New Manual Petcock Coming!

[Coyote]

I finally did it. I ordered the manual petcock from Parts n' More. I have been recommending this to folks for years but I don't think anyone ever bought one. So I'll be the first. $30 for the petcock and $8 for the adapter plate. On, Off and Reserve. Really hard to tell from the tiny picture, but it's supposed to have 3 outlets. 2 at 90 and 1 straight. Comes with one block off plug so I'm gonna have to figure out how to block the other as I only need 1 outlet. This is to replace the petcock on my GS1000. Tired of fighting it. I wasted $24 on a rebuild kit that didn't fix it. I installed an inline shutoff, but there really is no room and it came out really awkward. This is a universal unit so you need to by the adapter plate or adapter nut. The actual thread on the petcock is 3/8NPT male.
Parts n' More is based in Canada so shipping was a little steep at $11. I'm sure it would be much less if you live in Canada. Expect pictures and a list of likes / dislikes when I get it.

[Alan H]

Make sure the outlets can flow enough fuel at WOT or it'll run weak.
The original GT range fuel taps with 3 outlets are smaller bore than the single outlet later type, so will flow the same fuel as the earlier taps 'all three outlets'.
Just an observation.

[Coyote]

The GS uses a single outlet similar to the later GT's. The GS outlet is only slightly larger and is comfortable with a 5/16 fuel line. I have no idea what I am getting, but if necessary I can run 2 lines with a T between carbs 1 and 2 and another T between carbs 3 and 4. OR, I can set the whole mess on fire.

[Coyote]

Concerning the petcock. The adapter plate screws to the tank just like the OEM petcock. The new petcock then screws into the adapter plate on a pipe thread. I feel like I need to use something to seal those threads to prevent leaks. I know teflon tape is for natural gas and other dry pressure fittings. That leaves pipe dope. I seriously doubt that will hold up to fuel. Should I use teflon tape even though it's made for dry threads?

[yeadon_m]

I would expect ordinary PTFE white tape to seal OK providing you don't expect it to bridge big gaps. It won't dissolve but bits of it might flake / tear off and fall into the fuel line but I doubt it unless you really overdid it with the tape.
I have used Hylomar Blue (a clear, blue and sticky, messy liquid designed to be fuel and oil resistant) to seal tap to tank bolts with good results. In fact, I've never found the sealing washers Suzuki provides to be quite good enough (n=2 trials) so every time afterwards I've put Hylomar on the bolt threads, and on both sides of the washer and not had a leak. It is messy stuff though so apply it with a small electrical screwdriver and not a fingertip, or it'll get on everything!
Cheers,
Mike

[Coyote]

I gotta tell you. There was this maintenance man at work that used 15-20 wraps of the tape on pipe fittings and then wondered why it leaked. Must need more tape Looked like he was trying to screw in a golf ball.

[Coyote]

You would think as ancient as I am I would have learned to think things through. I got to thinking (too late) that the pipe thread on the petcock is bound to go through the adapter plate. That means I will have to modify the stock mount on my tank so the OD of the pipe thread can protrude through. I wouldn't have a problem with that if 78 GS1000 tanks were plentiful. They are about as common as chicken teeth. I really don't want to modify my tank. I won't get the petcock for at least another week Parts n' More decided to sit on my order for over a week. It's supposed to ship today (9-10). I ordered it on 9-3 and paid with PayPal.
If anyone out there thinks they can fix this OEM petcock, I'm willing to pay postage both ways and a reasonable charge. I messed with it for hours and it flat wont seal. Everything replaceable is new. Diaphragm, o-ring, 4 hole gasket and V seal. I have the original short spring and a longer one from a different petcock hoping the added tension would push it closed. Didn't work.

[BLAZY]

I ended up using a manual Pingel fuel valve and adapter plate on my GT500. Very high quality (with a price to match). Had to enlarge the middle of the long hole in the bottom of the gas tank slightly so the fuel pipe would feed into it, so it was a "no turning back" kind of update. But, it looks good and doesn't leak.

BTW, Yellow teflon tape is for fuel, oil, and gas connections, not white. White is for water. White will eventually break down when exposed to petroleum products.

[Coyote]

Had to enlarge the middle of the long hole in the bottom of the gas tank slightly so the fuel pipe would feed into it

That's what I'm going to have to do to my tank I'm sure. Don't know how much as I still don't have it. Supposed to be here tomorrow, but I suspect Wednesday.

[akendall1966]

When I bought a pingle tap and adaptor a few years back it came a small sachet of blue hylomar in the kit to be used both on threads and plate to tank seal. Worked for 4 years I ran the bike after fitting.

[Coyote]

It IS coming today. Just checked tracking and it's out for delivery. FedEx runs late in the afternoon here, but I should know what I got tonight. Expect pics and evaluation as I am the guinna pig on this petcock.