1978 GS1000E Fuel Petcock - Conversion?

[chuck hahn]

just let me know...open offer here.

[FLHGSRay]

Well, it seems that I am missing the rear tank cushion. Good call, guys, and thanks. Went to the local dealer and ordered the stuff this morning. Thanks again.

[Big T]

Well, it seems that I am missing the rear tank cushion. Good call, guys, and thanks. Went to the local dealer and ordered the stuff this morning. Thanks again.

Ray

we know because we've all been there before

[FLHGSRay]

Resurrecting an old, hyjacked, thread here. I think I just figured out my tank/petcock issue. This is a new pic of my petcock with the new rear tank cushion installed. It still is too close to the airbox.



I looked at pics of other bikes, and my owners manual, and they show the petcock much farther forward, to where it falls between the airbox and carb. Here's a pic from my owners manual. You can see the corner of the airbox aft of the petcock.



It's not a huge problem, it's just that the fuel line is VERY hard to route, as it has to make a 90 directly behind the petcock. Must be an issue with the replacement tank that the PO installed years ago. I guess I need to figure out if I should hunt for the proper tank, a different airbox, or just deal with the fuel line. I'd be interested in any input. Thanks.

[Big T]

Ray, you are correct, the tank has the petcock too far back

That being the case, I would suspect you have an 1980 tank designed for the leverless petcock.

How about a bigger picture of the petcock side of the tank, and an overall picture of the bike?

[FLHGSRay]

We've had this discussion before and couldn't figure it out. I know my bike is a one-owner, and he said this was the only tank he could get when the original rusted out.



I'm told the bolt spacing on the leverless petcock is different than the lever type. They're not interchangeable. Also, this is factory paint, but not a '79 color, and the rest of my bike is black.

[chuck hahn]

If he bolted on a 77 /78 750 petcock it IS NOT an 80 leverless tank...different bolt spacing. 80s were 50 MM. There will only be a little clearance but it wont hit the airbox..or shouldnt anyway.

Two solutions would be to A) file a little off the end of the lever.

B)..most prefered..take the two air box bolts out at the top on the frame and put a washer between the box and the frame and this will make the box sit a little lower...thus providing more clearance.

[FLHGSRay]

The lever isn't really a problem, & I think I've got the fuel line thing sorted out. Bought some of that thin transparent green fuel line. I don't like using it on a bike, but it solves my problem, as the OD is much smaller and it bends easier. As I said earlier, I have to do a 90* turn directly out of the petcock. I'd still like to sort out just what tank I have. If the fill cap is any clue, mine is rectangular and locking, key matches the ignition.

[steve murdoch]

The 3 blue stripes on your tank means it is from a 1980 bike.

[chuck hahn]

Looks like a 79 1000 tank to me..same lower profile like the 1000E and S have.

[chuck hahn]

Im wrong...just noticed what looks like badge mounts.....Cooley S tank is for sure out. Still maybe a 79 E tank.

[GSX1000E]

I have a '79 Cooley tank, a factory replacement '79 tank and a '80 1000E tank and they all three have the petcock located there and have the rectangular fuel cap.
If this Cooley tank was mounted on a '79 1000E like in these pic's AND it had the factory airbox installed, it would also hit it. Have you tried holding the tank up while tightening the rear rubber mount bolt?
It will gain about a quarter inch of clearance.

[FLHGSRay]

Like I said, the lever isn't really a problem. It's the fuel line having to route around the airbox. I have to make a 90* turn forward within about an inch of the petcock. The reason I tore into it today is that joint was leaking. That fat fuel line couldn't make the bend and stay on the petcock tube. This thinner OD fuel line should fix that. I'm gonna search for a correct tank, but I doubt I'll be willing to pay for it. I suppose I could move the petcock forward easily enough. Make a plate to cover the old mounting holes. A small sheet of Neoprene for a gasket? Hmm.

[FLHGSRay]

I'm thinking this is a factory replacement tank for a '79, and the factory just pulled a boner on locating the petcock mount. The paint was simply the factory not wanting to set up for a new (old) color and stripe, so they painted it in '80 colors.

[Sandy]

On a previous GS1000E I had back in the mid 80s I had to replace the gas tank. I ordered a Suzuki replacement that was supposed to be correct. It was painted in the proper '79 colours however the fuel tap and fuel tap placement was as on the '80 tank requiring me to also order the proper fuel tap. A lot of mixing and matching going on with Suzuki.