Fuel Filling #1 Cylinder After Sitting

[bergj1986]

I bought an 02 Katana as a project bike a few months ago and have been working on getting it right. Finally got the engine running correctly, but when I let the bike sit overnight, fuel fills up #1 carburetor and airbox. I've already done the following:

- Polish needles and seats (used a wooden dowel to clean the needle seats)
- Ensured the rubber tips on the needles are still pliable
- Floats move smoothly up and down (polished the float pins)
- Verified the needles don't leak by spraying them with soapy water and blowing into fuel inlet hose

I had an issue with the diaphram in the fuel petcock, so I removed everything inside the petcock and made a gasket to seal the assemble. The fuel is now always on. Could this be causing the problem? Shouldn't the float needles keep the fuel from flooding the engine?

[steves]

The petcock is leaking, and the needles probably need replaced on the floats.

Fuel always on is certainly the problem.

[bergj1986]

Can I use THIS to replace the internals of the petcock or are there other parts I will need such as a spring, etc? Parts diagrams don't show the internals of the petcock, only the assembly complete.

[steves]

There is no rebuild kit that I'm aware of for the 98+ yet. As I recall the diaphragm is good for all years of bike. It sounds like you probably installed it backwards though.

[bergj1986]

Does anyone have an exploded view of the internals of the petcock? Is it just a diaphragm or are there other parts as well? I need to know if I need to buy a complete petcock or just a new diaphragm.

[steves]

Should be a spring, a seal, and the internals from the knob.

[arsenic]

Does anyone have an exploded view of the internals of the petcock?

I bet the manual does.

[steves]

I actually don't think the manual does. The parts fiche doesn't. Suzuki treats it as one non-servicable part.

[arsenic]

I think you're correct Steve.

[bergj1986]

For the float needles, I was thinking of buying 4 of THESE

[arsenic]

Is 02 somewhere within 90-97 I was unaware of? Here's what you need:
98-06 GSX600F KATANA CARB KITS GSX600

[steves]

The float COULD just be stuck, that happens sometimes too. But for me, when in doubt replace old parts with new.

[bergj1986]

arsenic, the part you listed is for a Katana 600, will that also work with my 750?

[arsenic]

Nope, but these will:
1998-2006 SUZUKI GSX750F KATANA NEW K&L ECONOMY CARBURETOR REPAIR KIT