I ended up getting a Yamaha petcock manual fuel valve ( for a Raptor Quad). I searched and found this fix online. It works great and NO MORE fuel leak or stalling with my DRZ 400 S.
I was blaming the petcock, too, for those symptoms. But someone pointed out to me that even if gas was leaking past the petcock and into the carburetor - wouldn't the carb float push up on the needle pin and shut off any further gas flowing into the carb and prevent it from overflowing and spilling past the carb and piston rings into the oil sump? Maybe the needle pins should be checked and replaced, too?
@@thejunkman Oh thank God that there's another possibility for the diluted sump oil. I guess I should replace the old petcock first and see if that fixes the problem before tearing out the carburetors and disassembling them all. Thanks for the quick help.
@jaayjusthere Well depends on how you look at it. The factory design fails in as little as 5 years and can and will alow fuel to to drip on a hot engine or on your garage floor overnight causing a hazzard. The instalation of this fuelcock provides a more reliable way to shut off the fuel and prevents overflowing of the carburetor or spillage for fuel from a leak.
Very good, I'm guessing the one that needs to be capped off is the barb on the throttle side closest to the intake manifold(most forward one). mine arrived with no tank or any hoses at all on it & has 4 line ports on the carb. The fuel valve function info was good, just didn't help my situation any. Thanks for the speedy reply though, R.Tillery
Not knowing what kind of bike you have or if it has multiple cylinders I can't help you much more. However you need to cap off any vacuum port on the intake otherwise it won't run very well. Ports on the carburetor you will need to identify one is the fuel inlet and the rest are vent ports, well I guess one could be a vacuum port if there is not one molded into the intake. I guess the biggest thing is do you understand how a vacuum petcock and carburetor works? If not then I understand your confusion.
I tried this process and didn't get any leaks from the petcock. I plugged the tube coming off the vacuum port. When I turned the fuel valve on, gas came out of the carbs breather tube. When I put it on reserve, this did not happen. i starter the bike and it seemed to run fine but then shut off and would not restart. I noticed gas leaking from the front side of carb where it connects to the engine. When I took the carb off, the carb holder and port where full of gas. What did I do wrong? Thanks,
Carb (s) float valve not closing properly. Clean / replace accordingly. Most probably you dislodged "crap" into the fuel system while messing around. Always use a good fuel filter saves a lot of unnecessary work.
I don't know, lol but glad it is helping you fix your problem. Check out my website for more tips and tricks and to follow my vintage bike restoration called "barn fresh"
I have this very problem with my DRZ 400 S. The bike cut off after a short ride to the store. I noticed the leak around the same casket area you showed. A while back I changed out the tank with a Clarke 3.9 gallon. When I ordered the tank I also bought a cut out valve. It did not have the vapor line set up the stock one did. So I reused the stock petcock. My question is can I just block out the vapor line with a screw. Then use the new manual petcock?
Click the link in the description for more info. They make rubber/vinyl caps to cap off the vacuum port on the intake. To use the stock shut off you will have to use it in the "PRI" to let fuel flow as you will now not have a vacuum source to open the diaphragm. Click Here for more info www.thejunkmanadv.com/fuel-shut-off-conversion.html
hi! i just did this conversion, and now i have gas pouring out the bottom carb drain when the bike is running. (keihin fcr39 carb.) i plugged the vacuum hose on the top of the carb. what did i do wrong? thanks, doug s.
If you are going to be working things it would good to at least buy a cheap pair of plastic ones. They can be found at most hardware stores, tools stores, autoparts stores, and probably even Wal-mart. For only a few dollars. The cheapo ones are fine for basic measurements like this.
Thanks, 1 more question. Why is that when I connect the hose from the petcock to the carb there is no flow, but if I remove the hose from the carb the fuel flows out fine?
With the vacuum or the non vacuum? How do you know there is no flow. If the float (in the carburetor) is working then it shuts the fuel off when the engine is not running.
Yes, the carburetor doesn't use much fuel at any given time or not enough that you will see a flow. Think how small your jets are and even at full flow they don't move very much volume of fuel.
