noob mistake: tried to loosen the drain nut the wrong way and lost the threads

[Billy Ricks]

That how to should get you through it. Some of the petcocks vary a little but they work basically the same. You more than likely have a holed diaphragm in yours.

[Baatfam]

Thanks Billy. I am going to google out and make some calls. I am sure some online store should have it if not I will PM you.

Regarding the petcock problem, I am thinking I should drain the fuel tank, fix the petcock before refilling the oil.
Is this the way to go about it?
http://members.dslextreme.com/users/...ck_rebuild.pdf

Rebuilding the petcock rarely works...best to just replace it. They are not cheap, but it will work.

[ram]

Hope you get it sorted...

Side note... your signature is
OBNOXIOUS

YOU SHOULD MAKE IT SMALLER....

that is all...

Point noted and implemented!

[ram]

Rebuilding the petcock rarely works...best to just replace it. They are not cheap, but it will work.

I will start looking at eBay also and see whats out there. Probably BikeBandit or similar site could have an aftermarket part.

[Billy Ricks]

http://www.z1enterprises.com/searchresult.aspx?All=True&KeyWords=petcock

[Suzuki mad]

Sort the fuel leak first. Pull the pan cover off, get a gasket and have the hole time certed, refit and your then sorted.

If you look very close at the drain plug you will find a very flat crushed washer. If you tighten them up that tight they will only give you a little lip on the edge of the bolt as a give away.

[loud et]

Damn thats a lot of oil ! ( and gas) lol . We really need to UPGRADE the READ THIS BEFORE POSTING ANYWHERE thread. Need to make it more obvious to get new members INSTANTLY guided to a list of some sort with some top issues like petcock function (especially leverless) and that its a vaccuum system, explaination or what a real carb cleaning is V.S. a spray can, airbox v.s. pods explanation, why to get your bike running right before chopping it to make the baddest cafe anyones ever seen, etc....while they wait and hopefully read Cliffs page.
I downloaded my FREE manual and READ the thing and learned a lot about my bike. I ask noob questions too but I hope not at the ignorant level that many new guys do. I ATTEMPT to do the research, usually.
I consider myself a regular on here although not super active I am on a lot.
Dont take this personally RAM, its not directed at you. I know your pride is hurt enough with your plug mishaplol It does happen . I have snapped more bolts(when I know better then to force it), stabbed myself with screwdrivers, sprayed PB Blaster right into my eye....Bullseye! ouch!
Hang in there and read up on BikeCliffs welcome page for TONS of GS info...I think there is even a stripped drainplug tutorial to show you how to fix it. Good luck

[ram]

http://www.z1enterprises.com/searchr...yWords=petcock

I think this one might work.
http://www.z1enterprises.com/Petcock...zuki-1715.aspx

Thanks Billy !

Thanks Loud et! I usually keep searching., but today I was getting a lot of error messages while searching (website issue I guess).. thats why I posted this one!

[Billy Ricks]

I think this one might work.

http://www.z1enterprises.com/Petcock-vacuum-Suzuki-1715.aspx

Thanks Billy !

Thanks Loud et! I usually keep searching., but today I was getting a lot of error messages while searching (website issue I guess).. thats why I posted this one!

Looks like the right one. It's only about double what a kit cost so it's money well spent.

[loud et]

I think this one might work.

http://www.z1enterprises.com/Petcock-vacuum-Suzuki-1715.aspx

Thanks Billy !

Thanks Loud et! I usually keep searching., but today I was getting a lot of error messages while searching (website issue I guess).. thats why I posted this one!

No biggie man....I have trouble with the search function too

[ram]

Update

I removed the fuel tank and removed to petcock for inspection. It seems to work fine. the parts look good and rubber seems in good condition.

After removing the tubes, I set the knob in ON position and it did not leak. I resumed to collect the gas on PRI position and changed it back to on when I had to empty my 1 gallon jug into my car (Canadian tire was selling this one at $4.99 , the 5 gallon one was around $19).


I opened the petcock and things looks fine. I just mouthed and the diaphragm seemed to do the work. spring looked clean.


I remember I had earlier turned the knob into PRI when the bike was off just to start it. I could be that the carbs could have dumped this into the oil chamber.

So Now I suspect that the carbs will have to be cleaned. Glad that I have the manual and BikeCliff's website handy. I will take photos and see how that one goes.

I just have one question about the drain pan. In order remove them, is it necessary to remove the exhaust so that the drain pan could be removed? I will be working with bike on the ground.

[DannyMotor]

Where is your vacuum valve spring?

[tkent02]

I removed the fuel tank and removed to petcock for inspection. It seems to work fine. the parts look good and rubber seems in good condition.

That's a good sign, but make sure it's not leaking, even slowly.

I remember I had earlier turned the knob into PRI when the bike was off just to start it. I could be that the carbs could have dumped this into the oil chamber.

It actually takes a long time to fill the crankcase with fuel. If it was only on Prime for a short time, it must be leaking slowly when it's on with the engine shut off.

I just have one question about the drain pan. In order remove them, is it necessary to remove the exhaust so that the drain pan could be removed? I will be working with bike on the ground.

Not sure about the pan coming off without the pipes. Some fit, some don't. Try it and see.

I would leave the gas tank off and lay the bike over on that stack of tires if it were me. I'm too old to work underneath something like that..

[ram]

Where is your vacuum valve spring?

Its not in the photo, I had cleaned it and kept it aside along with the screws.

[ram]

It actually takes a long time to fill the crankcase with fuel. If it was only on Prime for a short time, it must be leaking slowly when it's on with the engine shut off.

Question: If it leaks slowly, is it possible to see it dripping when you take the pipe out from the petcock?

I also spoke to the PO and he told me that carbs need to be cleaned and Petcock should be fine. I am not going to take his words completely, but atleast now., if they leak, I would be replacing it.

From what I have heard, this bike has been sitting and the floats on the carb could be stuck. I had taken it for a ride (10kms) after tire change and saw fuel leaking from the carb# 1.

Not sure about the pan coming off without the pipes. Some fit, some don't. Try it and see.

I would leave the gas tank off and lay the bike over on that stack of tires if it were me. I'm too old to work underneath something like that..

I might be able to push it down, but I dont have the muscles to get it straight again. This thing is massive!! I am going to go to the local salvage shop and see if they have one available.