Replacing a Ninja petcock

[ralph13]

A while ago, I bought an old Ninja 500. It was the closest thing to a GS I found in my area at the time, and it wasn't very expensive.

However, the petcock needs to be replaced (not only is it not working, it's not even the right petcock. It seems like one from the ninja 250). I got the right petcock, and now I just need to replace the broken one.

This will be my first time working on a bike that isn't a little 50 cc moped, so I figured I would ask a few questions since a lot of you guys are more experienced with this kind of thing.

Is it better if I drain the fuel tank before taking it off?

Are there any major pitfalls that can occur while installing a petcock? I mean just small things that are easy to overlook that can cause big problems. If so I want to avoid them.

Thanks

[Kijona]

A while ago, I bought an old Ninja 500. It was the closest thing to a GS I found in my area at the time, and it wasn't very expensive.

However, the petcock needs to be replaced (not only is it not working, it's not even the right petcock. It seems like one from the ninja 250). I got the right petcock, and now I just need to replace the broken one.

This will be my first time working on a bike that isn't a little 50 cc moped, so I figured I would ask a few questions since a lot of you guys are more experienced with this kind of thing.

Is it better if I drain the fuel tank before taking it off?

Are there any major pitfalls that can occur while installing a petcock? I mean just small things that are easy to overlook that can cause big problems. If so I want to avoid them.

Thanks

Never done a Ninja before but I would imagine it's much like our GS500's. There's probably a secondary petcock/shutoff valve attached directly to the bottom of the tank that can be turned off to make things easier. One could turn this off by simply finding a very long flatblade screwdriver and lifting the tank about half an inch to get the screwdriver in.  Here's what it looks like on the GS (click to make bigger):



That being said, as an alternative, get a pair of vice grips or a clamp and also locate a few small pieces of wood. Use the wood to create an even clamping surface (or use some kind of other material). Clamp the fuel line shut just a few inches above the petcock, rather than taking off the tank and all that other stuff.

The idea is to squeeze the fuel line closed without damaging it, which if it's in good shape shouldn't be a problem. Just be careful not to clamp it so tight that it actually damages the fuel line. To put it in perspective, on the GS you can ALMOST squeeze the line shut with just your fingers. I would wager that the line on the Ninja is fairly similar. You might even be able to clamp it with one of these:



Also, you could just drain the tank completely into a bucket or something. Trying to lift the tank with it full of gas is going to prove challenging.

Pro tip: Stuff a bunch of old rags or other absorbent material into the frame and around where you will be working. This will capture any spills and help prevent a huge mess all over the bike.

[The Buddha]

I believe a ninja has a single petcock - not the 2 stage like the GS.
Cool.
Buddha.