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Brand new petcock experience?

BigD_83

BigD_83

Forum Sage
Past Site Supporter
I would like to put some feelers out there for people's experiences with brand new, Suzuki Genuine Parts petcocks. Skip to the end if you just want to see the question.

The background:

My petcock seized in the fall and I ordered and received a brand new SGP petcock in December. I got around to installing it a couple of weeks ago and managed to get the 650G out for a few short rides to see how things were going. So far so good on the mechanical side of things.

Last night, after a short ride (~15 miles) out to work and back home to warm up the bike, I started getting set up to do a highest idle adjustment and carb synch since it needed it with the new BUB header. As I worked my way around to the right side carbs I happened to glance down at the oil sight glass, and it was overfull. I had purposely left it just a hair below full when I changed the oil last time to be able to monitor the situation. The oil is not convincingly gassy smelling, but definitely higher in volume than before I rode.

Summary: bike on centre stand, engine still hot, sight glass says oil overfull, no huge smell of gas, All 4 plugs show lean, exhaust smells rich, a little white smoke from the muffler

I pulled the vacuum line first, and a little bit of gasoline dripped out from the nipple and the end of the hose. :mad: Not a lot, but more than I would expect from a BRAND NEW petcock.

As it turns out, because I waited more than 90 days to install it, and it was not installed by a Suzuki mechanic, the warranty is void. Live and learn on that one. I guess planning for the future is not in the service manual.

I don't need to go over the routine of failed petcock as there are plenty of threads on the problem, and I've "been there, done that", but

How many people have ordered a SGP petcock to have it fail?
 
BigD_83 said:
I would like to put some feelers out there for people's experiences with brand new, Suzuki Genuine Parts petcocks. Skip to the end if you just want to see the question.

The background:

My petcock seized in the fall and I ordered and received a brand new SGP petcock in December. I got around to installing it a couple of weeks ago and managed to get the 650G out for a few short rides to see how things were going. So far so good on the mechanical side of things.

Last night, after a short ride (~15 miles) out to work and back home to warm up the bike, I started getting set up to do a highest idle adjustment and carb synch since it needed it with the new BUB header. As I worked my way around to the right side carbs I happened to glance down at the oil sight glass, and it was overfull. I had purposely left it just a hair below full when I changed the oil last time to be able to monitor the situation. The oil is not convincingly gassy smelling, but definitely higher in volume than before I rode.

Summary: bike on centre stand, engine still hot, sight glass says oil overfull, no huge smell of gas, All 4 plugs show lean, exhaust smells rich, a little white smoke from the muffler

I pulled the vacuum line first, and a little bit of gasoline dripped out from the nipple and the end of the hose. :mad: Not a lot, but more than I would expect from a BRAND NEW petcock.

As it turns out, because I waited more than 90 days to install it, and it was not installed by a Suzuki mechanic, the warranty is void. Live and learn on that one. I guess planning for the future is not in the service manual.

I don't need to go over the routine of failed petcock as there are plenty of threads on the problem, and I've "been there, done that", but

How many people have ordered a SGP petcock to have it fail?
Click to expand...

I've never ordered a new one, my 1100 cock works fine, but I went into the rebuilding mode for my '79 GS1000E petcock, since a new one of those goes for $263 and change at Boulevard Suzuki :eek:. I would think if I spent that much for a failed new petcock, I'd be rather irate!
http://www.boulevardsuzuki.com/fich...y=Motorcycles&make=SUZUKI&year=1978&fveh=2146
 
sedelen said:
I've never ordered a new one, my 1100 cock works fine, but I went into the rebuilding mode for my '79 GS1000E petcock, since a new one of those goes for $263 and change at Boulevard Suzuki :eek:. I would think if I spent that much for a failed new petcock, I'd be rather irate!
http://www.boulevardsuzuki.com/fich...y=Motorcycles&make=SUZUKI&year=1978&fveh=2146
Click to expand...
$263 at Boulevard? Are the 1100 petcocks made of gold?

I'm happy to say that it didn't cost me that much, as I took advantage of some deep discounting from Boulevard during the December sale, but factor in the oil change, new filter, time, and worry...and it becomes more of a headache than I'd like to deal with when I'm supposed to be doing a long ride with a bunch of GSers this Saturday.
 
GS110X506158 said:
New petcock installed, 44300-47270, video from 2009
http://www.youtube.com/watch?v=3F8Q6XrpOFM

Old GSX with a new vacum operated OEM Suzuki Petcock installed, vacuum system sucks fuel throug the petcock and into carburator no 2. Why ...

:( Espen
Click to expand...
That bike has issues. That is a whole lot of gas being dumped into the #2 cylinder.

I don't think mine is that bad, but I'll know more when I get the clear line on it tonight.
 
I got mine for the 850 about two years ago from Z1. Not sure who makes it but it's working just like it's supposed to.
Trying to avoid buying one for the 78 1k.
 
BigD_83 said:
$263 at Boulevard? Are the 1100 petcocks made of gold?

I'm happy to say that it didn't cost me that much, as I took advantage of some deep discounting from Boulevard during the December sale, but factor in the oil change, new filter, time, and worry...and it becomes more of a headache than I'd like to deal with when I'm supposed to be doing a long ride with a bunch of GSers this Saturday.
Click to expand...

No, I didn't have a problem with my 1100 petcock, that price is for the
'78, '79 GS1000E petcock, and thats a steep discount over retail which I believe is around $311.
 
I have a brand new OEM one in a box.. for my 850 For some day when I need it.. ON SALE BikeBandit
 
Couple things:
One, not to suggest you're jumping to conclusions or anything, but you're sure that the petcock dribbled and not just had some gas up in the spout that dribbled out? When you remove the fuel line they'll dribble a tad sometimes.

