Installed the new $10 fuel petcock... - Kawasaki Vulcan Forum : Vulcan Forums
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post #1 of 17 (permalink) Old 02-27-2017, 04:10 PM Thread Starter
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Installed the new $10 fuel petcock...

I knew my OEM petcock was leaking. I found out last year when I was doing some investigating of some bogging issues my bike was having.
I bought the petcock rebuild kit...against the advice of several people here...and discovered exactly what they warned me about; that the leaking was actually WORSE after the rebuild.

Anyway, I also picked up one of those cheap Chinese-made petcocks thats designed for the Kawasaki Quads, but fits our bikes. I think it was $10 from Amazon.
So, I installed it today, but I had to make two mods first:
1. I hade to removed the thumb lever and grind it down so that it would flip to "on" without hitting the seam of the tank. 5 minutes on the grinder solved this issue.
2. I had to use a screw-type hose clamp because the main fuel port is smaller diameter than the OEM petcock. Thankfully, I have hose clamps.

First thing I noticed after install was that fuel was no longer pouring out of the petcock when the bike was off. The next thing I noticed was the I didn't smell the stench of gasoline, which was a byproduct of the fuel pouring out of the old petcock.
The third thing I noticed was that the bike started right up and idled/rev'ed smoother than before, even though it was still cold.
This is curious to me since the carb should have properly metered the fuel coming out of the petcock regardless of how much flowed out, yes?

At any rate, I can't wait to take it for a test ride. I might have a small window before the rain comes.
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post #2 of 17 (permalink) Old 02-27-2017, 05:09 PM Thread Starter
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Okay, as I suspected the running condition hasn't changed. The bike does start easier, but I'm still getting popping and backfiring on deceleration, so I'm going to have to pull the carb, I think.
It was supposedly rebuilt before I bought the bike and everything ran great for the first few months.
At least I'm not dumping fuel anymore.
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post #3 of 17 (permalink) Old 02-28-2017, 01:09 AM
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Hi, gtrdave43!
Somewhere I already mentioned the reason for backfiring I had.
https://www.vulcanforums.com/forums/5...re-adjust.html
I had a faulty air cut-off valve. You should check it first.
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post #4 of 17 (permalink) Old 02-28-2017, 06:42 AM Thread Starter
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Yes, I was looking over my previous threads.
Where is the cut-off valve located? Do I remove the carb to get to it?
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post #5 of 17 (permalink) Old 02-28-2017, 07:51 AM
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See it here.
https://www.motorcyclespareparts.eu/...or-581143.aspx
Ref. No. 43028

And yes! You will have to take it off and dissemble. (Be careful with spring that shoots in Your face and don't loose the little o-ring under the valve cover!)

P.S.
The membrane originally should be soft and rubber-flexible, without holes and damages in it. When it's old it gets rather hard and crunchy The valve should move freely towards/backwards the spring.

Last edited by tehnis; 02-28-2017 at 08:05 AM.
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post #6 of 17 (permalink) Old 02-28-2017, 08:02 AM Thread Starter
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Quote:
Originally Posted by tehnis View Post
See it here.
https://www.motorcyclespareparts.eu/...or-581143.aspx
Ref. No. 43028

And yes! You will have to take it off and dissemble. (Be careful with spring that shoots in Your face and don't loose the little o-ring under the valve cover!)
Great, thank you!
I will check this out asap.
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post #7 of 17 (permalink) Old 02-28-2017, 08:18 AM
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but I'm still getting popping and backfiring on deceleration

that is caused by being lean in the pilot circuit, the fix is to turn the pilot mixture screw out another full turn, (turn it counter-clockwise 1 turn more)

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post #8 of 17 (permalink) Old 02-28-2017, 09:37 AM
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There's a rather simple way to check if a mixture was too lean or too rich. Check Your spark plugs
Check the way they look.
Actually You should always check Your spark plugs first. If You have some spares, You can even change them for diagnosing such kind of problems.
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post #9 of 17 (permalink) Old 02-28-2017, 09:59 AM
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Also make sure idle is adjusted to Kawasaki specifications. (not too slow)
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post #10 of 17 (permalink) Old 02-28-2017, 10:20 AM Thread Starter
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Quote:
Originally Posted by sfair View Post
Also make sure idle is adjusted to Kawasaki specifications. (not too slow)
I do have to check that. I think it might be a little low.
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