Help Install new petcock

[Guest]

Hi all,

I'm picking up my new petcock tonight. The whole assembly. This is the first time I'm doing anything to the fuel tank area. I have a Clymers manual in my garage, but can you guys give me a safe, step by step on how to take the old petcock out and install the new one. I have almost a full tank of gas on the bike. I've never taken the tank off the bike. I know this is easy stuff for most of you, thanks for help

[Dave8338]

Pull the main fuel line to the carbs and route it into an empty container...set the petcock to prime and drain the tank. Remove tank.

[waterman]

After removing tank, simply unbolt existing petcock and replace with new.:-D

[Suzuki mad]

Between the petcock and the tank there will be a rubber gasket, that may or may not come with the petcock. IF you can replace the seal. Under each of the bolts (there should be 2) you will find a sealing washer. These go hard over time and may not reseal when you put the petcock back on. Get new washers too.

Suzuki mad

[thewiz]

maro, just a couple of notes from someone who fretted taking the tank off the first time (now a 5 minute job).....

You may have to disconnect the fuel sending wires before you pull the tank off. Check you manual for which ones they are.

After following the advice above, don't fill you tank up all the way until you are certain it doesn't leak. Will save re-draining your tank all the way again.

Make sure your vacuum hose is still firmly attached to your carbs and to your petcock when finished.

Also note, the two rubber spacers on the frame at the front of the tank are both in place while you are re-installing the tank. Nothing worse than getting everything back connected and find one on the floor. Ask me how I know.

[hikermikem]

Under each of the bolts (there should be 2) you will find a sealing washer. These go hard over time and may not reseal when you put the petcock back on.

Just wanted to stress what Suzuki mad has stated. Make sure you replace these sealing washers under the bolts that attach the petcock to the tank. These are essentially flat washers with a rubber seal in the middle that "hugs" the bolt as it passes through. Without that seal washer (or using a worn out one) the mounting bolts will leak. I don't believe they come with the new petcock assemblies - you have to order them separate.

[79-GS550-L]

Also note, the two rubber spacers on the frame at the front of the tank are both in place while you are re-installing the tank. Nothing worse than getting everything back connected and find one on the floor. Ask me how I know.

Wait, there are supposed to be 2 of those? I've only got one. I have, in this order:
frame, rubber washer/spacer, tank bracket, metal washer, spring washer (I think, maybe not), then bolt. Where should the other rubber thing go?

[maro]

Thanks for all the great replies. I bought everything on this list. My local ordered me the correct quanities as well http://houseofmotorcycles.bikebandit...X/1981/1008237

that should do it, no?

[BassCliff]

Tanks a lot!

Hi Mr. maro,

After you open (or take off) the seat you'll see a bolt right at the base of the tank. Like so:



Just take out the bolt and the tank will pull toward you and lift off. But first be sure to drain the tank, disconnect the vacuum and fuel lines, and disconnect the wires that connect to the fuel gage. Here's a picture:



There will also be a long vent hose coming down from the tank. You can leave that on if you want. Just be sure to route it back properly when you put the tank back on.

Thank you for your indulgence,

BassCliff

[spyug]

Just a tip if you can't get those sealing washers. Get a piece of rubber inner tube from a bicycle. Cut two pieces about 1/2 inch square and poke a small hole in the center of each. Pushing the bolts through to enlarge the hole but they will still be tight fitting and form a seal when installed.

Used this tip on 3 bikes now including the GS and no leaks. A dab of silicone on the thread of the bolts around the rubber also can give peace of mind but really is not necessary.

Now what are you going to sort out next?

Good luck with the project.

Cheers,
Spyug.

[maro]

thanks to all,

New petcock successfully in! Used cortec rubber and cut little squares for washers. Presumably works nice. Refilled my tank with about a gallan. Tried to start. crank crank, No start. got about two cranks before the battery died. (Bike has been sitting for a couple weeks).

So, maybe it's not the petcock that was the issue? Maybe I don't have enough gas? Maybe my battery wasn't strong enough to turn over?

[BassCliff]

thanks to all,

New petcock successfully in! Used cortec rubber and cut little squares for washers. Presumably works nice. Refilled my tank with about a gallan. Tried to start. crank crank, No start. got about two cranks before the battery died. (Bike has been sitting for a couple weeks).

So, maybe it's not the petcock that was the issue? Maybe I don't have enough gas? Maybe my battery wasn't strong enough to turn over?

Hi Mr. maro,

Congratulations on the successful installation of your petcock. That's something I have not done yet.

If you've got a gallon of gas in the tank, that's enough to get it started. If your battery is dead you might try push starting it. But that might be difficult, especially when it's cold outside. Do you have a trickle charger? Can you jump start it from a car battery? Make sure the car IS NOT running when you jump your bike.

Thank you for your indulgence,

BassCliff