Pingle Knockoff howto

[free99]

Hey there,
I was running low on funds restoring my 1983 GS450L, when I realized the vacuum petcock was leaking fuel into the vacuum port. I tried a rebuild kit off ebay, no dice.

I wound up making a manual petcock using spare material from work and a compatible fuel valve from eBay. All in, total cost would be $50 for a high quality valve which I believe competes with more expensive alternatives in almost every way, and that's if you have to buy everything from scratch.

I've attached a schematic of the final assembly, but I think you'll understand pretty quickly what I did. Here's the link to a high res PDF: https://ufile.io/xn8yfucs

I believe this should work for any medium size GS, perhaps even the larger displacement ones.

Let me know if you have any questions or concerns

---

All this stuff is off eBay:

[TABLE="class: grid, width: 500, align: left"]
[TR]
[TD]Item[/TD]
[TD]Cost Ea.
[/TD]
[TD]QTY[/TD]
[TD]Net Cost[/TD]
[/TR]
[TR]
[TD]9mm (3/8") 6061 Al Bar[/TD]
[TD]$13[/TD]
[TD]1[/TD]
[TD]$13[/TD]
[/TR]
[TR]
[TD]M14x1.5 RH Tap[/TD]
[TD]$8.20[/TD]
[TD]1[/TD]
[TD]$8.20[/TD]
[/TR]
[TR]
[TD]M6x1.0x20 Stainless Button Cap Bolt[/TD]
[TD]$0.87[/TD]
[TD]2[/TD]
[TD]$1.74[/TD]
[/TR]
[TR]
[TD]Manual Petcock w/ Reserve (search for GPZ/KZ750 petcock)
[/TD]
[TD]$10[/TD]
[TD]1[/TD]
[TD]$10[/TD]
[/TR]
[TR]
[TD]M6 Copper Washer[/TD]
[TD]$0.16[/TD]
[TD]2[/TD]
[TD]$0.32[/TD]
[/TR]
[TR]
[TD]2mm Thick Fuel-compatible gasket material (e.g. Viton)[/TD]
[TD]$14.50[/TD]
[TD]1[/TD]
[TD]$14.50[/TD]
[/TR]
[TR]
[TD="align: right"]

---

Grand Total:[/TD]
[TD]

---

[/TD]
[TD]

---

[/TD]
[TD]

---

$47.76[/TD]
[/TR]
[/TABLE]

 

[free99]

I hope this PNG will stick around, just in case the PDF doesn't.

 

[free99]

Final Result:

 

[Gorminrider]

Oh gee! isn't that cool! (and good on you for sourcing some viton sheet. Costs a fortune doesn't it? )

 

[free99]

Thanks Gorminrider This guy's got something similar to what I used listed for $14.50 including shipping: https://www.ebay.com/itm/VITON-RUBB...6-SQUARE-ACID-CHEMICAL-HIGH-TEMP/190795526610

Oh I guess relative to regular rubber, yeah, expensive. But hey, only gotta do it once if you do it right (probably).

 

[Grimly]

Excellent, ta.

 

[salty_monk]

any clearance issues with the carbs? Presumably not... would have to be something confirmed on a case by case I guess

 

[Guest]

I installed an actual pingel adapter years ago, and just used hylomar with no gasket. Sealed it just fine.