Petcock issues

[Suzuki_Don]

Well so near, yet so far.

I have fitted the 650 cylinders, head and a few nights ago the CV carbs. Now I find the tank will not fit onto the frame without the petcock interfering with the top of the No. 1 CV carb (different shape to the VM that was there originally). There is always a holdup, so frustrating. Anyone got a match and can of gas.

I have three Suzuki petcocks and none of them will fit with the clearance I need. The petcock that was on the tank (brand new 90 odd dollars) has the fuel outlet pointing forward at about a 45 degree angle and sits directly on top of the #1 carb. If I raise the tank to get the clearance I need then the rear tank mounting bracket will not line up.

See pics of the new petcock I bought and will not fit because of lack of clearance.

This pic shows the angle of the fuel feed from the other side.

Another pic of the good petcock, shame I cant use it.

I have another petcock, but not sure of it's internal condition and it has the fuel nipple pointing in towards the centre of the bike which is good, but the vacuum nipple hits on the frame and will not allow the tank to sit centrally in the frame. I tried disassembling the petcock to aim the nipple in a different direction, but there are holes internally that need to line up, mainly an air hole to the outside atmosphere.

I guess I need a petcock that has both of the nipple facing in towards the centre line of the frame away from the carbs or facing the rear of the bike. Also the depth of the body of the petcock cannot be too large. On the other petcock I have the actual square shaped body touches the #1 carb.

The other option I guess is a pingel type tap. But as having never seen one before I am not sure which one I would need and which adaptor plate (offset or ordinary) to use. Don't want to purchase this hardware I find it still doesn't fit properly. There is not a lot of clearance between the frame and the #1 carb. The petcock almost needs to be a customised one to fit in this gap. I am running out of ideas. Spent 4 hours in the shed last night with the tank on and off, petcocks on and off and am about to pull my hair out.

Any suggestions, can people check out the petcocks on their bikes and see if they have one with rearward facing outlets or inward facing (not forward facing) fuel and vacuum outlets. Or anyone had experience with pingel.

Thanks again.

 

[hampshirehog]

Don, this one looks like it's the 'small' tap and the tubes face the other way:
http://www.z1enterprises.com/detail.aspx?ID=1715

I used to be a fan of Pingel but 2 leaky ones in 18 months mean I'm finished with them now (even if they did replace the 1st one FOC).

I've just bought one of these and will be fitting at the weekend:
http://www.z1enterprises.com/detail.aspx?ID=1744. It'll fit straight on the adapter plate.

To work out if you need the offset plate (which I doubt but I can't remember for sure), remove your current tap and see if the feed is in the middle of the 2 mounting holes or not.

 

[Suzuki_Don]

Thanks Wally, that's a great price on the fuel tap at $13. Seems too good to be true. Let me know how it goes with the fitting. If it leaks or not. Very interested. The other tap (vacuum) looks like it will work as well. Friday morning here so will have to wait till I get home and fit the tank again and see if I think it will have the clearance that I need. The big issue will be if the fuel outlet interfers with the rear frame downtube.

I don't know why they dont make them with the fuel outlet facing towards the cente of the bike.

Thanks for your good suggestions. For a while there didn't think I would get any.

 

[Theo]

Hey Don. I have the first petcock hampshirehog linked to, so if you need any measurements to be sure of clearance, let me know and I'll be happy to take them.

 

[Suzuki_Don]

Hey Don. I have the first petcock hampshirehog linked to, so if you need any measurements to be sure of clearance, let me know and I'll be happy to take them.

That's great. Thanks Theo. I might take you up on that. The issue is that you don't know what will actually fit without buying one and then if it doesn't fit it's bad luck. And these things are so damned expensive. I already have three and none of them will fit and give me the clearance that I need.

Cheers.

 

[Suzuki_Don]

Hey Don. I have the first petcock hampshirehog linked to, so if you need any measurements to be sure of clearance, let me know and I'll be happy to take them.

Theo can you measure the petcock from the centre of the right hand mounting bolt hole to the centreline of the vacuum nipple. I need to know how far this nipple is inside the mounting holes to see if it is going to mess with the frame. I think all the other stuff should clear OK.

Also can you measure the OD of the fuel outlet nipple, the regular part and also the raised part that the rubber fuel line pushes over.

Thanks. I owe you one.

 

[Suzuki_Don]

I've just bought one of these and will be fitting at the weekend:
http://www.z1enterprises.com/detail.aspx?ID=1744. It'll fit straight on the adapter plate.

To work out if you need the offset plate (which I doubt but I can't remember for sure), remove your current tap and see if the feed is in the middle of the 2 mounting holes or not.

Wally, how did the fitting of the fuel tap go. Any leaks from the fuel tap. That's certainly a cheap price at $13. Some feed back would be good.

 

[tkent02]

Some dirtbikes and dual sports have very small manual petcocks, some even have the same bolt spacing. Sorry I don't know which model bike.

