petcock rebuild

[Parr8hed]

Had some fuel leaking from the petcocks. The fuel lines were wearing and some fuel was leaking where the lines attatch to the petcocks. (I have just rebuilt carbs with new needle valves and seats, also have in-line shut offs in both sides so not really worried about leaking in carb bowls, engine etc.) So I rebuilt the petcocks with new rebuild kits. when I re-installed the tank there was gas leaking out of the petcocks on both sides! The were both on "on" and not "prime". Since these are vacum operated should'nt these not be dripping gas now? I have heard others talk about putting washers in the petcock to help stop the leaks. Not sure where you put them in, and if I need them or not?

[andreashweiss]

The petcocks are a real pain to deal with. Many times I have rebuild them put them all together and there it is a slight but small leak. Just be patient take them apart again and keep trying. Sometimes a gasket moves a bit during reassembly. Also try and tighten the large bolts going into tank a bit more. Sometimes slight leak from there.

[randy]

Here's a wacky one for you. Installed all new petcock kits a couple of months ago. After putting it all back together, left petcock wouldn't close, was pissing fuel with the bike off. Found out that the little brass pinhole valve in the vacuum diaphram cover was clogged. So, there was enough engine vacuum to open the diaphram, but when I shut down, the vacuum wouldn't bleed out, holding the valve open. Cleared the clog, fixed the problem!

[Paulio]

uhm yes, had a similar problem meself. A slight weep from both petcocks, not enough to lose significant amounts of fuel but enough to cause a slight aroma around the bike and me when i rode it which as you know does not endear us to the opposite sex.

1/ Remove 2 screws, front plate, spring washer & lever
2/ Remove rubber gasket
3/ clean the whole lot
4/ replace rubber gasket EXACTLY THE SAME WAY AS IT CAME OUT (very 'portant that bit)
5/ Take spring washer and gently increase each bend by a small amount to increase the overall springiness.
6/ Carefully replace the washer front plate and screws.

Presto, no more leaks and best of all completely free! A slight downside is that slightly more force is neede to turn the petcocks.

[Parr8hed]

Sure now you tell me, after I have a full tank of gas! When I run it down a little, I will give that a try. I remember those things to look a little weak. Any fixes if I break one while bending? Just trying to sort out future problems that I always seem to have!

[DiverRay]

Travis;
just bend it a VERY small amount. It is a "flat" spring, and it should not take much. And, if you ride like I do, you should have an empty tank Friday!!
Ray

[TopCatGr58]

Hey Travis and others,

A different fix approach if the wavy washer breaks, I found some thin neoprene O-rings at the hardware store that were the right diameter to fit, put some lithium grease/lube on it, and put it in, worked great!!
T.C.

[randy]

New spring washers are still available.