I found 2 rebuild kits for the frame petcock.  They look identical in various photos, but seem to be from 2 different brands with different model numbers. But maybe they're from the same manufacturer?

One from All Balls
https://www.allballsracing.com/60-1072.html
https://www.motorcycleid.com/all-balls/fuel-tap-repair-kit-mpn-60-1072.html

The other from Parts Unlimited
https://www.parts-unlimited.com/search;q=0705-0416

Has anyone tried either of these or know which might be the better option?  The prices are close enough to not make a difference.

You need that pentagon shaped thing. The one on the bottom wont work. They're putting up a generic pic, you order for the GS and you should get the one on top.
Cool.
Buddha.

Quote from: The Buddha on July 06, 2022, 06:54:10 AM
You need that pentagon shaped thing. The one on the bottom wont work. They're putting up a generic pic, you order for the GS and you should get the one on top.
Cool.
Buddha.

Thanks for the info!  So if I understand correctly, you're saying the kit from Parts Unlimited is just a generic photo, and does not include all the parts.  That the one to get is from All balls?  FortNine sells both of them so I want to be sure.
Yes for sure I need that pentagon shaped diaphragm!

No, they're all generic photos. The all balls one is the pic of the package, who knows WTF is in that package.
That one that looks like a smiley with the flat mouth rubber gasket is a kawasaki part.
The pics have all possible parts in the realm of petcock rebuild kits. If you buy the FS one with its part number, you should get the pentagon and its associated parts and not that round thing and its associated parts.
I's shocked they dont have the honda part (has 4 dots in a rubber gasket, not the smiley) also pictured in that mix on there.
Cool.
Buddha.

Quote from: The Buddha on July 06, 2022, 05:51:59 PM
That one that looks like a smiley with the flat mouth rubber gasket is a kawasaki part.
The pics have all possible parts in the realm of petcock rebuild kits. If you buy the FS one with its part number, you should get the pentagon and its associated parts and not that round thing and its associated parts.
I's shocked they dont have the honda part (has 4 dots in a rubber gasket, not the smiley) also pictured in that mix on there.

I most definitely need the 'smiley' gasket in addition to the pentagon diaphragm.
The only pieces in that generic photo I don't need is that oval 'racetrack' gasket and one of the panhead screws. Everything else looks spot-on.  Are we talking about the same part?

I'm not sure what you're referring to as the "FS one with its part number".  Is there some other kit out there that I haven't found?

Grrrr Typo. FS=GS.
OK the bike has the smiley gasket with the 2 round holes and 1 elongated hole ? I thought our bikes didn't, they had a tapered delrin drum doing that function. Maybe only 89-00's are that way.
Cool.
Buddha.

Quote from: The Buddha on July 07, 2022, 07:06:31 AM

OK the bike has the smiley gasket with the 2 round holes and 1 elongated hole ? I thought our bikes didn't, they had a tapered delrin drum doing that function. Maybe only 89-00's are that way.

I only know about my 2005 so don't know how it compares to others.
But I went back to parts fiche and it looks like the 'racetrack' gasket goes with the tank petcock.  I've no reason to mess with mine but if I get parts for it, well I guess that's nice to have a spare.
https://www.gomotoonline.com/oemparts/a/suz/508b06eff8700235307234e2/fuel-chicken

I think I will order the all balls kit.  They seem to have a decent reputation for quality. It's annoying their site only has a photo of the box, but other sites actually show the parts

Yea the 89-00 is different than that one and it doesn't have that 90 degree part.
Cool.
Buddha.

OK I bought the all balls one for the 89-00 - and the important part, the square thing and the round plate that sits inside of it came separate with a hole in the square thing. What did you buy and how to install the round thing into that square thing.
BTW the equivalent of the square is the pentagon in yours. That is the diaphragm.
Cool.
Buddha.

Quote from: The Buddha on July 15, 2022, 05:51:04 AM
OK I bought the all balls one for the 89-00 - and the important part, the square thing and the round plate that sits inside of it came separate with a hole in the square thing. What did you buy and how to install the round thing into that square thing.
BTW the equivalent of the square is the pentagon in yours. That is the diaphragm.
Cool.
Buddha.

I ordered the All Balls rebuild kit from Fortnine. Their customer service confirmed it's just a generic pic and they guarantee part fitment.
The kit arrived today with ALL the seals, washers, o-rings, screws, spring and diaphragm. It also contained that 'racetrack' shaped gasket and an extra screw & o-ring.  I can only imagine those are for tank petcock?

The pentagon is flat piece of plastic with a hole in the middle and rubber sheets on either side.  You can't separate the 2 diaphragm sheets so there's only 1 way to install it.  You have to neatly fold up one sheet and feed it through the hole in the plate. Once it's through it should flatten back out.  It's very easy as long as you're gentle and patient, and don't just scrunch the rubber and try to jam it through.

I was on the right track from the beginning.  Just difficult to find confirmation.  I don't 'do videos' but there's always a first time.  I may try filming the disassembly, unboxing the kit, and reassembly.  There are plenty of K's out there, and a leaky vacuum petcock is a common problem.  Often disassembly & cleaning is all it needs. But once it gets old, might as well replace the parts.

Mine is wrong and labelled wrong from all balls. There's no way this thing will fit, the 4 hole diaphragm is about 1/2 the size needed for the 89-00 GS. The box even has a part number and says GS500 89-00. LOL.

Basically an entire production run from all balls is now trash. They're going to be very very unhappy when they hear of that from me.

Cool.
Buddha.

Quote from: The Buddha on July 17, 2022, 08:31:23 AM
Mine is wrong and labelled wrong from all balls. There's no way this thing will fit, the 4 hole diaphragm is about 1/2 the size needed for the 89-00 GS. The box even has a part number and says GS500 89-00. LOL.
Basically an entire production run from all balls is now trash. They're going to be very very unhappy when they hear of that from me.
Cool.
Buddha.