You could also make an adapter plate to fit a really small one with closer spacing, that would allow you to move it farther aft just a little bit...

When you find something that works, let me know.
I am following in your footsteps.

 

[Suzuki_Don]

Some dirtbikes and dual sports have very small manual petcocks, some even have the same bolt spacing. Sorry I don't know which model bike.

You could also make an adapter plate to fit a really small one with closer spacing, that would allow you to move it farther aft just a little bit...

When you find something that works, let me know.
I am following in your footsteps.

Thanks. Some good thoughts there Tom. Glad to see someone following in my footsteps. Glad to share any info that I can.

 

[hampshirehog]

Don, it fits and doesn't leak. The only thing I'm not 100% happy with is that the fuel pipe nipple faces backwards which leaves me a bit tight on fuel pipe length (buy a longer hose!) and also a bit of a tight bend to avoid the side panel. I thought it would before I fitted it. I've got round it really easily by adjusting the angle of the tap so it's not square - maybe 35-45 degrees off. It then fits fine and is completely useable (even switching to reserve will be fine when riding). The action is also very nice and smooth - doesn't feel cheap at all. Nobody in their right mind would notice it out of line as it's tucked away down there but, maybe I'm not in my right mind - it niggles me slightly that it's not on square.

Maybe I'll get used to it, just forget or I might solder on a brass bend. Anyway, it's staying on there for now as even a thimbleful of leaked petrol is more than a week's wages now.

 

[Suzuki_Don]

Thanks Wally, Don't let yourself get too paranoid about it. I know what it's like, it can be annoying, but you will get used to it. I was glad to hear that the tap works well.

I have ordered the Suzuki style vacuum tap (your first suggestion in your earlier post) and am hoping it fits OK. Otherwise I will go with the one you have used. It is certainly less expensive than the similar styled Pingel tap.

Thanks for the feedback.....

 

[Suzuki_Don]

Still wont fit

Still wont fit

Well I received the vacuum type petcock that Wally suggested from Z1 and it still doesn't fit and give me the clearance that I need. That makes four Suzuki petcocks in my stocks now and none of them will fit the bike with the necessary clearance required.

My next option is to make up a plate to fit between the tank and the petcock to lower the petcock a bit and see if this will give me the clearance that I need. The main problem here will be preventing gas leaks as there will now be two seals required between the petcock and the tank surface.

 

[Guest]

What about the infamous 80 petcock. It was made for this very problem.

 

[Suzuki_Don]

Bill, be more specific - what problem. I have one petcock that interfers with the carbs and another one that interfers with the frame tube where it bends down behind the motor.

Any help greatfully appreciated.

 

[chuckycheese]

True

True

What about the infamous 80 petcock. It was made for this very problem.

That's very true, Bill, but the bolt spacing on it is 50mm.

 

[Guest]

That's very true, Bill, but the bolt spacing on it is 50mm.

Thanks Charles! I forgot about the minor detail.
Bite the bullet and get a Pingle.

 

[Suzuki_Don]

Spacer Made to Lower Fuel Tap

Spacer Made to Lower Fuel Tap

Last night I made a spacer to fit between the petcock flange and the petrol tank. The spacer needed to be 8mm thick to push the petcock down enough to clear the frame rail curve behind the carbs. I made the spacer from a piece of 8mm aluminium plate (actually one of Dan's caliper brackets. I knew they would come in handy for something one day.

That's all Folks!!

 

[Guest]

Great work Don
Now seal that plate with some Hylomar. Works a treat!

 

[Suzuki_Don]

Great work Don
Now seal that plate with some Hylomar. Works a treat!

Thanks Bill. Not sure if we can get Hylomar here is OZ. So I went ahead and made a gasket from a rubberised cork gasket material which is resistent to petrol, oil, etc. according to the manufacturers spec. sheet.

By placing the 8mm spacer under the petcock it lowered the petcock so the two bulges on the vacuum plate did not contact the frame any more. But looking at the petcock from the vacuum side of the unit the screw at the top left was still touching the frame.

So I decided to countersink the hole in the cover and fit a 4mm countersunk screw, only one problem - I couldn't find one anywhere. So my friend Ron put a chamfer on a standard screw so it would fit in the countersunk position which lowered the screw enough to give the clearance that I needed.

The following pictures show what was done, although you will need to look hard at the photos to see it.

 

[faafaafowhigh]

My all stock GS750 has the "Dreaded 1980 Petcock" (nylon barrel screw no lever). After following the carb cleanup series to at "TEEEE" I still have fuel spitting back into my airbox. I will be purchasing a new petcock; however, i am unsure of which one to replace it with. Should I replace the dreaded one with the exact same dreaded OEM, or go to Z1 for their version of the dreaded one. I'm also curious what difference in materials if any between the two. Thank-you all in advance for your comments and advice.

I came to this diagnoise by switching petcock to prime and pinching off the vaccumm tube from petcock to carb #2.