So after trying to do a fix on my '99 500E's lower petcock for the fuel starvation issue, my petcock is leaking a little fuel. Not much, just enough to make the thing shine with it, and riding doesn't seem to exacerbate the issue, but I decided to just go ahead and replace it... with the '04-'07 petcock, which I know goes a ways to dealing with that selfsame starvation issue.

Does anyone have any guides for doing this, or is it as easy as putting the proper hoses in the proper places? The fact that it's for a 500F and mine is a 500E won't cause any issues, right?

Also, can I keep the main petcock on the tank the same, or does that need to be swapped for the newer version as well? So far as I can tell, that one is fine, so if I can keep it, I'd prefer to.

EDIT: Also, would I get rid of the vacuum hose, or does that go somewhere I'm not seeing on the diagram?

This link should help ya out a bit (with the hose routing):

http://wiki.gstwins.com/index.php?n=Main.HoseRouting

I don't think you'd have to mess with the tank petcock.

Yeah, I got to that page while figuring everything out - thanks!

New problem, though: The darn thing doesn't fit. The bolt holes are way at the outside relative to the frame, where as the petcock mount is built for the stock's bolt holes all the way inside.  It looks to be about an inch, too much to accommodate my shiny new petcock.

I'm not finding any words of wisdom for bridging this gap.  Anyone have any advice for doing so before I go to the hardware store and cobble together something ungodly (and very likely unsound) to do the job?

Also, just as a sort of fun story, the good hose routing diagram on that page helped me realize that the guys at my mechanic shop had been working off one of the faulty ones, so now I know why my reserve doesn't work.

I'm trying to put a '04+ petcock on my '02 bike. Apart from hose routing there shouldn't be any problems, right?

EDIT: I have installed the '04 petcock on my '02 bike. The hoses were a bit smaller but I pushed them in. After install, the bike ran like never before. I felt like it had the fuel it needed. Less pops, richer sound, etc. However, now it doesn't start properly. I think I need to clean my carbs or something. But I recommend changing petcock if you have fuelling issues