Petcock assembly -- V-seal

[Coyote]

I am assembling my petcock (GT550). It's the later model that uses a V-seal in the lever OD. One side of the seal is beveled and the other side is grooved. Which side faces in?

Also, how do you retain the one filter that just slips in the hole? (reserve filter).

[jabcb]

Service Bulletin GT-37 shows how the "V" seal is installed.
http://www.ozebook.com/compendium/techb ... 034-39.pdf

[Coyote]

That's exactly opposite of what I thought. I figured the 'cup' side would face the fuel. Oh well, that's why I asked. Now if I just knew where to get that o-ring. Put a lot of new parts on but did not replace the o-ring. I can tell just with lung pressure that it's going to leak. Float needles and seats look good, but I hate to rely just on that. A working petcock really shines when you need to remove the tank. No runs, no drips, no dribbles, no problem.

[jabcb]

Looks like all of the little parts for the petcock are currently available from Suzuki.
http://www.partzilla.com/parts/search/S ... parts.html

The petcock gasket (part #3) actually has a little tab on it.
Haven't thought about it before, but that tab might be there to hold the reserve filter in place.

[Coyote]

That tab is for the next generation petcock and filter. The base of the newer filter was oval and that tab held it down. That tab must be removed on our style petcocks as that tab nearly completely covers the hole for the reserve filter. The tab is used on my 78 GS1000 but can't be used on our type. Other than that, the 2 gaskets are identical
I got most of the needed stuff in the fiche. The o-ring I need is not shown because it's on the back side of the petcock. Suzuki never sold pars for that side. Some rebuild kits have the o-ring and some don't. It's sad because that o-ring is the most critical part of the whole thing. It IS what shuts off the fuel when there is no vacuum.

[jabcb]

HVCCycle has rebuild kits that include the o-ring.
http://www.hvccycle.net/suzuki-gt-fuel- ... -hvc200s1/

If you can figure out what size the o-ring is, then most likely you can get it at The O-Ring Store.
http://www.theoringstore.com/index.php? ... &cPath=368

[Coyote]

I am aware of that kit, but all I need is the o-ring. I already have a new 4 hole seal, bowl gasket, v-seal and tank seal / gasket. I'm not about to spend $30+ for an o-ring.
The original o-ring is still in place but I know from past experience that it will break if I remove it. It's hard and brittle. Once it breaks, it's hard to match it up with another. It is approximately the same size as the o-rings that go below the oil pump manifold, but it has a thinner cross section. I once tried one of those o-rings from under the pump and it didn't work.
SOMEBODY out there knows the dimensions or number of the needed o-ring. The people that make that rebuild kit have a whole bucket full.