When your Petcock is too big for its britches

[jharvey]

Greetings all, and happy spring,

Over the winter, I had to get the petcock replaced on my 1980 GS400ET. (Or GS450ET in the US or GSX400ET in the UK) Naturally, the original part is long since out of production, and though I had still been able to get an OEM replacement a couple of times in the past, it wasn't possible this time around, so the mechanic got a "universal" petcock to do the job.




The original (Suzuki part# 44300 44172) can be found here…

https://www.cmsnl.com/en-ca/suzuki-gs450et-1980-t-usa-e03_model16015/partslist/BLCK0030.html

https://images.cmsnl.com/img/products/cock-assyfuel_big4430044172-01_4fb8.jpg

And the replacement looks something like this…




Screenshot .jpg






Unfortunately, as I discovered now that I'm returning to riding in the warm weather, the replacement petcock is too wide as you face it – resulting in the PRI 'wing' of the front face trying to gouge a hole in the front of my side cover (pressing against it with enough force that the side cover's mounting peg broke).


I managed to find a replacement side cover in the Netherlands, and in the interim have had to hacksaw a hole in the front-facing part of the ‘repaired’ side cover, but I’d like to be able to avoid having to do that to the replacement when it arrives.

Does anyone (especially if they own this particular bike model) have any suggestions for a specific vacuum petcock that is either an aftermarket clone of the original, or at least one ‘narrow’ enough to fit this bike without colliding with the sidecover?


Thanks,

[rphillips]

I had a similar problem when installing a eng with CV carbs on a GS1000S frame designed for VM carbs., pet cock at slightly different location... I fabricated a piece of metal to raise the rear of the tank (and petcock) appx. 1 in...Worked perfect and had to be a GS1000 expert to ever notice the difference. May not work at all for you, but just say'in.

[jharvey]

I had a similar problem when installing a eng with CV carbs on a GS1000S frame designed for VM carbs., pet cock at slightly different location... I fabricated a piece of metal to raise the rear of the tank (and petcock) appx. 1 in...Worked perfect and had to be a GS1000 expert to ever notice the difference. May not work at all for you, but just say'in.

Thanks for the suggestion. I'll keep it in my back pocket, but given the way that the seat's physical lines and trim stripes flow into the tank...

1980_GSX400E_500.jpg

I'd rather keep that as is if possible. But it's an option I hadn't considered, so thanks again.

[rphillips]

OOhhh, not good with those stripes, the old GS1000's were nothing like yours... Good luck. and

[dgates1]

Found this.. under previous part number. Might be worth a call to see if they actually have it in stock.

https://www.motosport.com/oem-parts/part-number/44300-41371

[Big T]

Being a 1980 model, your bike would have come with the dreaded lever less petcock
It is much slimmer that what you have a installed now
Likely a Pingel is your best hope

[rphillips]

Looking at parts fiche, it seems the "80" GS450 was spared the dreaded leverless valve.

[jharvey]

Found this.. under previous part number. Might be worth a call to see if they actually have it in stock.

https://www.motosport.com/oem-parts/...er/44300-41371

Amazing - in countless searches over the last weeks/months, including sites around the world, I hadn't come across a site claiming to have one in stock. I've fired off an email to confirm - and to see if they also carry repair kits - I expect that even if it's a 'new' part, there's a good chance it was manufactured a couple of decades ago, so I should be prepared for 'aged' rubber.

Thanks!

[jharvey]

"...dreaded leverless valve"?

I know that on the 2 occasions in 45 years I had to switch to Reserve, the lever was stiff as a board - but so is the arm on current one. (Which, apart from conflicting with the side cover, results in fuel starvation on non-stop-and-go riding unless it's on Prime. Another reason it needs to be replaced.)

What made this one ... dreaded?



Thanks

[rphillips]

Please don't leave us wondering, let us know what they tell ya.

[jharvey]

Please don't leave us wondering, let us know what they tell ya.

Absolutely - though I doubt I'll hear back this weekend. And after having a look on the schematics, well, as the succession number for my original, it may be a replacement in the sense that it'll fit the holes and flow fuel, but this...

https://www.suzukipartshouse.com/oemparts/a/suz/508b20dcf870023530724113/fuel-cock

sure doens't look much like this...

https://www.cmsnl.com/en-ca/suzuki-gs450et-1980-t-usa-e03_model16015/cock-assembly-fuel_4430044170/

Time will tell,

[jharvey]

Heard back from Motosport with the attached picture (full points to them for a quick and helpful reply).

I expect it would attach to the tank fine, but definitely a different animal - and not a vacuum petcock.


Suzuki 44300-41371.jpg

So the closest match to date is a unit from a European supplier which looks identical to my original, except that the fuel and vacuum attachment points are on the right rather than left side of the the petcock. The question there is whether the hoses will then 'run up against' the left side cover, so I guess I'll have to do some eyeballing and guesstimation.