That's unfortunate.  Mine says "GS500F 04-09" and the parts all look correct.  Every screw is in a separate bag LOL.
I'll know for sure once I install it.  Worst case I send it back as the seller guarantees fitment.

Is there any chance your bike's petcock is not the original one?

I also have every screw in a separate bag. But my petcock is a 100% match to the microfiche and I also have seen maybe 50 of these things in my and my customers bikes. No, its original. BTW no other bike in the history of the effing planet has a GS500 frame petcock.
Cos no bike ever had a "frame" petcock. That stupid idea is unique to GS500's.
Dont get me wrong, I believe a katana 600 had much of the internals of a GS500 petcock especially where the diaphragm is concerned, however it didn't have a "frame" petcock.
I've not found a single bike that uses a GS500 clutch perch/lever or a GS500 frame and tank petcock. Enlighten me if you know otherwise.
Cool.
Buddha.

Quote from: The Buddha on July 17, 2022, 12:03:40 PM
I also have every screw in a separate bag. But my petcock is a 100% match to the microfiche and I also have seen maybe 50 of these things in my and my customers bikes. No, its original. BTW no other bike in the history of the effing planet has a GS500 frame petcock.
Cos no bike ever had a "frame" petcock. That stupid idea is unique to GS500's.
Dont get me wrong, I believe a katana 600 had much of the internals of a GS500 petcock especially where the diaphragm is concerned, however it didn't have a "frame" petcock.
I've not found a single bike that uses a GS500 clutch perch/lever or a GS500 frame and tank petcock. Enlighten me if you know otherwise.
Cool.
Buddha.

I finished rebuilding the petcock and all the parts fit fine.  The new diaphragm spring is a bit smaller than the original but I went with it anyway.

After putting everything back together and turning the fuel on, the petcock started leaking right away (fuel dripping from the airbox drain).  At first I thought maybe I left it on PRI for too long, but after cleaning up, it did it again in the ON position.

I removed the petcock and will take a look at it tomorrow.  The only thing I can think of is that new smaller spring isn't strong enough to close the fuel valve.  I'll diagnose it and post my findings.

In hindsight I should have tested it upstairs with water or something before going through all the hassle.

I have a GS550 kit I will try to install maybe saturday morning.
Will know then, my kit had no spring. Only the diaphragm and the oval O ring.
Cool.
Buddha.

I brought the petcock upstairs and tested it with water.  I capped off the ON outlet and poured water into the RES hose.
Yup it's definitely leaking.  Actually a trickle. No wonder the carb flooded so quickly.

Sucking on the vacuum line opened it right up as expected.
I tried blowing into the vacuum line to force the diaphragm the other way, and the leak stopped immediately!  Looks like the valve o-ring isn't being pressed hard enough against the valve seat.

I tried reinstalling the original spring and it definitely works better. Instead of a trickle it's just a drip. Blowing into the vacuum line stops the leak.  Keep in mind this is just the water in a short hose.  The pressure from a full tank of fuel will obviously make it worse.  I tried stretching the spring and it was a slight improvement but definitely not a solution.

At this point I think it just needs a better spring to force the valve closed.  The o-ring seat is clean with no visible damage so I doubt that's an issue.

Here is a photo of the new AllBalls kit spring next the the original one (before stretching)

OMG, I am wondering what my kit is going to do, I got one for a gs550 and a slew of other bikes (not GS500) off the shelf at the local dealer.
Definitely looks like a crapshoot in almost all cases.
Cool.
Buddha.

Quote from: The Buddha on July 29, 2022, 05:58:45 AM
OMG, I am wondering what my kit is going to do, I got one for a gs550 and a slew of other bikes (not GS500) off the shelf at the local dealer.
Definitely looks like a crapshoot in almost all cases.
Cool.
Buddha.

Note that the old spring is taller and stiffer, but has the same number of turns.  The gap between the cover and diaphragm is very small. So the spring is almost fully compressed all the time.  You definitely don't want more windings or the valve won't open at all.

I tried stretching the old spring way out, so at rest it is now 25mm (from 20mm).  The extra stiffness was just enough to completely stop the dripping.  I'm not an expert in springs so I don't know if this is a long-term fix.  If the metal is fatigued it might weaken quickly.
But for now it seems to be holding so I'll just keep an eye on it.
The dealer (FortNine) guarantees fit for that part, so I'm still waiting to hear what solution they offer.

Oh eff it. The one I got for gs550 doesn't fit, isn't even close matter of fact.
I'm lost here. I'll probably buy a remanufactured petcock courtesy our best friends in china and pray that they dont bomb that flight along with Taiwan. With the luck I've been having lately, definitely possible.
Cool.
Buddha.

Quote from: The Buddha on July 30, 2022, 08:12:06 AM
Oh eff it. The one I got for gs550 doesn't fit, isn't even close matter of fact.
I'm lost here. I'll probably buy a remanufactured petcock courtesy our best friends in china and pray that they dont bomb that flight along with Taiwan. With the luck I've been having lately, definitely possible.
Cool.
Buddha.

I THINK I found something helpful.
Does this look like yours?  Found it by accident trying to find one for my bike.
https://www.motorcycleid.com/kl-supply/fuel-petcock-assembly-mpn-18-4134.html?singleid=3330641119&url=113036462

Looking in K&L's 2022 catalogue they also seem to have individual parts for a rebuild in Pg 177. At least the rubber parts. I don't see any springs unless they're included with the diaphragm.
I'm pretty sure K&L could package a rebuild kit for the older GS500, but they just haven't bothered as they seem to cover most other models.

You can download the catalogue here
https://www.klsupply.com/catalog/