Not sure what you are referring to? If you are talking about the vacuum port on the carb, yes that needs to be plugged. not sure what "hose" you are talking about.
Rodrigo Munoz Yes, I answered that. If you do not plug the vacuum port on the carburetor you will have a massive vacuum leak directly into the intake and an extreme lean condition. The bike may not even start. I believe I state this in the video and if you went to my website (link in the description) it explains this as well along with more information.
My 1996 Suzuki Quad runner LT-F250 has been sitting in my basement for over 10 years. I have removed the carb, air filter, and fuel shut off valve under the tank. Should I just replace the shut off valve or should I tear it down and rebuild it? How does one clean out the gas tank? It may sound like an easy answer until you read the service manual and it tells you to remove the engine and yes the motor is in the way. I do not want to remove the tank. Any suggestions would be grateful. Peace, Mo
Please ask your question in the comments at this link. www.thejunkmanadv.com/fuel-shut-off-conversion.html I hate G+ and this commenting system. It is much easier for me to respond there. Plus I have a lot more videos over there that will help you out.
thejunkman Thanks anyway. By the time it took you to type your answer, I could have gotten your suggestions. I went to your site and it required me to sign in. Another pain in the butt. I got enough passwords as it is. I guess if you do not want people to ask you questions on you tube you should block the reply section so you don't have to spend so much time re-directing people to your site. Peace
Maurice Gundrum No need to register for comments on my site. I have a hard time keeping up with comments here, I just hate G+/RUclips comments after the change and I can better manage them on my site and I have more information written over there than in this video. Your comment is fair though. Replace the valve, cleaning the tank you must remove it to do it properly. I wouldn't think you would need to remove the engine to remove the tank, but I am not intimately aware of the LT250. Thanks for the comment.
Thank you for your reply. I will try again but signing in was the first thing when I pulled up your page. I too did not think you had to remove the engine and thought it was a joke when I read this in the manual. When I went back in the basement and looked at it some more saw that the tank was molded under the frame rail sticking out too far to be pulled up and out the top. It has to be lowered and pulled out from the center/side of the framed and not the top. In order for it to be pulled out from the side, you have to have the engine out of the way. Someone needs to be shot for that one. Peace.
thejunkman Let me explain myself better. I've heard (I don't know anything about bikes) that the fuel petcock needs a diaphragm so it doesn't leak gas or something. Then I was reading about this manual petcock that somehow doesn't need it. Sorry if I can't explain myself better.
Yes, auto parts stores will sell an assortment. However a length of hose and a machine screw will work as well. doesn't look pretty, but anything to plug the orifice into the intake is what you are trying to achieve.
There is no vacuum routing. This video is about eliminating the vacuum component in the petcock. The only thing to note, and this is said in the video, is to cap off the vacuum port on the intake.
I ended up getting a Yamaha petcock manual fuel valve ( for a Raptor Quad). I searched and found this fix online. It works great and NO MORE fuel leak or stalling with my DRZ 400 S.
well done explanation of these vacuum petcocks, and the quick fix.
Thanks. Don't forget to check out all the other tips, tricks and projects I have over on my website. www.thejunkmanadv.com
I have a Suzuki DR200 as well and had to replace my petcock valve so this video helped me out a lot! Thank you!
I was blaming the petcock, too, for those symptoms. But someone pointed out to me that even if gas was leaking past the petcock and into the carburetor - wouldn't the carb float push up on the needle pin and shut off any further gas flowing into the carb and prevent it from overflowing and spilling past the carb and piston rings into the oil sump? Maybe the needle pins should be checked and replaced, too?
If the diaphragm is leaking it will leak into the vacuum port and wash down the cylinder
@@thejunkman Oh thank God that there's another possibility for the diluted sump oil. I guess I should replace the old petcock first and see if that fixes the problem before tearing out the carburetors and disassembling them all. Thanks for the quick help.
Yes, as long as your tank takes a 22MM thread. Use a caliper to measure.
@jaayjusthere Well depends on how you look at it. The factory design fails in as little as 5 years and can and will alow fuel to to drip on a hot engine or on your garage floor overnight causing a hazzard. The instalation of this fuelcock provides a more reliable way to shut off the fuel and prevents overflowing of the carburetor or spillage for fuel from a leak.
