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New petcock leaking gas

JTGS850GL

JTGS850GL

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Past Site Supporter
I just replaced my petcock with a stock unit. After installation I discovered that I get a little weeping of gas around both bolts. The unit came with one gasket that puts both bolts inside the gasket ring. What is supposed to seal the screws that are used to mount the petcock? Was I supposed to have another O-ring or something to seal the screws?

On the bright side, replacing the petcock did solve the issues with gas in the vent line. I also replaced all four of the float valves and now the bike is running proper.
 
Yes...there are little washers with rubber middles that seal the bolts..you need them. See a parts fiche and youll see them
 
They are called "sealing washers" - available at hardware stores, probably in plumbing section for about 30 cents each for 1/4 inch size (this fits fine for 6 mm bolt)
 
chuck hahn said:
Yes...there are little washers with rubber middles that seal the bolts..you need them. See a parts fiche and you'll see them
Click to expand...

tom203 said:
They are called "sealing washers" - available at hardware stores, probably in plumbing section for about 30 cents each for 1/4 inch size (this fits fine for 6 mm bolt)
Click to expand...

Thanks for the help guys. I'll go to the local Home Depot or Ace Hardware and see if they have a couple. The strange thing is that the petcock I took off didn't leak but didn't have the washers either. I think the PO used pipe dope to seal the threads.
 
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Did the washers stay stuck on the old petcock?
Also,I have seen some that someone had just used thread sealer on,instead of replacing the washers.
 
Due to my impatience I've cut black fuel line before, cut a thin slice and used it as a gasket, worked for years without leaking. Just make sure the fuel line is the right size, needs to barely fit over the bolts. The slice of fuel line is so tight that you have to spin it down the bolt. Works like a charm.
 
Picked up the 1/4" sealing washers at Home Depot. 4 washers for $0.83. Found them in the nuts and bolts section under rubber washers.
thx4.jpg

Ended up picking up a few rubber fender washers to go between the tank and the frame as well. The stock ones were missing and the PO bolted the tank straight to the frame. Always picked up a little vibration through the tank and didn't know why until I removed the two bolts near the seat and found the vibration went away.
 
azr said:
Due to my impatience I've cut black fuel line before, cut a thin slice and used it as a gasket, worked for years without leaking. Just make sure the fuel line is the right size, needs to barely fit over the bolts. The slice of fuel line is so tight that you have to spin it down the bolt. Works like a charm.
Click to expand...

What an awesome idea!!

JTGS850GL said:
Picked up the 1/4" sealing washers at Home Depot. 4 washers for $0.83. Found them in the nuts and bolts section under rubber washers.
Click to expand...

Are these rubber washers from Home Depot likely to be fuel resistant?
 
Bow_Tied said:
What an awesome idea!!



Are these rubber washers from Home Depot likely to be fuel resistant?
Click to expand...

That was going to be my question as well... I'd advise letting them sit in a jar of gas for a few days and see what happens. If you use them, keep a close eye on them.

I used fiber washers on my petcock and it hasn't leaked yet. I would have preferred nylon, but the hardware store didn't have them in the right size.

But the OEM washers are probably the best way to go. You can try the hardware store ones, but consider adding the OEM ones to your shopping list the next time you place an order.
 
The ones I got from Ace have sealed nicely for two years- likely buna rubber which swells nicely in presence of gas to make nice seal.
 
The washers I picked up at HD are constructed of neoprene rubber over a galvanized disc spring washer made by Everbilt. Should hold up well with gas. So far they're tight and dry. I see no issue with using them and the 1/4" version is a perfect fit on the 6mm bolts.
 
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