My Petcock Solution ($27.08 All new parts)

OK, so I just got my XJ650 last week, and had major fuel problems.. not enough fuel, leaking out the petcock, whatnot. I tried taking apart the OEM petcock, messing with it, it eventually just kept leaking like crazy. So I did some searching around here and saw someone mention Z1enterprises.com

Basically I replaced the vacuum activated petcock with a manual ON/OFF/RES one.

These are all the parts necessary to do this:

Petcock Adapter Plate 34mm 3/8 NPT
Petcock Custom Chrome Single Outlet 3/8 NPT

I just installed these on my bike today, and it works great. No leaks, no headaches, I just have to get used to switching on and off the fuel before/after riding.

Here's the pictures I promised:


When you order these parts, the only problem is that the gas tank hole for the petcock screen is not wide enough, as you can see.


Here I am using a dremel tool and a soft pad to buff the area down to clean metal, where the gasket will make contact.


Now I am using a dremel tool drill bit (it would be a lot faster with a carbine round bit, but it only took me about 10 minutes anyways) to widen the hole. You don't need much, perhaps 2-4mm on each side.


Test fitting the petcock.


Applying the provided (comes with adapter plate) Hylomar blue sealant on all the gaskets and surfaces.
This stuff is real sticky, and hardens before you put it on. Safe for fuel.


The instructions for the petcock say to use teflon to seal the threads, which I did not have, so I used the Hylomar blue. Hylomar is also a thread sealant so I assumed this would be fine.


Installed petcock on the gastank, hooked everything up. Rode to town and back, no leaks, no problems! Actually it died once, but I realized I forgot to switch it to the ON position. lol

Hope this helps everyone with petcock problems. It sure beats the $20+ rebuild kit thats not even a sure way of fixing your OEM petcock.

-Tim

 

This works for XJ650 and XJ750's so far as I know. The only issue you need to worry about is making sure the adapter plate is correct (34mm for XJ650/750).

 

Oh YEah also very important, you have to block off the vaccuum nipple at the top of one of the carbs, which is connected to the OEM petcock. I cut the vacuum tube and screwed a large screw into it, and secured it with a ziptie. This seems to be airtight.

 

Thanks for the info, pictures and parts link.

 

Excellent!

This post seems like a good candidate for a sticky.

 

Well that's a nice shiny new Petcock. You didn't mention the cost?
Frankly I prefer the Repair Kit on the Vac operated OEM unit.
Done with even average care it works perfectly once again, in my experiences and the Vacuum gizmo is actually quite a clever thing.. one never has to worry about flooding his crankcase with gasoline due to forgetfullness... a realissue with increasing frequency of 'oldtimer's memory.
The OEM bits worked perfectly, usually for 20 long years or more.. give a bit of tlc .. they've earned it..and they will continue for a lot longer .

 

Uh, I did mention the cost.. look at the title of the post. And I posted the links to both items.

The OEM petcock works fine, but the rebuild kit is expensive. Almost as expensive as the parts I bought altogether. Also the kit won't fix the wear from the metal washer that hits the sidewall on the inside of the petcock, which may keep the petcock from working right even with a new gasket kit.

This was just my cost effective, true-fire solution

 

Also if your needle valves are good, you shouldn't be getting flooding anyways. And if they're not, you probably wouldn't just be replacing the petcock alone.

 

Thanks tichuang,

This is just what I've been looking for!
The Pingle solution was too expensive!

If I forget to shut off the fuel valve and the needle valves dont hold for some reason, at least I'll know to look at that oil sight glass to see if my crankcase is full of gasoline.

Lots cheaperb than buying anew engine.

 

Something tells me that this setup is in my not too distant future. I'm marking this thread just to remind myself. And because it's pretty cool.

 

Wow! That's awesome. I'd love to be able to do that with my Virago. Unfortunately my OEM petcock has a fuel supply, fuel return, and vacuum lines. Something tells me that just blocking of the fuel return line along with the vacuum line would just lead to problem.

 

Thanks for the info !

BTW- will this petcock work on an XJ550 tank?

