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Petcock Rebuild

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  • Petcock Rebuild

    Has anyone has success rebuilding their 98+ petcock? I have a 2000 and the petcock was working just fine, but it ws leaking. So I pulled it apart and siliconed the sealing surfaces to stop the leak and replaced the o-rings. Well, it stopped the leak, but after it ws assembled, it just dumped gas in all positions (I found this out when I removed the gas line and fuel just poured out in all settings). So, I picked up the rebuild kit and replaced the diaphram (no silicone this time) and it doesn't leak, but I get VERY little flow and no flow on PRI. My question is this: There is a brass circular spring on the selector side (Knob > spring > plastic conical piece > brass circular spring). Where or how does this circular spring set inside the body/ conical plastic piece? If needed, I can disassemle and take some pics.

    I replaced the filter a couple months ago and the fuel line today and I can see fuel flowing in the filter when running, but seems low compared to what it was. Kinda want to avoid a new petcock, but I wanted the opinion of the knowledgeable forum first. I think this circular spring thing is the issue as I did not pay that close of attention when taking it out. OH and I took it out because it looked bent and tweaked sitting inside the housing (maybe it's supposed to be this way?).

    BTW, the bike runs GREAT after my mulitple cleansings! Plugs are clean, idles perfect, purrs like a kitten, and plenty of power, minus the lack of fuel flow.
    Last edited by muddblood; 07-21-2013, 02:13 PM.

  • #2
    Do they make a rebuild kit for the 98+ petcock? I've searched but no luck.

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    • #3
      See this thread for info http://katriders.com/vb/showthread.php?t=96553
      It is for a pre, but not much difference, and I believe the rebuild kits for a pre will fit a post.
      2002 GSXF 750

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      • #4
        Look at partsfish... They've got all the diagrams you need for your app

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        • #5
          Originally posted by quadruss83 View Post
          Do they make a rebuild kit for the 98+ petcock? I've searched but no luck.
          According to the wiki, the 98 and older rebuild kit will work. The diaprham and front o-ring are the same, and I can confirm this...it does indeed work.

          So an update. I did use the pre 99 rebuild kit and no more leak!! Bike runs like a champ now!! I just have a VERY slow PRI position.
          Last edited by muddblood; 07-30-2013, 12:10 PM.

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          • #6
            Originally posted by muddblood View Post
            Accordingt to the wiki, the 98 and older rebuild kit will work. The diaprham and front o-ring are the same, and I can confirm this...it does indeed work.

            So an update. I did use the pre 99 rebuild kit and no more leak!! Bike runs like a champ now!! I just have a VERY slow PRI position.
            Something still isn't right then.

            Prime is manual, and nothing you replaced should effect it. The assembly on the other hand... improperly inserted selector part internally, or the prime spring not in the proper place... can mean you prime isn't working correctly.

            I'd check the spring first. It's the most common to get damged. If it is bent/damaged, check to make sure the internal selector was put in the correct way and not turned 180 out (and thus caused the bent/damaged spring).

            Krey
            93 750 Kat



            Modified Swingarm, 5.5 GSXR Rear with 180/55 and 520 Chain, 750 to 600 Tail conversion, more to come. Long Term Project build thread http://katriders.com/vb/showthread.php?t=96736

            "I've done this a thousand times before. What could possibly go wron.... Ooops!"

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