just rebuild the stock petcocks while converting them to manual? Less money, far less hassle....

[Lonerider62]

I would hire (if I had to) someone to get the bike out of the house before you have to explain to your insurer why the gasoline from your motorcycle caused the house fire. Then fix the thing yourself when you get home vs having the wife/kid try to deal with it. There are too many variables out there when it comes to those fuel petcocks to waste a bunch of time and money trial and erroring it.

[Aches n Pains]

I put a Pingel petcock on my KZ1000 and it's not a big deal. May have to file a very little bit on the tank where the Pingel fits. KZ has a single petcock so the economics worked.

On my XS11 I took out the octy and replumbed the system with a shutoff in the line from each petcock.

http://www.amazon.com/Briggs-Stratto...d_sim_sbs_lg_1

Cheap and easy fix that seems to be foolproof (haven't had any problems with the shutoffs). You can either plug the Prime outlets on the petcocks or run a line fuel between the primes on both petcocks. Run the line from each petcock to an "X" fitting and on the other side of the X run a line to 1/2 and 3/4 fuel sources on the carbs. As a note, I have also swapped out the air box for pods which makes this type of mod a bit easier.

[81xsproject]

For like $5 you can buy motion pro in-line valves. Easy, simple, way more reliable....

Okay, correction. They went up a bit since I last saw them, but here's one for $10 http://www.z1enterprises.com/Inline-...Barb-2866.aspx
here's one for $15 http://www.z1enterprises.com/Inline-...Line-3290.aspx

[jetmechmarty]

Brent rode up to my house tonight and handled the problem. I can rest easy until I get home in a few weeks. I'm lucky to have friends like him!

[Brent]

now safe

I would hire (if I had to) someone to get the bike out of the house before you have to explain to your insurer why the gasoline from your motorcycle caused the house fire. Then fix the thing yourself when you get home vs having the wife/kid try to deal with it. There are too many variables out there when it comes to those fuel petcocks to waste a bunch of time and money trial and erroring it.

I removed tank and capped petcock disharges with short pieces of fuel line. Tank is now outside under cover hill. No detectable leak now, but if it should occur, Fumes will go downhill away from house. Easy enough, but removing the seat...NOT for a wife & daughter wrenching alone for the first time with sense of urgency

Gas fumes inside are surely serious. Safe now.

[79XS11F]

Medical clamps on the fuel lines will do the trick unless the fuel lines are hard as rocks. They can be purchased at many places other then medical supply shops where they are very costly. I got an assortment of them at Princess Auto which is likely very similar to Harbor Freight. They were around 5 bucks a piece. They are handy to have in the garage for this sort of issue
Rob

[jetmechmarty]

My fuel lines were all replaced over the winter. They are already hard as rocks and have shrunk. I'm going to replace it with Tygon.