Fuel valve (petcock) rebuild gone badly ... help!

[Vanzetti]

My advance thanks to any help anyone can offer:

I just rebuilt the fuel valve in my 1980 GS1000G (using the gasket kit from Old Bike Barn : http://www.oldbikebarn.com/part.php?...Rebuild%20Kits), because it was leaking about a droplet of gas every 5 seconds when the bike was running.

The problem: I took the tank off, drained it, took off the valve, put in the new gaskets, put it back on, and drove it around a bit about an hour ago - when I shut it off, there were no visible drops of fuel - with the exception of some moisture (gasoline) around this part of the fuel valve (whose gasket I just replaced):



Now, an hour later, I went back to the bike, and there is a small pool of gas that is leaking from this gasket from the fuel valve. There are 3 things I think could have gone wrong here:

1.) I did not replace the split-lock washers on the 4 screws which puts the back part of the valve together; I could not get the washers off the screws, and I was short time, so I just screwed them back on.

2.) I may have incorrectly put together the fuel valve. Below are two pictures of possible ways the back of the fuel valve could be put together. The first picture, with the back of the valve on the right, and the rest of the valve on the left, is how I mated it together and how it currently exists on the bike. The second picture (with the front piece reversed) is perhaps how it should have been put together - I messed up and did not record how it was when I took it apart. If anyone knows how these pieces are supposed to go together, I would GREATLY appreciate the guidance.



3. Maybe the gasket kit from Old Bike Barn sucks. I don't know.

If anyone can help me out (and soon!), I'd be very appreciative. I'm a bit at the end of my rope with this old bike - I have just finished replacing the brakes, the seat, and I've redone the electrics - but if I keep having problem after problem, I'm giving up on the thing.

[catfishk]

the pic on the right seems the correct way to assemble it. in this picture, the veins in which the fuel flows in the various positions would be in alignment with the recess in the gasket

i have read and been advised that the rebuild kits aren't reliable. however, you have ordered AND received a correct part from Old Bike Barn, which seems an anomaly in itself!

i was told to get a new petcock, so i bought a used one for $15 from a salvage yard. it works great but will probably give up sometime sooner than the new $45 part... unfortunately i chucked the old unit without opening it up

[catfishk]

but if I keep having problem after problem, I'm giving up on the thing.

oh, and don't give up! you are going to get a lot of curve balls with this old bike but once sorted out, it is more enjoyable having worked the bugs yourself! good luck!

[Vanzetti]

So it seems that the leak might actually be coming from the bolts that connect the valve into the gas tank; it's very unclear, because it's a slow leak, and there's moistness from the top of the valve down.

Clymer's manual states that there is a sealing O-ring that is to go in between these bolts I just mentioned; however, the Old Bike Barn kit did not include such O-rings, nor was there any O-rings when I removed the valve. In any case, I bought some O-rings at the nearest Autozone and will put them on when I reinstall the valve.

I've also bought some lock washers and screws to replace the ones on the back of the fuel valve; but these being the source of the leak seems unlikely to me.

Finally, the bike ran great (aside from the leak) when it was on: therefore, wouldn't it be fair to say that the intermediate piece that I described in my original post (#2, shown in the first of the two pictures) is most likely installed correctly?

[catfishk]

i was thinking that the valve might have been stuck to 'prime' if the gasket was installed backwards, possibly, overflowing the carbs. but you are probably right that if it was running well, it was on correct

i used some teflon thread sealant goo on the bolts when i re-installed my petcock, to prevent leakage. i am not sure if it helps any, but it doesn't leak currently

your fuel petcock looks different from this Bike Bandit schematic, though only a GS1000GT is listed;

http://tinyurl.com/3buy6n

[catfishk]

forgetful me... there should be a gasket between the petcock and the tank (bottom left in the bike barn link). that is the only seal i have, other than the thread sealant on the bolts

[Go Mifune]

http://tinyurl.com/3cvd8n
the kit this guy sells on ebay for an 80 gs1000g looks very different than your gasket

[gremlin]

it looks ike your missing the vacume valve. its the one in the photo top right next to the number 1. wtih out the valve you will leak out that gasket. i would say since you missed it, some one befor you removed it.

[bwringer]

BUY A NEW PETCOCK. IT'S THE ONLY WAY.


It controls the flow of an explosive fluid six inches from your crotch. Why cheap out? $40 - $70 and you're set for the next 20 years.

[Deesel]

BUY A NEW PETCOCK. IT'S THE ONLY WAY.


It controls the flow of an explosive fluid six inches from your crotch. Why cheap out? $40 - $70 and you're set for the next 20 years.

Where is the best place to get a new petcock?
Would the dealer have one?

[bwringer]

Where is the best place to get a new petcock?
Would the dealer have one?

You'll need to order the petcock from your favorite source of Suzuki parts, whether that's your local Suzuki dealer, BikeBandit, Flat Out, or wherever.

A few GS Suzuki petcocks are available aftermarket through Cycle Recycle II.

http://crc2onlinecatalog.com

Dig through their hideous site to the fuel system parts and compare the listings and the photos carefully with your original petcock. If they stock yours, it will usually ship out within a day.

BikeBandit is probably the fastest for OEM parts (you usually get your parts in about a week), and shipping is very inexpensive (click the OEM parts fiche link):

http://bikebandit.com

Flat Out is the cheapest by about 20% - 25%, but they're a little slow (2+ weeks) and charge a ridiculous amount for shipping. I usually only use them for large orders of lots of parts:

http://flatoutmotorcycles.com/fiche_select.asp

[Deesel]

You'll need to order the petcock from your favorite source of Suzuki parts, whether that's your local Suzuki dealer, BikeBandit, Flat Out, or wherever.

A few GS Suzuki petcocks are available aftermarket through Cycle Recycle II.

http://crc2onlinecatalog.com

Dig through their hideous site to the fuel system parts and compare the listings and the photos carefully with your original petcock. If they stock yours, it will usually ship out within a day.

BikeBandit is probably the fastest for OEM parts (you usually get your parts in about a week), and shipping is very inexpensive (click the OEM parts fiche link):

http://bikebandit.com

Flat Out is the cheapest by about 20% - 25%, but they're a little slow (2+ weeks) and charge a ridiculous amount for shipping. I usually only use them for large orders of lots of parts:
http://flatoutmotorcycles.com/fiche_select.asp

Thankyou for the resources!