Petcock Rebuild

[Supersport396]

I had them turned off while the tank was off to do some other work and after about 3 weeks I started smelling gas but I have 2 old corvettes in there so that's not unusual. One petcock was leaking. It appears to have started slow but then it was so strong it had been leaking quite a bit. After reading through multiple threads on this, I came away with MikesXS kits don't work and that GeorgeFix kits are the way to go. Am I understanding that correctly? My octopus is still there and all fuel lines are recently replaced. I have not taken the petcock apart but everything on this low mileage bike is in good condition so hoping it can be rebuilt.

Thanks for any advice
Brian

[LAB3]

From reading this forum and similar forums for other makes it seems the trick to making petcock rebuilding work is to polish the surface where the o-ring makes contact with the body of the petcock. A Q-Tip or similar item placed into the chuck of a drill would be my first choice to get that done.

[cajun31]

I had them turned off while the tank was off to do some other work and after about 3 weeks I started smelling gas but I have 2 old corvettes in there so that's not unusual. One petcock was leaking. It appears to have started slow but then it was so strong it had been leaking quite a bit. After reading through multiple threads on this, I came away with MikesXS kits don't work and that GeorgeFix kits are the way to go. Am I understanding that correctly? My octopus is still there and all fuel lines are recently replaced. I have not taken the petcock apart but everything on this low mileage bike is in good condition so hoping it can be rebuilt.

Thanks for any advice
Brian

GeorgeFix sells good kits. The only complaint I had were the Orings that are supposed to seal the actual assembly to the tank. I have found them to be a tad bit too small in diameter to make a good seal. Had one leak and destroy my paint job around the petcock. I replace those with thicker rings and problem solved. Other than that the only other reported issue that I can think of is the diaphragm for the Octopus has been reported to not seal correctly to make that device operate correctly. I would advise you carefully inspect that part to be sure it needs to be replaced. It had something to do with the metal piston in the middle of it not being long enough to close it off when the bike is shut off. I have always been in the habit of turning my petcocks off when I park the bike. I mean even for a few minutes I turn them off because these bike are notorious for fuel flooding problems.

[Supersport396]

GeorgeFix sells good kits. The only complaint I had were the Orings that are supposed to seal the actual assembly to the tank. I have found them to be a tad bit too small in diameter to make a good seal. Had one leak and destroy my paint job around the petcock. I replace those with thicker rings and problem solved. Other than that the only other reported issue that I can think of is the diaphragm for the Octopus has been reported to not seal correctly to make that device operate correctly. I would advise you carefully inspect that part to be sure it needs to be replaced. It had something to do with the metal piston in the middle of it not being long enough to close it off when the bike is shut off. I have always been in the habit of turning my petcocks off when I park the bike. I mean even for a few minutes I turn them off because these bike are notorious for fuel flooding problems.

Where did you source the thicker oring? I agree with shutting them off every time but since these were off, I have no confidence.

[cajun31]

O-Ring Assortment Pack - 397 Piece Metric O-Ring Assortment

[LAB3]

Another important thing to remember is to replace the fiber washers on the mounting bolts, they may look good but I've been fooled by them before. They only cost pennies at the hardware store, if they don't have them in metric sizes there's an English sized one that's just a hair too small. A rolled up piece of 320 grit sandpaper helps for easily reaming it out to size.

[Supersport396]

O-Ring Assortment Pack - 397 Piece Metric O-Ring Assortment

Oh, ok I thought you were referring to the oval one.......Thanks!

[DiverRay]

He IS referring to the oval rings. They just happen to be round until installed.

[Supersport396]

I see said the blind man lol.

[cajun31]

I see said the blind man lol.

The larger diameter Orings in this kit are the ones I replace. The smaller ones go in the petcock.
Fuel Petcock Repair Rebuild Kit for Yamaha XS1100S Special 79-81 K&L 18-5100V | eBay