stock petcock

[oldyam80sg]

OK so I'm looking at my stock petcocks that were on my 80 SG taken off a long time ago.I am missing the washer(i think its fiber material)that mounts it to the tank.No filters either as they separated a long time ago.They turn nice and would look nice if they worked but how do i tell? Installing them on the tank is a no brainer as then i can see if they leak.Should i rebuild them as i never had to.Where is the cheapest place to get filters?And i looked on E Bay at georgefix but see no rebuild kits available.Everything appears to be working and the oblong O-ring looks in good shape.

[conquest87tsi]

I recently "rebuilt" the petcocks on my SF. They didn't leak when I had them on the tank, but I am going to paint the tank once it gets above 45-50 degrees around here so I thought I would check them out. What I did to test them was to move the selector to the different positions and blow through both outlets and ensure that I was only able to blow through the correct one. I.e. for PRIME I should only be able to blow through the rear one(or front, I can't remember now). Though my petcocks never leaked, I was able to blow through both outlets when on ON for one of the petcocks.

Upon disassembly I found that the rubber control "plate" had a nick in it that I concluded was allowing this. As both sides are identical I just flipped it. I then replaced the o-ring with a viton oring and reassembled and my problem was solved. I replaced the petcock to tank oval oring with a regular round oring. Pretty sure that is what the kits come with anyhow. I also tapped the prime outlet and screwed in a M5 bolt as I eliminated my octy. I of course had to disassemble to get all the brass out after I decided to tap it.

I really don't know of a place for the plastic filters. I'm sure someone else does. Mine were still good, but I did notice one was missing the little oval shaped cap on the bottom. Funny thing is that my filters from a parts bike were missing it on the same one.

[oldyam80sg]

OK i found the rebuild kits on E Bay from georgefix but they don't come with the oblong O-ring.Also the filter towers are not cheap-are they necessary?

[skids]

OK i found the rebuild kits on E Bay from georgefix but they don't come with the oblong O-ring.Also the filter towers are not cheap-are they necessary?

I have used regular O-rings for the perimeter of a standard petcock and have used fiber washers for the bolt seals. However, do not use a steel washer or lock washer in conjunction with the fiber washers or leakage will occur down the threads.

[crazy steve]

The filters are needed if you want to have reserve; without them, when you run out of fuel (no matter where the lever is pointing), you are out....

[conquest87tsi]

As Skids said a round oring will work for sealing to the tank. I believe that the large o-ring that come in the petcock kits are for this.

As far as a fiber washer for the bolts I don't remember seeing them. Are they necessary? Does anyone know or a supplier.

[brcree]

pets

Hey Old....yes the small fiber washers are needed. They go on the mount bolts. If you don't put them there it WILL leak! I found out the hard way.

[XS1100_OEM4ME]

Hardware store

As Skids said a round oring will work for sealing to the tank. I believe that the large o-ring that come in the petcock kits are for this.

As far as a fiber washer for the bolts I don't remember seeing them. Are they necessary? Does anyone know or a supplier.

You can get in most HW stores in the plumming section. Not made for gas, but mine haven't leaked in two years

[jetmechmarty]

3Y1-24514-00-00 for about $16 ea. That's for the tower or filter net.

The George Fix kit has the o'rings for mounting the petcocks.
XS1100 SPECIAL PETCOCK KIT

[oldyam80sg]

I guess that we use the bigger O-ring to mount it to the tank? I asked georgefix and he thinks so too.

[jetmechmarty]

I guess that we use the bigger O-ring to mount it to the tank? I asked georgefix and he thinks so too.

Yes. That is correct. The kit also includes the diaphragm for the spider valve. I rebuilt all three with this kit and it worked just dandy.

[conquest87tsi]

Fibery Washers

Just to clarify. The fiber washers go on the the exterior of the petcock correct? Between the bolts and the petcock? It has been 6 months since I removed them and I replaced the philips with allen heads so I may have tossed the washers with the bolts. If I did, then I guess I answered my own question.

[skids]

Yes. The petcock body is sealed with the big O-ring. The fiber washers seal leakage that would seep along the threads and around the bolt heads. The washers are installed between the bolt heads and the petcock body.

[skids]

PS allen heads are OK if they seal the washer properly. The inside diameter of the washers need to be pretty tight on the bolt threads. Flanged bolt heads provide a bigger sealing surface for the washers ... more contact area if you follow me. Your allen bolts may do fine. They are much easier to deal with than those damn phillips head bolts!

[conquest87tsi]

I went out to look at my petcocks and it appears that I did notice the fiber washers when I removed the petcocks 6 months ago. There are 3 stuck to the petcocks and one on a bolt. That happens to be the only bolt I didnt toss, so I must have noticed it.

The washers on the petcocks look a little worn out, I think I'll look for replacement.
I have one more question. I don't have my tank here and noticed that the allen bolts I have with the petcocks are 5mmyou longer than the original bolts. Are the threads into the tank all the way through into the tank? Or will I bottom out my allen bolts?