Leaking tank petcock

the mole · November 01, 2011, 04:30:10 AM

My GS started leaking fuel yesterday, at first I thought it was a stuck carb needle and drained both, but closer inspection showed it was leaking from the tank petcock itself. Has anyone else had this problem? I'm guessing there's an o-ring in there that probably needs replacing, but any advice on how to attack it would be appreciated. Thanks!

rayshon · November 01, 2011, 05:23:45 AM

Sure it's not the actual tube?

I had gas leaking from there, turned out to be the upper part of the tube was pretty $%#*'d up

jp · November 01, 2011, 09:12:47 AM

Do you have the stock gas line on? I had to use hose clamps to keep 5/16" line from leaking at the petcock. It didn't leak right away, but started to leak a couple of weeks after replacing the line.

the mole · November 01, 2011, 02:11:10 PM

Stock fuel hose, in good condition, fuel certainly seems to be leaking down on to the hoses from somewhere on the petcock. Has anyone ever pulled one of these apart?

adidasguy · November 01, 2011, 03:26:00 PM

Tank fuel valve does have an O ring. It is held on with 2 bolts. They could be lose or the brass tubes on the fuel valve could be lose (which means replace it). Or the fuel valve itself could be leaking (replace it).

Could be nothing more than bad hose connection - the most common cause of fuel leaks there.

It comes of by undoing the 2 bolts (take gas out of tank first!)
Comes straight out. Be careful not to damage the fuel screen - very delicate.
O ring is an oval so but a new one.
Bolts have 2 washers with rubber on them - that keeps fuel from leaking from around the bolts. REPLACE THEM! If you can find a small crush washer, that might work.

First thing to do is lift up the back end of the tank and see where you really have a leak. Wipe everything dry. If you can't see a leak right away, puff a little baby powder around there. Watch for wetness in the powder.

the mole · November 01, 2011, 04:29:35 PM

Thanks adidas, I'm 99% sure the leak is from the valve itself, its coming from above the hoses but not leaking from where it attaches to the tank. I think I'll have to take it off and see if I can rebuild it.

adidasguy · November 01, 2011, 05:04:54 PM

I have a couple with bad filter screens. The filter screen pulls off (carefully). These got damaged in the parts drawer. The actual valve is held on with a spring clip. Let me know if you can't clean it out. There is probably a worn out O ring in there.

So valves with torn screens can be cannibalized of just swap filter screens. Let me know. I can ship tomorrow. Used fuel valves usually are $25-$50. Just pay shipping. I have plenty of them.

..................
Oh, you're in Ausie country. That kind of rules out shipping.

the mole · November 01, 2011, 05:43:31 PM

Yeah, probably cheaper to find one over here!

I've just got to have a rant here, much as I like the GS there are a couple of things that annoy me about it and of those the worst is that *(^&%$%#%$@ fuel tap. Its the only way to cut off the fuel flow if the hose from it to the frame chicken gets damaged or the frame chicken won't shut off. BUT YOU HAVE TO LIFT THE TANK TO GET TO IT!!!
I'd like to get hold of the guy who designed that one and very slowly choke him. WTF, if you have a leak onto a hot engine you need to shut it off ASAP, not go looking for a 3 foot long screwdriver.

adidasguy · November 01, 2011, 06:23:12 PM

You get at it with a long screwdriver from the right side of the bike. No need to lift the tank.
If the valve is controlled from the left side of the bike, it is installed backwards.

(Actually, a 10 inch screwdriver is enough. I don't know where to buy a 3 foot screwdriver. Maybe time and space is different down there

)

the mole · November 02, 2011, 01:59:57 AM

Hey, when you get to my age you're allowed to exaggerate a little!

My point is that a safety related item like that should be easily operated without any tools. It's only hidden away like that for aesthetic reasons=

IMHO.

gtscott · November 02, 2011, 04:30:42 AM

http://www.silverlinetoolbox.co.uk/silverline-598470-turbo-2919-85923 this is 450mm long so about 1.5 foot, its about the longest i can find

phendric · November 02, 2011, 02:49:31 PM

Quote from: the mole on November 01, 2011, 02:11:10 PMHas anyone ever pulled one of these apart?

I did, yesterday, though not for a GS500 (different Suzuki bike, but I'm pretty sure they're similar, if not identical). There are two pieces of rubber you should check - the large, oval one that seals the gap between the petcock and the tank, and a small round one that goes on the vacuum-operated valve. In my case, I stopped the leak by changing the valve o-ring.

adidasguy · November 02, 2011, 03:00:23 PM

I think we're confusing the frame petcock with the tank petcock/fuel valve. Tank doesn't have a vacuum line.

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Leaking tank petcock