calling all petcock pros! - Kawasaki Vulcan Forum : Vulcan Forums
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post #1 of 19 (permalink) Old 08-02-2016, 07:44 PM Thread Starter
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calling all petcock pros!

I removed the petcock to carb hose with the petcock in the ON position and noticed a drip. I know this means bad things, so I attempted removal and disassembly, all looked good, but it continued to leak upon reinstall. so, Ill go buy a 91.00 new one. I just dont trust the rebuild kit...do you?
next, I think the gas flows only when the bike is on because of a vacuum tube. but...I did the epa removal thing, so MY tube coming from the petcock is now capped. Is this a major problem? the bike could never have run with only the tiny drip, so im assuming that somehow when the bike is powered on, gas does flow more. im also thinking this issue is why I found gas running out of my tailpipes the other day...and I thnk some gas got in the oil...past the rings, because the oil level is now higher. any thoughts or experience on this/?

thanks!!
nrg
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post #2 of 19 (permalink) Old 08-03-2016, 04:18 AM
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Hi!
As far as I know, there are as minimum two types of fuel taps on VN800 models. (You should consider that when buying repair kits.) Anyway, both types use vacuum. The fuel should not drop without negative pressure form engine side. It flows only when vacuum gets applied. You are right on that. Rebuild kits are ok but You should examine the whole condition in general whether and what to buy. I also removed my EPA and in general it has nothing to do with the fuel tap problem.
The gas in oil is a big problem I'm sorry about that
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post #3 of 19 (permalink) Old 08-03-2016, 07:16 AM
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inside the petcock is a small rubber diaphragm and a spring and a plug, when the air flows thru the carb throat and creates a vacuum this vacuum runs thru that carb to petcock hose and the vacuum pulls on the small rubber diaphragm inside the petcock, and this in turn releases the spring pressure on the plug and this lets some gas to flow thru the hole, the reason you have a drip with your petcock in the ON position is this spring inside the petcock is weak and there is not enough pressure pushing on the plug against the hole, thus letting some gas to drip thru the hole. You have 2 options to fix it, you can take the spring out of the petcock and give it a gentle pull to stretch it a bit -or- you can buy a petcock re-build kit and hope the re-build kit comes with a new spring, either way you do it, that spring inside your petcock is the problem. Watch this youtube video How to Fix Your Motorcycle petcock without a rebuild kit https://www.youtube.com/watch?v=5DqvB_5gP20

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post #4 of 19 (permalink) Old 08-03-2016, 08:10 AM
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Excellent explanation from btom!
But be very careful with stretching the spring! It's calibrated (like springs in carburetor valves) and should hold the exact pressure. If overstretched diaphragm will not work in needed diapason. If it does not work any more, consider to replace.
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post #5 of 19 (permalink) Old 08-03-2016, 12:35 PM
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maybe buying a petcock re-build kit would be better than trying to stretch the spring, so maybe the re-build kits contain a new spring, I don't know

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post #6 of 19 (permalink) Old 08-03-2016, 12:39 PM
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I just checked ebay and yes this petcock re-build kit does contain a new spring, I can see it in the photo of the kit

96 05 Kawasaki VN800 Vulcan 800 Classic New K L Fuel Petcock Repair Kit 18 5023 | eBay

Thunder Mfg teardrop 40's K&N 170MJ 48PJ 2.75turns DynoJet Needle DNO106 2nd notch V&H Cruzers Aeromach risers Michelin Commander IIs Wix 51358 filter 17T/40 Sprockets, 2357 rear bulbs
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post #7 of 19 (permalink) Old 08-03-2016, 12:53 PM
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Got mine here, $65. Part 51023
Kawasaki Motorcycle Parts 2005 VN800-B10 Vulcan 800 Classic FUEL TANK Diagram

2005 800 classic
2012 Voyager ABS
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post #8 of 19 (permalink) Old 08-04-2016, 08:30 PM
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I ordered a kit off ebay and installed it just like the old came out, still leaked, wasted whatever I paid for it. Not saying you might not have better luck, also had gas leak into oil and had to regasket stator cover, ended up ordering an o.e.m. off ebay and now it is fine. Good luck.
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post #9 of 19 (permalink) Old 08-04-2016, 10:41 PM Thread Starter
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took it off, cleaned it, probably overstretched the spring, put it back. put a cup of gas in the tank...........mopped up a cup of gas off the garage floor and ordered an oem on amazon for 91 us dollars. lol. I got the same luck as old 8hundred on this bike. im not taking any chances this time. Id like to ride this 2k turning into 4k bike I bought someetime before I start collecting pension. next stop, the kawi dealership to see if they can tune my carb to the vance and hines. oh yeah, then I just realized i bought this thing with 17k on it and have NO idea if anyone has ever done the valves. lol. dang.

~nrg
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post #10 of 19 (permalink) Old 08-05-2016, 03:18 PM
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so the whole cup of gas you put in the tank ended up on the garage floor? how did all that gas go thru the petcock like that?

Thunder Mfg teardrop 40's K&N 170MJ 48PJ 2.75turns DynoJet Needle DNO106 2nd notch V&H Cruzers Aeromach risers Michelin Commander IIs Wix 51358 filter 17T/40 Sprockets, 2357 rear bulbs
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