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I'm now a beleiver on petcock rebuild kits sucking

JTGS850GL

JTGS850GL

Forum Sage
Past Site Supporter
I purchased a petcock rebuild kit and THOUGHT it was a successful install. Everything seemed to work just fine for the first few days. Today I went to start the GS1000G only to find the cylinders almost hydro-locked. I pulled the hose off the petcock and... Gas poured out like it was in the prime position. I know I need to see why the gas got past the floats as well. All new float needle and seats were installed. I'll de-gang the carbs and check each one to verify float level and see if there is any creep.

Just ordered a new OEM petcock from PartsOutlaw.com with a free shipping promo code. $82 later I'll have a new OEM petcock coming. I should have listened to those that said that the success rate was low on the rebuild kits. :o

I will analyze the reason for failure and post back.
 
I know the reason the ones I have tried failed..the oring on the plunger that seals against the counter sunk area are too ft and they hang up and wedge in there sideways. And Im have never found that "just right " oring either.

And be sure to change the oil before you crank it over and fill the filter full of gasoline also. Bet the crankcase smells ripe.
 
I'm curious about the float problem and what you did exactly to fix it.

This is why I wanted to add an inline fuel valve somewhere along my fuel line. Still kinda do.
 
Rebuild Kits

Rebuild Kits

JTGS850GL said:
I purchased a petcock rebuild kit and THOUGHT it was a successful install. Everything seemed to work just fine for the first few days. Today I went to start the GS1000G only to find the cylinders almost hydro-locked. I pulled the hose off the petcock and... Gas poured out like it was in the prime position. I know I need to see why the gas got past the floats as well. All new float needle and seats were installed. I'll de-gang the carbs and check each one to verify float level and see if there is any creep.

Just ordered a new OEM petcock from PartsOutlaw.com with a free shipping promo code. $82 later I'll have a new OEM petcock coming. I should have listened to those that said that the success rate was low on the rebuild kits. :o

I will analyze the reason for failure and post back.
Click to expand...


That sucks! At this point I'm a little concerned about the amount of money I'm spending on my 32 year old "T". {Reason: Just when I fix an area, it somehow manages to unfix itself}

Anyway, I buy lots of parts from partsoutlaw but my recent purchase of a Fuel Petcock was through Z1...and it cost me just over $50 including shipping. Of course, I bought my V&H 4-1 pipes and Progressive Shocks from them so they have a history of my purchases.

I bought all the components for a Camchain Tensioner rebuild and have yet to complete it. (From Partsoutlaw) I've got to get the front sprocket loosened so I can complete my 530 conversion. (Oh yeah, I got my kit from Z1 as well)

Post pics of your new part as well as the old. Disassembly pics would be good too. I recommend Z1 for those components I purchased.



Ed
 
I haven't found a petcock for a 1980 GS1000G on Z1's site. Let alone for $50. Even if I did, I'm a little too gun shy to go any route then OEM now.
 
I bought the one from Z1, but as stated on here before, they are different.
Mine also failed, and i replaced it with OEM.
I cant remember the Z1 owners name on here, but i believe he generously offered another one if i sent the failed one back, not really worth the gamble + postage from here unfortunately.
 
Oem

Oem

JTGS850GL said:
I haven't found a petcock for a 1980 GS1000G on Z1's site. Let alone for $50. Even if I did, I'm a little too gun shy to go any route then OEM now.
Click to expand...


It's best to call them...Rob from Z1 is awesome! Option 1, btw.

I'll happily report back my findings on the fuel petcock I purchased. Trust me, I'm all about OEM parts...ask Mike at Partsoutlaw.

Of course, when I spend money, I look forward to the happiness it will bring. That's probably why I don't mind spending it. I am clearly happy with the results.


Ed
 
Happiness

Happiness

mrbill5491 said:
Ed is happy happy happy. Well, I at least try to help out on that. He loves ride. So far so happy. I would like to try and help him with his other fixes, though I'm afraid time is running out before he has to leave.
Click to expand...


OMG, Bill...you have been a God sent.

So eager to help me it is truly a testament to the great person you are. I am grateful to have you as a friend.



Ed
 
Ed is happy happy happy. Well, I at least try to help out on that. He loves to ride. So far so happy. I would like to try and help him with his other fixes, though I'm afraid time is running out before he has to leave. Oh yeah Ed, we kind of have a new air compressor, still in the box yet though. I can't use it until the boss gets his reimbursement check for it. Was on sale at Sears so we rushed into buying it with out an Okay from the chairman of the board lol. If they bulk at it, we may have to take it back boohoo. Hopefully they won't make too big a stink about it. If not, I'll need something, like say a stubborn sprocket nut to break it in lol.
 
Sprocket Lock

Sprocket Lock

mrbill5491 said:
Oh yeah Ed, we kind of have a new air compressor, still in the box yet though. I can't use it until the boss gets his reimbursement check for it. Was on sale at Sears so we rushed into buying it with out an Okay from the chairman of the board lol. If they bulk at it, we may have to take it back boohoo. Hopefully they won't make too big a stink about it. If not, I'll need something, like say a stubborn sprocket nut to break it in lol.
Click to expand...

I'm kinda at a standstill with the sprocket...since your 630 chain is working fine, I am not in a rush to R-square it. (R2/Remove & Replace)

We've got a busy month...not sure if I'm gonna do the 530 conversion before I leave NM. I can't believe I've been here since Oct and now when crunch time is near, all the excitement seems to be happening.

I truly hope I mis-diagnosed my oil leak...looking forward to this weekend's acitivities in Ruidoso.



Ed
 
Last edited:
i found that the reason for repair kits to fail is because the little O ring. On the end of the prime screw is not included in the kit, & its this that lets fuel past.
 
JTGS850GL said:
I haven't found a petcock for a 1980 GS1000G on Z1's site. Let alone for $50. Even if I did, I'm a little too gun shy to go any route then OEM now.
Click to expand...
This Florida guy sells different petcocks direct and thru ebay- might have your model. I bought one two years ago; made in Japan and a duplicate of the the original . I suspect the same manufacturer supplies suzuki dealers with their replacement units. Here's his leverless 80 version.....

http://www.georgefixs.com/servlet/the-524/1980-GS550,-GS750,-GS850,/Detail
 
The petcock on my 1980 is the one with a lever so it's a little pricier then the no valve type he lists. Still feel that $82 delivered for an OEM petcock is a reasonable price. At least I wont have to worry about it for a while.

Now, as to how the gas got through the float bowl valves is another question that needs to be resolved. Looks like I'm going to have to pull the carbs and see which one is leaking.:(
 
tom203 said:
This Florida guy sells different petcocks direct and thru ebay- might have your model. I bought one two years ago; made in Japan and a duplicate of the the original . I suspect the same manufacturer supplies suzuki dealers with their replacement units. Here's his leverless 80 version.....

http://www.georgefixs.com/servlet/the-524/1980-GS550,-GS750,-GS850,/Detail
Click to expand...
Plus 1 on George. I used him for replacements on both my bikes. And like you I suspect they are the same manufacturer Suzuki uses...
 
bccap said:
Plus 1 on George. I used him for replacements on both my bikes. And like you I suspect they are the same manufacturer Suzuki uses...
Click to expand...


I have used his valve cover gaskets in the past and they seem exactly the same as Suzuki.
 
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