 

I'm not sure, your best bet is to measure the distance between the centers of the two bolts, but my guess is that it should fit

 

It looks like you lost your reserve setting. Is that true?

 

No, there is still a reserve. There's a tube inside the screen that goes to the ON setting, and when fuel drops below the tube, it goes to reserve.

 

tichuang, since you've had this setup installed for a little while now, I was wondering, have you had any issues with having the vaccum hose that was originally hooked up to the OEM petcock plugged? I can't see that it would cause a problem, but I just wanted to be sure. I ordered the parts this weekend and hope to get them before Turkey day so I'll have something to do.

 

All you have to do is go to theauto parts store with one of your vacuum caps and they should be able to match it up rather cheaply. I for one don't do the screw in the hose thing unless it's an emergency.

 

Yeah, I was planning on going to Autozone and picking one up (actually might replace them all since they seem to be a bit mangled). What I was really wondering is if blocking off the vaccum line effects the engine any. Excuse my dumbness on this matter, kinda new to all of this.

 

Shouldn't cause any problem at all provided you didnt have a vacuum leak when you last tuned it

 

Well, considering I'm trying to get the dang thing tuned right now, that shouldn't be a problem. ;-) Would have it done already except my jerryrigged fuel supply didn't work at all (nice to have gas all over the floor of your garage, makes the house smell REAL nice)

 

hey beardking, nope have not had any issues. i'm really happy with the result, except now i have bigger problems to worry about, I just split the case yesterday to fix my 2nd gear...

you install your parts yet? during my trying to fix the old petcock, and messing with the new one, i spilled huge amounts of gas around haha

 

I have a 750 tank and a 550 tank, and know for a fact that the openings are the same

 

tichuang, yeah, I got mine replaced, synced up my carbs, and bought and used a colortune since that last post. Bike runs like a top now. Of course, it's been too freaking cold since I fixed it to go out riding, so now I just go out and start it up every once in a while.

 

tichuang
Have you tried you petcock mod yet?

I'm wondering if you get enough fuel flow?
I've a friend who said that valve wouldnt supply enough fuel for his Harley.

I'll buy it if it works good for you.

Thanks

 

This is perfect...I have a leaky pet myself, and was looking for a good way to fix it. I'll give this a try.

Thanks for posting this.

 

Good Post. Wish i had read this before i hit the dealer Saturday.

I had purchased the rebuild kit for my 750 but it doesn't include the diaphram for the vaccum on the back side and it alone was $13.

I just dropped $75 on an O.E. to fix my problem.

 

Yeah I found this just in time myself...well at least while the bike is in winter storage...so I can wrench on it all I want.

Now I just need to find out how to change my email address on here....that is the hardest thing I have to do. :lol:

 

PG just contact the Snosheriff. He can direct you and it's not too dificult.

 

yeah, I PM'd him and he just changed it for me.

Thanks

 

Well I installed this on my XJ550 on Sunday and used a circular file to make the fuel pickup hole bigger and it fits like a charm. I am doing some other things before I start it up and tune it, so I won't know how it works, but I can say this... IT DOESN'T LEAK ANYMORE!!!!!

Just put new carb boots on the engine side as well and capped all 4 vacuum ports. Once the fuse block I ordered arrives, I should be good to start it and tune it for when all this cold and snow disappear.

 

I'm totally ordering this this system this week!!

 

What system ...

I think you forgot the LINK ... !!

 

Any difference in these setups (tanks, fuel line, room, etc) it's already being used on and a 85 Maxim X?

 

Answered my own question.

I measured the holes on my 85 Maxim X tank and ordered the 44 mm sized petcock adapter from Z1. It doesn't work for the X, I need something in the area of 45, maybe 46 mm from screw hole to hole in order to work.

I thought this would've been a great thing and planned on getting this thing running next weekend. That's probably shot now, as the former petcock was really crudded up on the inside from sitting for 19 years. Maybe I'll try cleaning it up, but it appears hopeless from what I saw when taking it apart. I'll try the dealership tomorrow to see how long a new one may take to get.

