Pingle Knockoff howto

[free99]

Hey there,
I was running low on funds restoring my 1983 GS450L, when I realized the vacuum petcock was leaking fuel into the vacuum port. I tried a rebuild kit off ebay, no dice.

I wound up making a manual petcock using spare material from work and a compatible fuel valve from eBay. All in, total cost would be $50 for a high quality valve which I believe competes with more expensive alternatives in almost every way, and that's if you have to buy everything from scratch.

I've attached a schematic of the final assembly, but I think you'll understand pretty quickly what I did. Here's the link to a high res PDF: https://ufile.io/xn8yfucs

I believe this should work for any medium size GS, perhaps even the larger displacement ones.

Let me know if you have any questions or concerns

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s-l1600.jpgAll this stuff is off eBay:

Item	Cost Ea.	QTY	Net Cost
9mm (3/8") 6061 Al Bar	$13	1	$13
M14x1.5 RH Tap	$8.20	1	$8.20
M6x1.0x20 Stainless Button Cap Bolt	$0.87	2	$1.74
Manual Petcock w/ Reserve (search for GPZ/KZ750 petcock)	$10	1	$10
M6 Copper Washer	$0.16	2	$0.32
2mm Thick Fuel-compatible gasket material (e.g. Viton)	$14.50	1	$14.50
Grand Total:			$47.76

[free99]

I hope this PNG will stick around, just in case the PDF doesn't.
Fuel Adapter.jpg

[free99]

Final Result:
IMG_20200_shrunk-6.jpg

[Gorminrider]

Oh gee! isn't that cool! (and good on you for sourcing some viton sheet. Costs a fortune doesn't it? )

[free99]

Thanks Gorminrider This guy's got something similar to what I used listed for $14.50 including shipping: https://www.ebay.com/itm/VITON-RUBBE...P/190795526610

Oh I guess relative to regular rubber, yeah, expensive. But hey, only gotta do it once if you do it right (probably).

[Grimly]

Excellent, ta.

[salty_monk]

any clearance issues with the carbs? Presumably not... would have to be something confirmed on a case by case I guess

[kingofvenus]

I installed an actual pingel adapter years ago, and just used hylomar with no gasket. Sealed it just fine.