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**92xjunker** · 10-12-2015, 08:21 PM

Welcome to katriders
1. No it does not, pic needed here as it is a weird spring. It may be serviceable
2. Only carb 4 has that port
3. Bad petcock and a set of carbs that need service will dump fuel into the cylinders and eventually into the oil sump.

**grizzlyhunter04** · 10-13-2015, 08:14 AM

Thanks junker, unfortunately the spring was destroyed getting it out. Best description is a thin stamper sheetmetal washer thats wavy or rippled.

**shpielers** · 10-13-2015, 09:09 AM

Welcome

1) think that spring isn't available separately, but could be wrong.
2)carbs 1/3 will need plugs installed or you will have vac leaks. Bad ones.
3)petcock needs rebuild/replace. Carbs also need attention. Float needles are shot, orings shot, debris clogging them and holding floats open etc. If the floats sealed fuel wouldn't make it to the case.
Transmission: 2nd gear shift fork likely culprit. Common weak point.

**grizzlyhunter04** · 10-13-2015, 10:58 AM

Thanks shpielers that's what I was getting at the three ports on those carbs that come out horizontally all pointing to the right are not capped that's why I figured they probably have to be the one the double check

**maniac1886** · 10-13-2015, 01:03 PM

try Bikebandit.com to see if you can buy just the petcock spring washer.

The carbs need work. Check out Carbs101 on here. Fancy walkthrough on how to tear em down. Your best bet is to seperate them, dip them for 24 hours, then blow them out. You will most likely need all new rubber inside. There are black rubber plugs you will need to replace, the float bowl gaskets will need to be replaced. the orings around the float assembly will need replaced, and it wouldnt hurt to replace the orings and possibly vacuum caps on the topside (black plastic top lid). The vaccum port on carb 4 that is plugged probably goes to the petcock. It is vacuumed accuated, the nipple facing opposite of the switch (toward the right side of the bike) is the vacuum pickup to engage the petcock and that is powered by carb 4.

BUT..... Im surprised no one else touched on this....

Before you go doing all that, you need to assess 2nd gear. It is most probable that the dogs are worn and the only way to fix it is to split the case, and either have them undercut, or buy a new set of gears (dangerous to buy used as you might get an equally worn pair). You need to make sure you are willing to invest in that before you start dumping money into this bike. There is the option to just ignore it, and skip 2nd, but i have a buddie that did that for an entire summer, and let me tell ya, it gets old. Check this thread out, someone else having similair issues.

http://katriders.com/vb/showthread.php?t=137465

**loneraider** · 10-13-2015, 01:59 PM

++++1 maniac1886 said
maybe that's why the previous owner sold it -as in way too much time and $money to get an old katana on the road. Unless
your doing all the work yourself and you know what your doing ( putting it all back together the right way ) maybe its worth it. Just don't pay a shop to
fix it or your going to get screwed!

**grizzlyhunter04** · 10-13-2015, 08:07 PM

thanks guys for all the information my intention was get the petcock on it take it for a ride see exactly how it acts and then over the winter pull the motor and transmission and split the case I do all the work myself I know my way around ATVs dirt bikes and other vehicles and stuff pretty well so as long as I pay attention and use the book I think I'll be in good shape kind of using it like a project / practice machine thanks again for all the helpluckily I only spent 200 bucks for the bike and got it from my brother in law knowing about the issues. kind of like a guilty pleasure you want to do it even though it's embarrassing to say you want to

**JIB** · 10-14-2015, 05:32 AM

Welcome to KR. Good luck with the rebuild.

**92xjunker** · 10-14-2015, 10:44 PM

Originally posted by maniac1886 View Post

try Bikebandit.com to see if you can buy just the petcock spring washer.

The carbs need work. Check out Carbs101 on here. Fancy walkthrough on how to tear em down. Your best bet is to seperate them, dip them for 24 hours, then blow them out. You will most likely need all new rubber inside. There are black rubber plugs you will need to replace, the float bowl gaskets will need to be replaced. the orings around the float assembly will need replaced, and it wouldnt hurt to replace the orings and possibly vacuum caps on the topside (black plastic top lid). The vaccum port on carb 4 that is plugged probably goes to the petcock. It is vacuumed accuated, the nipple facing opposite of the switch (toward the right side of the bike) is the vacuum pickup to engage the petcock and that is powered by carb 4.

BUT..... Im surprised no one else touched on this....

Before you go doing all that, you need to assess 2nd gear. It is most probable that the dogs are worn and the only way to fix it is to split the case, and either have them undercut, or buy a new set of gears (dangerous to buy used as you might get an equally worn pair). You need to make sure you are willing to invest in that before you start dumping money into this bike. There is the option to just ignore it, and skip 2nd, but i have a buddie that did that for an entire summer, and let me tell ya, it gets old. Check this thread out, someone else having similair issues.

http://katriders.com/vb/showthread.php?t=137465

This is true but, if it's a big Kat, fixing it is a no brainer. At least it is for me..

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