Petcock handle hard to turn

[Nessism]

My '850 has the petcock with the small lever and it's a real pain to turn between ON and RES. Took it apart today and everything looks good inside. Works perfectly also. The petcock is old but doesn't have a lot of use since the bike is under 4000 miles. Can't see any corrosion on the inside.

My old 550T had a similar petcock and the lever was also hard to turn. Is hard to turn a characteristic of this style of petcock? The petcock on my '79 550 has a large lever and is easy to turn.

Feedback appreciated.[-o<

[tkent02]

Wild ass guesses here, did someone rebuild it with the wrong orings or something?
Maybe some rubber part swelled up with immersion in alcohol laced gasoline?
If you remove the circular spring that holds the tension on the handle does it turn freely, or is it stuck even with no tension???

[80GS750]

is there anyway to lube the mechanism thats actually in contact while its turning??

if so, give it a shot and see what happens

[Nessism]

Wild ass guesses here, did someone rebuild it with the wrong orings or something?
Maybe some rubber part swelled up with immersion in alcohol laced gasoline?
If you remove the circular spring that holds the tension on the handle does it turn freely, or is it stuck even with no tension???

Bike has killer low mileage so I'm almost sure the petcock is stock. And the small lever petcock does not have the circular spring.

Lubed the o-ring around the lever before I installed it but didn't put a whole lot on there figuring gas would just wash away the lube. Might take it back apart and put more on the second time.

[jadesystem]

I have the same problem on my 1150. Very tough to turn from "on" to "prime" to "reserve". I have yet to tear into it. Whatever the case, I will see why this is so. I'll probably put 10-wt machine oil to ease the friction.

I feel this is the main problem with limited fuel going into my carb bowls.
It always dies on me every time I take it out. Everytime I'm down stranded on the freeway. I put it on prime with direct fuel dumping,
and it restarts and goes. It is not the carbs as I've already rebuilt it...
but this stiff petcock. Another issue is bad valve seals burning oil which
I'll take care of soon.

I may just buy a petcock rebuilt kit online, but they are not cheap for
just a few gaskets and O-rings as I presume.

KT :-D\\/

[jadesystem]

Another thing is to use 8mm (or was that 10mm) clear or yellow gas lines instead of the black stock ones. You can see the gas go from the tank to the carb bowls. A very easy troubleshooting technique just at a glance.

No more guessing for fuel delivery !!

[Zooks]

Are you eating your weeties each morning Ness???

[hikermikem]

My old 550T had a similar petcock and the lever was also hard to turn. Is hard to turn a characteristic of this style of petcock? The petcock on my '79 550 has a large lever and is easy to turn.

Feedback appreciated.[-o<

My 1100G has the same issue - VERY hard to turn that little lever between PRI & ON & RES. Sometimes I have to use a pair of pliers. Other than that however, I've had no fuel issues concerning the operation of the petcock - works perfectly fine.

I've recently bought a rebuild kit from Z1, but haven't yet installed it - my thinking is that after the rebuild it will turn easier...

My 550L has the larger (read longer) petcock lever and that's very easy to move. Maybe that's why they changed them??

[Nessism]

Took the petcock back apart and found the problem. There is a tapered-cylinderical plastic piece that rotates when the lever is turned. The plastic piece is wedged into the petcock body very tightly - too much so in the case of my petcock. I clearanced the plastic piece by sanding lightly so it doesn't bind up so much. Lever turns freely now.

[Barneycanoe]

I'll have to try that. My GS850L is exactly the same, petcock id fine, works perfectly but needs pliers to turn to RES. Good thing I have the tool kit.

[TheCafeKid]

Took the petcock back apart and found the problem. There is a tapered-cylinderical plastic piece that rotates when the lever is turned. The plastic piece is wedged into the petcock body very tightly - too much so in the case of my petcock. I clearanced the plastic piece by sanding lightly so it doesn't bind up so much. Lever turns freely now.

Damn Ed, you are a CRAFTY son of a gun!

[twiggy2cents]

ive had problems with that white piece i might do this let us know if you have any problems with leakage

[jimfj]

Glad you have figured this out for me!! I have the same problem and I thought I was either a wimp or Just too lazy and cheap to buy a new petcock.

It's not often that I have to go to reserve but when you do its nice to be able to do it with out having to get off the bike and use pliers.

BTW, I like the fact that someone else is okay with tearing into something instead of just saying "It's broken, buy a new one".

Jim

[Odinist]

The one on my 550 has always been a bit hard to turn, but recently it was damn near impossible. A quick spray of WD40 and it's like butter.

[bonanzadave]

A quick spray of WD40 and it's like butter.

BTDT. Not quite butter.... but at least better. Mine is also tough to turn.