1978 GS400 Help!!!

[pete]

Thanks for the info Pete!! I'll keep and eye out for either of those cleaners. I forgot to mention that the gas I drained was perfectly clear. Not murky or dirty looking at all. Hopefully that is a good sign of what is to come as I dig further.

Good stuff, if what comes out of the tank is perfectly clear then that should in theory mean you have no rust issues.

[TimB]

Thanks again for the info guys!! I took the petcock apart tonight. Was not too bad looking other than some gummy stuff(but VERY little of it). When I drained the tank I did note that fuel only emptied when I switched it to "Reserve". From what I read, "prime" should empty fuel no matter what the fuel level(which was about 3+ gallons!!). Any idea why?? Also any idea where to locate some new rubbers for the petcock. They appear to be in good shape but I would rather replace them while I am tearing things apart rather than after everything is assembled. Thanks!!!!

Tim

[pete]

You sure you had it on reserve? If it's a vacuum operated fuel tap like most of them are, then it shouldn't just drain fuel on either "On" or "Res", only on "Prime".

Mine has a screw for the prime function, the tap just switches between "On" and "Res".

Sounds like either something's wrong with your fuel tap or maybe it really was in the Prime position?

As for replacing the rubbers, there are rebuild kits available for some of them at Z1 or on eBay and there have been mixed reports of success and failure with them.

My suggestion would be just buy a new one if you can, mine was less than $80 brand new from Boulevard Suzuki...

[TimB]

Thanks Pete!! After looking at it with a different perspective I think I was using the prime function. Mine looks almost exactly like this one...

http://members.dslextreme.com/users/storagecliff1/images/suzuki_petcock_rebuild.pdf

I was looking at it as if it was an arrow pointing towards "Fuel", "Res", or "pri". Now I realize that the circle end of the lever indicates the position. Good to know it's not junk!! I'm going to attempt to clean it and re-use the current rubber for now. Once I see if I can get the bike running then I will go back and replace if needed since it's an easy fix.

[SVSooke]

The 78 petcocks are around $300,ask me how I know.Had a good one I sent off to FC with that 79 400 tank.Really wish I had it back now

[pete]

Thanks Pete!! After looking at it with a different perspective I think I was using the prime function. Mine looks almost exactly like this one...

http://members.dslextreme.com/users/storagecliff1/images/suzuki_petcock_rebuild.pdf

I was looking at it as if it was an arrow pointing towards "Fuel", "Res", or "pri". Now I realize that the circle end of the lever indicates the position. Good to know it's not junk!! I'm going to attempt to clean it and re-use the current rubber for now. Once I see if I can get the bike running then I will go back and replace if needed since it's an easy fix.

Cool, that makes sense and glad to see it's working

Mine looks quite different to that...

The 78 petcocks are around $300,ask me how I know.Had a good one I sent off to FC with that 79 400 tank.Really wish I had it back now

ouch! Are the bolt spacings the same as the other type? I still have my old one around if you need me to measure...

[SVSooke]

Yes they are.Thinking of putting the good one from the 750 build in the Skunk as a for now measure.

[pete]

Yes they are.Thinking of putting the good one from Othe 750 build in the Skunk as a for now measure.

Sounds like a plan to me! If you don't care about 100% original that would be a good swap...

[TimB]

Here are some pictures of the Petcock...

[pete]

Make sure the O ring is still nice and rubbery, give it a good clean (probably fresh fuel will help), and use the proper sealed washers to reinstall and it should be all good

[TimB]

Sounds good Pete!! One question.... "sealed washers"?? I took out what was left of the air filter last night. I'll post some pics of what was left tonight.

[pete]

Sounds good Pete!! One question.... "sealed washers"?? I took out what was left of the air filter last night. I'll post some pics of what was left tonight.

There are washers under the bolts that hold the fuel tap in and they're special ones that have a fuel safe seal built in. If you use ordinary washers fuel will leak out around them...

[Englishman]

I'm trying to find alternative taps for my 400 project to eliminate the vacuum line - just a nice simple on-off arrangement. Hard to find anyone who gives dimensions for the bolt holes though.

Mark

[pete]

Tried Z1? Pretty sure they have them... I think there's a Pingel brand that also has an adaptor plate to suit, although that may just be for the bigger GS' too...

[TimB]

This is what was left of the air filter. Pretty nasty stuff!! There were also some seeds stored in the filter from whatever animal had been living there!! Any suggestions to where I can find a new filter? I don't think this one is going to cut it!!