Any other ideas out there to make this work, or other sources for the adapter plate?

 

tichuang
so does this petcock give you enough fuel flow for higher rpms?

 

I am using the exact same petcock, and I have no more fueling problems. It is a cheap and easy fix. Plenty of fuel available.

 

Here's an update on the actual cost.

Merchandise Total: $32.87
State/Province Tax: $0.00
Shipping: $11.10
*Order Total: $43.97*

I ordered mine today. I got the petcock at $14 and the adapter plate at $18.

 

well..after messing with yhe piece of crap repair kit :roll: with no success.....i tried rick"s trick.........THIS FREAKIN WORKS!!!!!!

way to go rickomatic...yu hydromatic elecreostacic geneous yooooo 8) 8) 8) 8) 8)
http://www.imagetex.com/albums/userpics ... ix_002.jpg

 

Well I just finished installing mine. I don't have a dremel so I had to hand file it. Not too bad and not tooo long to do it! I will let it sit overnight and fill the tank in the morning. Looks better than what I had on there.

So far I really like it. Only time will tell if it is an improvement. It could pose leaking problems and I have to train myself to shut the fuel off. I will of course remember to turn it on once I start running out while riding, but I don't have that type of reminder to shut it off. That will be the real test of my mental ability. Still I like the idea of not having to worry about fuel in the oil. Replacing the petcock for only $14 is a plus too. Yamaha wants $95 for a new one. I paid $75 for the last one.

Thanks for the idea tichuang!

 

I have a 700N and bought the 44 mm adapter plate I tried the one that the original post showed it was a 34 mm and I figured that if a 650 and a 750 used a 34mm that my 700 should too.

NOT!

all I need now is time to do the fix.........
Hope I can do it this year....... that's how it's been, that's why you all haven't hear from me for a while.

reading a previous post about needing a 45 or 46mm fo a 700X, I hope I didn't goof up again.

 

This thread seems to have a lot of life still but the one question I have that no one has given an exact answer to is that if the 44mm adapter plate doesn't work for a 700 tank what does? Or wouldn't it be possible to just drill out the adapter plate holes a bit to match the screw holes in the tank? It looks as though the kit screws are smaller than the OEM screws.
Has anyone else come up with another solution for an after market cheap replacement?

-Mark

 

Mark, I bought the 44mm the 2nd time and it was just about a mm small.

I, however modified it by redrilling the countersunk holes a bit bigger and then made the mounting holes a little bit oblonged and it works just fine.

I am definatly pleased with the manual petcock and recomend it. (You will have to modify the tank hole a bit too)

I am metriclly challenged. I'm too old school and prefer 1/16" and 1/32" , or 1/64".

I will say that when I called Z1 Enterprises and told him what my measurement was with a set of calipers (in Inches) he had trouble converting the fraction to decimal too.

I HATE WHEN THEY CHANGE THE GAME ON ME......and refuse to change!

Bottom line if I had it to do over, knowing what I do now... I'd go 45mm

 

So there is a 45mm adapter plate? I didn't see one listed.
-Mark

 

Actually, another thought I had was couldn't you just kluge a cheep inline petcock inbetween the vacuum petcock and the carbs?
-Mark
(actually this is a cheap trick to up my posts count to lifer ;^)

 

Bummer, notice how they are wise to that trick and only gave you 10 posts on both?

I would advise a call to Z1 or an e-mail and ask.

I machined mine because I didn't want to go thru the hassle of returning it.

BTW, mine woks great!

 

THAT's not fair Sno!

My last post was a legit post and you kept the counter the same!! 779

 

Now that I'm doen with this modification,
Anyone interested in a BRAND new 34mm Pingle petcock adapter as listed in the 1st string of this article?

I'm interested in selling it.

My bike needed one that the bolt spacing was 45mm so instead of returning it I thought maybe someone else would be interested in saving a buck.

Just PM me

 

Does anyone know the dimensions of a 900 or 1100 petcock.....what is the spacing between the holes? Will the 45mm adapter plate work for those also?

 

What size adapter does the XJ750RH Seca Need?

 

34mm