Petcock valve help please.

Troystg · September 28, 2009, 09:31:50 PM

Hi All-

Well unfortunately today I found another reason to not like my local stealership.

I rode from Lafayette LA to Birmingham AL. As I was getting ready to exit in Hattisburg MS the main tank started to run out of gas. I switched to the reserve and the bike died.. Out of Gas. I KNOW my petcock valve and routinely run the tank empty to have to switch to reserve. However today was the first time I had to go to reserve since the bike was in the shop. Low and behold there was no reserve.

I was lucky and pissed. Lucky n the fact that it happened as I was on the exit so it was a short push to a station. Pissed because I know the dealers mechanic did it and they actually charged a premium to do it.

So finally the questions are;

How could they have reversed the valve to drain the reserve tank while the valve is set for main?
How do I repair it with the stock tool kit in Birmingham AL before I ride home?

Any and ALL help appreciate.

Thanks again,

Troy #309

TLRam1 · September 28, 2009, 11:19:15 PM

Troy,

I don't think the petcock can be put together wrong, IIRC it's actually pop riveted together. Drain the tank in a gas can (Main-ON) than switch to reserve and see what happens, if you pull the petcock this has to be done anyway.

Charles S Otwell · September 28, 2009, 11:27:44 PM

It may be a wild shot but that happened to mine not too long ago, an oversize o-ring was used and tightened down too tight closing off the reserve hole, clean your petcock valve replace or clean the filter and replace with the proper o-ring, that is if you don't find another culpret responsible for the problem..

sporacer · September 29, 2009, 09:06:35 AM

How many gallons did the tank hold when you filled it? If the previous post is not the answer, I suspect a bad manual petcock that drained the tank main and reserve even though you had the lever in the main position. If it held more than three gallons you used your reserve also. I just replaced my defective petcock a few weeks ago. The failure mode was it flowed gasoline from the tank to the outlet no matter what position the lever was in. OFF or On or Reserve, gasoline freely flowed. I didn't take it apart to see how it works, but their must be a seal or O-ring than can fail and let gasoline flow. I removed the petcock from the tank and checked its operation with an air blow tool and it seemed the reserve inlet was open to the outlet no matter the lever position. Of course I didn't know this was the case when I pulled the gas line to remove the tank to check the air filter. I poured quite a bit a gas on my shoes and on the bike before getting my finger over the outlet and removing the tank and standing it on its end.

My bike is a 94, which I bought in June. The strainer, which is part of the petcock assembly was not only very dirty but was twisted and distorted. I suspect the plastic it is made of cannot handle modern gasoline. The strainer probably needs to be on a 5 year maintenance cycle unless you can find a regular source for no alcohol fuel. The crud on the strainer looked like rust, so I did the electrolysis rust treatment on the tank and sucked a bunch of iron oxide out, even though none was visible through the petcock or filler holes.

drkngas · September 29, 2009, 09:46:37 AM

Quote from: sporacer on September 29, 2009, 09:06:35 AM
The failure mode was it flowed gasoline from the tank to the outlet no matter what position the lever was in. OFF or On or Reserve, gasoline freely flowed.

I noticed mine is free-flowing the fuel no matter what position it is in. My reserve still works properly but there is no OFF. Luckily the tank was down to the last 1.5 gallons when i pulled the tank and I was able to prop it up to keep the fuel from running out. I guess replacing the petcock is the only fix. On a related note..... I ran out of gas about a half mile from the gas staion last month and LUCKILY! I had that 30 ounce gas bottle that Curtis posted on here a while back in my pack. No pushing for me!

Greg Cothern · September 30, 2009, 11:37:35 AM

SPORACER where are ya located?

sporacer · October 04, 2009, 06:54:51 PM

Central SC. Chapin

Troystg · October 08, 2009, 09:13:22 AM

Today I hope to take a ride and check the petcock a final time before I tear into it Saturday.

I have ~86 miles on the main tank and expect it to be dry within the next 10 and have to switch to reserve. If it doesn't that means the valve is malfunctioning. <The indicator IS on main>

I will have a plastic gallon gas can on the back in case it doesn't function correctly and I drain the reserve tank also.

dc112675 · October 09, 2009, 10:23:42 PM

Quote from: drkngas on September 29, 2009, 09:46:37 AM
Quote from: sporacer on September 29, 2009, 09:06:35 AM
The failure mode was it flowed gasoline from the tank to the outlet no matter what position the lever was in. OFF or On or Reserve, gasoline freely flowed.

LUCKILY! I had that 30 ounce gas bottle that Curtis posted on here a while back in my pack.

May I ask what you are referring to? Is there a safe way to carry a small bottle of gas around? At 40 mpg a 20 oz bottle should get you about 7 miles, and 30 oz should get you 10. If I go real easy on the gas (50 mph) I can get over 50 mpg. With that figure 20oz would get me 8 miles and 30oz would get me 12 miles.

TLRam1 · October 09, 2009, 11:00:41 PM

Quote from: dc112675 on October 09, 2009, 10:23:42 PM
Quote from: drkngas on September 29, 2009, 09:46:37 AM
Quote from: sporacer on September 29, 2009, 09:06:35 AM
The failure mode was it flowed gasoline from the tank to the outlet no matter what position the lever was in. OFF or On or Reserve, gasoline freely flowed.

LUCKILY! I had that 30 ounce gas bottle that Curtis posted on here a while back in my pack.

May I ask what you are referring to? Is there a safe way to carry a small bottle of gas around? At 40 mpg a 20 oz bottle should get you about 7 miles, and 30 oz should get you 10. If I go real easy on the gas (50 mph) I can get over 50 mpg. With that figure 20oz would get me 8 miles and 30oz would get me 12 miles.

drkngas · October 10, 2009, 04:32:33 PM

Thanks Terry for responding. That is exactly the bottle (1 of them anyway) that I carry. Maybe I should buy a second one.

Curtis_Valk · October 11, 2009, 01:08:24 AM

Quote from: drkngas on October 10, 2009, 04:32:33 PM
Thanks Terry for responding. That is axactly the bottle (1 of them anyway) that I carry. Maybe I shold buy a second one.

I carry four of them. <wide grin>

Curtis

lragan · October 11, 2009, 02:41:10 PM

Quote from: Curtis_Valk on October 11, 2009, 01:08:24 AM
I carry four of them. <wide grin>
Curtis

Well, yeah, but you ride a Valk -- that giant slurping sound is the gas through the carbs...

Capt. Howard · October 11, 2009, 06:09:17 PM

Quote from: lragan on October 11, 2009, 02:41:10 PM
Quote from: Curtis_Valk on October 11, 2009, 01:08:24 AM
I carry four of them. <wide grin>
Curtis

Well, yeah, but you ride a Valk -- that giant slurping sound is the gas through the carbs...

Lawrence I hope that is not the case...I just brought home my new "BABY"...

[attachment deleted by admin]

Curtis_Valk · October 11, 2009, 06:52:25 PM

Quote from: Capt. Howard on October 11, 2009, 06:09:17 PM
Quote from: lragan on October 11, 2009, 02:41:10 PM
Quote from: Curtis_Valk on October 11, 2009, 01:08:24 AM
I carry four of them. <wide grin>
Curtis

Well, yeah, but you ride a Valk -- that giant slurping sound is the gas through the carbs...
Lawrence I hope that is not the case...I just brought home my new "BABY"...

Capt. I've hit 40 mpg a few times with my Interstate but that is not usually the case. 33 to 36 is the norm unless yours is a '97 and then you can expect a couple mpg less usually.

Curtis