Xj700x rebuilt petcock still leaking

I just rebuilt my petcock new o rings and diaphragm still a slight drip when in the on position without vacuum prime works correctly

 

Did you polish all of the mating surfaces when you had the petcock apart?
Petcock Rebuild

 

I had the same problem when I rebuilt mine. Chacal suggested that I take a small socket, 8mm or so, and ever so slightly dent the metal flange attached to the plunger to slightly lengthen the reach of the plunger. So slight that it is barely noticeable. I did it and it's been working correctly for the last 3 years. Some folks also add a washer between the spring and housing to create more pressure. Chacal said that some of the rebuild kits apparently use slightly shorter plungers and/or o-rings.

 

Actually the new o-ring is not tapered and not hollow, so it doesn't seal as well as the original one, this being important if you unfortunately have one of those not-so-well machined petcocks (I've been said there was a big batch of those).

 

I put this off for awhile but it was a warm Michigan day today 36 degrees so I figured I'd play with it took this thing back apart three times cleaned all surfaces tried a washer behind the spring for more pressure on diaphragm no go then tried elongating the spring for some more pressure as these tend to wear down also bent the pressure washer back to original shape on the face plate of the valve now I'm still getting a drip when in on position and prime working correctly but it seems to have less if no drip in reserve I don't know what else to do short of spicing in another valve in fuel line after petcock that I would have to turn off every time

 

When I owned an X, I had a similar problem, I decided to buy a new petcock, it was expensive but I didn't have to worry about a leak anymore. Some of the old ones don't give good results with rebuilt kits.

 

Look at my comments above about the metal flange. I bet if you do that it will solve your problem. I got that advice from Chacal after several attempts and it hasn't leaked since--going on 3 years. The washer and elongated spring will never be enough if the metal flange is preventing the plunger from seating properly and with enough pressure. Sometimes the rebuild kits are just a tad to short or the o-ring on the plunger is slightly smaller. Put the plunger into the smallest socket it will fit into and slightly tap the back side.

 

so its your nipple that drips?

 

Nope, it's my plunger that can't reach the bottom!

 

Yes