Petcock... Rebuild

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  • rphillips
    Forum Guru
    Past Site Supporter
    Super Site Supporter
    • Jun 2005
    • 7611
    • Norene TN

    #1

    Petcock... Rebuild

    I don't know how to create a poll, but Suzuki GS petcock rebuild, Did it work for you?
    1983 GS1100E, 1983 CB1100F, 1991 GSX1100G, 1996 Kaw. ZL600 Eliminator, 1999 Bandit 1200S, 2005 Bandit 1200S, 2000 Kaw. ZRX 1100
  • Grimly
    Forum Guru
    Past Site Supporter
    Super Site Supporter
    • Sep 2012
    • 5762
    • Ireland

    #2
    Originally posted by rphillips
    I don't know how to create a poll, but Suzuki GS petcock rebuild, Did it work for you?
    Yep, but only with genuine Zuk rubber parts. I had to clean the movable surface of the selector disc with 1000 grade for a good finish.
    Not long after that, the brass inlet pipes came loose on both of my petcocks, so I epoxyd them into place and had no trouble for a couple of years until the vacuum diaphragm went leaky.
    At that point I replaced it with a manual tap.
    Dave
    '79 GS850GN '80 GS850GT
    Only a dog knows why a motorcyclist sticks his head out of a car window

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    • dgates1
      Forum Mentor
      Super Site Supporter
      • Jun 2024
      • 344
      • Arlington, TX

      #3
      I have one of those flat ones without the lever on my 850GL. When I took it apart, the diaphragm and O-ring (although a little sticky from sitting for a long time) were good, but the rubber check valve it had all but disintegrated. Ended up blowing the pieces of it out. So the petcock works in the "ON" position but will not hold vacuum in the "PRI" position. No rebuild kits come with this check valve (Number 5 in the drawing). Not even sure you could get it installed if they did. So I ordered a whole new petcock but K&L has had them on back order for some time. They do still make it, but all of the distributors are out of stock. They are saying they should ship sometime this month.

      Doesn't really answer your "poll" but if you have one of these, rebuilding is not really an option if that check valve is shot.

      Petcock.jpg
      ​​
      - David
      80 GS850GL, 82 GS1100G
      Arlington, TX
      https://visitedstatesmap.com/image/ARMNMTNDSDTXsm.jpg

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      • salty_monk
        Forum LongTimer
        GSResource Superstar
        Past Site Supporter
        Super Site Supporter
        • Oct 2006
        • 14001
        • London, UK to Redondo Beach, California

        #4
        Nope... I always just buy new OEM. I think it's only half down to the seals, the Petcock itself wears so any new seal set might work for a while but not for long as it doesn't have as much material to play with
        1980 GS1000G - Sold
        1978 GS1000E - Finished!
        1980 GS550E - Fixed & given to a friend
        1983 GS750ES Special - Sold
        2009 KLR 650 - Sold - gone to TX!
        1982 GS1100G - Rebuilt and finished. - Sold
        2009 TE610 - Dual Sporting around dreaming of Dakar..... - FOR SALE!

        www.parasiticsanalytics.com

        TWINPOT BRAKE UPGRADE LINKY: http://www.thegsresources.com/_forum...e-on-78-Skunk/

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        • Nessism
          Forum LongTimer
          GSResource Superstar
          Past Site Supporter
          Super Site Supporter
          • Mar 2006
          • 35787
          • Torrance, CA

          #5
          I rebuilt the petcock for my KZ, using OEM internals. I wouldn't bother trying with aftermarket parts unless there was no other option.

          P1010520 by nessism, on Flickr
          Ed

          To measure is to know.

          Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

          Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

          Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

          KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

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          • gustovh
            Forum Sage
            Past Site Supporter
            • Oct 2006
            • 4994
            • Vernonia

            #6
            Yes it did, only had to refresh the O ring seat and replace the O ring. That was 15 years ago still functions as designed.

            V
            Gustov
            80 GS 1100 LT, 83 1100 G "Scruffy"
            81 GS 1000 G
            79 GS 850 G
            81 GS 850 L
            83 GS 550 ES, 85 GS 550 ES
            80 GS 550 L
            86 450 Rebel, 70CL 70, Yamaha TTR125
            2002 Honda 919
            2004 Ural Gear up

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            • first timer
              Forum Sage
              • Aug 2002
              • 3429
              • Tucson, Arizona

              #7
              Just used a K&L rebuild kit (18-4344), worked fine, everything worked like stock, just need to make sure all your surfaces are clean and old gasket material is removed. I would use the kit again. Maybe I am lucky, my oem petcock was stock, un molested and had no corrosion.
              78 GS1000 Yosh replica racer project, 82 Kat 1000, 10 990 ADV-R, Some dirt bikes

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              • KiwiAlfa156
                Forum Mentor
                • Sep 2012
                • 661
                • New Zealand

                #8
                Yep, installed a kit - diaphragm and gasket from Z1 Enterprises. Worked perfectly.
                82 GSX1100SXZ Katana
                82 GSX750SZ Katana
                82 GS650GZ Katana

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                • argonsagas
                  Forum LongTimer
                  Charter Member
                  GSResource Superstar
                  Past Site Supporter
                  • May 2002
                  • 18761
                  • Toronto, Canada

                  #9
                  I bought a kit on e-bay, but do not recall the name.
                  It worked fine for the next six years, which is when I sold the bike.

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