Two, for the later style petcocks, the product Z1 carries as replacement IS exact OEM. Not OEM replacement, but genuine OEM same petcocks different box than Suzuki put it in. Made in the same factory etc etc. So I wouldn't spend any extra on a "SUZUKI" or "SGP" labeled box. The same cannot be said for the earlier models with the big lever however, and I've yet to find a suitable replacement for those. However, if you shop a little, you will find a couple of things. Kawasaki used the same petcocks on a few models.. If you go to Babbitts or bike Bandit or whatever, and look at the Kaw version, it's often times more expensive than the GS version..although there is nothing different. I know that some of the early 80s XS twins used the same petcock with the same bolt spacing as well (for instance the 81 XS400) and can be cheaper still than the Zook version. Off the same online supply house no less..!

Anyway, if indeed your petcock has failed already, I'm sorry. That truly sucks a big one.
 
Looks like I am better off buying it from Z1 for my 80 850G. sorry for your bad luck!
 
I've replaced the petcock on both my GSs (one from PartShark, another from Z1, I think). Neither box marked SGP. Both have been flawless.

Josh is right that the fuel nipple will dribble a bit when you take the hose off. I've never seen that on the vacuum line.

I think if I was in your shoes I'd leave the vacuum line off for a while and see if any drips form, just to confirm the diagnosis. Dissasembly and inspection would follow any further drips. If you have a simple defective diaphragm, then a rebuild kit seems to be in order.
 
tom203 said:
That stinks- I got one from a FLorida guy ( I hope georgefix sends me disneyworld passes for all this hype ) for $45 delivered. Exact copy of my original, but RES kicks in at lower level. Did this new one look exactly like old one- maybe suzuki dealers are rebuilding them to generate business!


http://www.georgefixs.com/servlet/the-148/SUZUKI-GS450%2C-GS650%2C-GS750%2C/Detail
Click to expand...
Tom,

The new petcock is an exact OEM replacement petcock direct from Suzuki, AFAIK.

Frankly, I didn't pay attention to where the intake was for the reserve.
 
TheCafeKid said:
Couple things:
One, not to suggest you're jumping to conclusions or anything, but you're sure that the petcock dribbled and not just had some gas up in the spout that dribbled out? When you remove the fuel line they'll dribble a tad sometimes.

TCK,

Thanks for the feed back.

I'm trying to come up with an alternate explanation for gas in the crankcase because as I said in my original post, I have fuel coming out the vacuum nipple when I pull the vacuum line off, and there are drops of fuel on the #2 vacuum spigot. The weirdest thing is that I saw a vapour or mist in the clear vacuum line when I was synching, but no gross liquid gasoline flowing in the vacuum line as in the link posted by GS110X506158 further along in the thread.

There is no evidence of fuel leaking down the fuel line (i.e. no drips/puddles under the tank in the morning. I guess what concerns me most is that the plugs were showing lean, but the crankcase oil volume rose.

Other than petcock failure, how could gas get into the crankcase?

Two, for the later style petcocks, the product Z1 carries as replacement IS exact OEM. Not OEM replacement, but genuine OEM same petcocks different box than Suzuki put it in. Made in the same factory etc etc. So I wouldn't spend any extra on a "SUZUKI" or "SGP" labeled box.

The best news is that Boulevard is coming through for me in a big way and is shipping out a replacement petcock at no charge. The original purchase was not obscene, as it only set me back $34.00, down from the $100+ retail price.

Anyway, if indeed your petcock has failed already, I'm sorry. That truly sucks a big one.
Click to expand...

Yeah, its not good, but I'm a patient fellow. It helps to have a GS friend in the city willing to loan a bike out as well. As always, it'll get resolved with the help of all the good folk on here.
 
BigD_83 said:
Tom,

The new petcock is an exact OEM replacement petcock direct from Suzuki, AFAIK.

Frankly, I didn't pay attention to where the intake was for the reserve.
Click to expand...
I'm very surprised the Chinese haven't copied these things yet -or have they???. My replacement had same casting "marks" as my original- only the screws were slightly different. I bet some small shop in Japan has been making these for 30 plus years. Big companies have a nasty habit of searching for lower price components from anywhere ("let's save 3 cents" )- seems likely that something like petcock would be sourced from China.
 
Most likely the petcock is fine. Oil expands when it gets hot so you can not judge the fill level when the engine is hot. There are tons of threads in the archives on how to properly measure oil fill level so you might want to search. Bottom line is the bike must be on a level surface, engine cold, bike on center stand before you can judge the oil level.

Try running a piece of clear tubing for your vacuum line. Some condensation and/or fuel vapor accumulation inside the vacuum line is normal and nothing to worry about so don't confuse this with fuel running down the line.

Oh, and fuel can't fill up your crankcase with the engine running anyway. There is no path for the fuel to reach the crankcase other than though the cylinders, and that can't happen with the engine running.
 
Last edited:
Thanks, Ed.

I'm hoping I have just made an error in reading the signs, but the oil level is higher with a cold engine/on centre stand than when I last changed it. Quite a bit in fact, but not above the sight glass like before. Now that you mention it, the first time I noticed the really high level was 10 minutes after that short ride when I was warming the bike up for the carb synch.

I'm going to have someone else give the oil a sniff as I think I'm permeated with gas vapours and can't smell anything but gas this morning.
 
The oil always smells like gas so that's a bad test; blow-by gasses mix with the oil.

Do the clear vacuum tubing test and ride.
 
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