Can't find a Petcock for my 81 GS650E

[Jerry]

Can't find a Petcock for my 81 GS650E anyone have any Idea? I have looked at all the on line places I can think off and can't even find a Chinese one on eBay.
They are apparently a one year only. I only see them for the 82 650e. Any help would be appreciated.

[tom203]

Yes, seems to be oddball with vac and outlet ports facing forward….can you adapt a rear facing port unit? Enough room for hoses?

[rphillips]

The Suzuki pet cocks I've worked on, the back plate is square & can be installed pointing either up, down, forward, or backward. I've not worked on one from a "81" 650.

[Jerry]

I tried an old petcock from my 82 1100e and I think I can make that work if I raise the year of the tank about 1/2" and notch the front of the side cover.
now I will start looking for that one. I might even try rebuilding the one I have. Thanks for all the response.

[rphillips]

Oh, I thought you didn't have one & needed one. What's wrong with the one you have? Many here have had problems with rebuild kits & naturally don't recommend them, but I've had good luck with them. If it's not completely shutting fuel off, when eng. not running, you can take it apart, check the rubber seal for cracks or gouges, clean seal & seat good, & stretch the spring just a little. These things are really simple & little to go wrong. Good luck.

[hank2]

Yes, the '81 GS650's had a one-year petcock. Later years had a fuel gauge sending unit, so the petcock was placed much more forward on the tank edge. The other years model could have the bottom portion flipped around, but the vacuum port (or is the fuel outlet?) would still be facing the wrong direction. Maybe some sort of 90-degree fitting? I would love to convert it a Karcoma somehow.

[tessmar]

Yes, seems to be oddball with vac and outlet ports facing forward….can you adapt a rear facing port unit? Enough room for hoses?

My very early (9/76 build date) GS750 "pre-B" has a similar petcock, with both ports facing forward. One is an air port, not a fuel outlet. It pushes the internal diapraghm so fuel only flows in the "On" or "Res" positions while the engine is running. "Pri" flows fuel all the time and can indeed "overpower" the float needle on the #4 carb. I could not find a replacement petcock which allowed the backplate to be reinstalled...the one I have has the backplate as a (perhaps pressed in) permanent mounting. I use a 90 degree fitting on the fuel outlet hose to the carbs to compensate for this. But I have not been able to get the "On" position to feed fuel, though there does seem to be positive pressure from the smaller diameter hose. I also have not found a rebuild kit for the original petcock which works. All the supposed "correct" kits or petcocks I've looked at are not correct for the bike.
I think the 90 degree fitting might solve Jerry's routing problem...I got mine from some boating supply company whose name I cant recall. If I can find the invoice I will post that info. But if anyone has an idea about my other issues please let me know

[Jerry]

Oh, I thought you didn't have one & needed one. What's wrong with the one you have? Many here have had problems with rebuild kits & naturally don't recommend them, but I've had good luck with them. If it's not completely shutting fuel off, when eng. not running, you can take it apart, check the rubber seal for cracks or gouges, clean seal & seat good, & stretch the spring just a little. These things are really simple & little to go wrong. Good luck.

No I don't have one that is usable the the tube for the fuel hose is missing and it is frozen. I was referring to the old one from my 821100e. I ordered a kit k&L kit for it and will see if I can make it work. I have never tried to rebuild on before but I don't have much choice.

[Jerry]

Now you guys have me thinking. The same kit I ordered is for the 650 as well as the 1100e. The fuel tube that is missing was evidently pressed into the petcock. I think I may be able to thread the outlet and use a screw in fitting. I will check that out tomorrow.

[Jerry]

Well I solved one problem I turned down an old brass fitting and made a sleeve that was a press fit into the petcock. After I froze my brass sleeve and heated the petcock I pressed it in and used a 1/4" pipe tap to cut threads. Now i can use a 1/4'' barbed hose fitting.
Now i have to wait until the rebuild kit comes to see if i can get this thing working. i would welcome any advice from those that have rebuilt one successfully.
IMG_4033 by Gerald Kaiser, on Flickr