I do not have a caliper to measure threads is this something autozone can do for me? Thank you fro your help. Your a very generous person!
Not bad in general, however doesn't this negate the safety feature? When you crash this won't shut off.
Very good, I'm guessing the one that needs to be capped off is the barb on the throttle side closest to the intake manifold(most forward one). mine arrived with no tank or any hoses at all on it & has 4 line ports on the carb. The fuel valve function info was good, just didn't help my situation any. Thanks for the speedy reply though, R.Tillery
Not knowing what kind of bike you have or if it has multiple cylinders I can't help you much more. However you need to cap off any vacuum port on the intake otherwise it won't run very well. Ports on the carburetor you will need to identify one is the fuel inlet and the rest are vent ports, well I guess one could be a vacuum port if there is not one molded into the intake. I guess the biggest thing is do you understand how a vacuum petcock and carburetor works? If not then I understand your confusion.
If it doesnt shut off the needle and seat should stop it flooding the engine otherwise they are faulty as well?
@4averick That is why these type of shutoff's are not as safe as they seem to be.
I tried this process and didn't get any leaks from the petcock. I plugged the tube coming off the vacuum port. When I turned the fuel valve on, gas came out of the carbs breather tube. When I put it on reserve, this did not happen. i starter the bike and it seemed to run fine but then shut off and would not restart. I noticed gas leaking from the front side of carb where it connects to the engine. When I took the carb off, the carb holder and port where full of gas. What did I do wrong? Thanks,
Carb (s) float valve not closing properly. Clean / replace accordingly.
Most probably you dislodged "crap" into the fuel system while messing around. Always use a good fuel filter saves a lot of unnecessary work.
@ 5:50, "Band cap clamp". Is that an American pie reference slip? Thanks for the vid. Will try this on a 2000 Katana 600.
Nice
I don't know, lol but glad it is helping you fix your problem. Check out my website for more tips and tricks and to follow my vintage bike restoration called "barn fresh"
I have this very problem with my DRZ 400 S. The bike cut off after a short ride to the store. I noticed the leak around the same casket area you showed. A while back I changed out the tank with a Clarke 3.9 gallon. When I ordered the tank I also bought a cut out valve. It did not have the vapor line set up the stock one did. So I reused the stock petcock. My question is can I just block out the vapor line with a screw. Then use the new manual petcock?
Click the link in the description for more info. They make rubber/vinyl caps to cap off the vacuum port on the intake. To use the stock shut off you will have to use it in the "PRI" to let fuel flow as you will now not have a vacuum source to open the diaphragm. Click Here for more info www.thejunkmanadv.com/fuel-shut-off-conversion.html
good vid!!
hi!
i just did this conversion, and now i have gas pouring out the bottom carb drain when the bike is running. (keihin fcr39 carb.) i plugged the vacuum hose on the top of the carb. what did i do wrong?
thanks,
doug s.
Thejunkman,
Will the 62163-75 petcock works as a direct replacement for the petcock on a 1972 F7?
Thanks,
Frank
Shouldn't there be some sealing washers (fiber) for the mounting screws?
+Patrick B not on this style, a gasket dose that here
If you are going to be working things it would good to at least buy a cheap pair of plastic ones. They can be found at most hardware stores, tools stores, autoparts stores, and probably even Wal-mart. For only a few dollars. The cheapo ones are fine for basic measurements like this.
Will this work on an ltz400? Will there be nothing wrong if I plug the vacuum?
Nope, no harm or performance issues.
Thanks, 1 more question. Why is that when I connect the hose from the petcock to the carb there is no flow, but if I remove the hose from the carb the fuel flows out fine?
With the vacuum or the non vacuum? How do you know there is no flow. If the float (in the carburetor) is working then it shuts the fuel off when the engine is not running.
With the non vacuum, I have and inline filter and you can see there’s hardly no fuel going through. Or is that normal?
Yes, the carburetor doesn't use much fuel at any given time or not enough that you will see a flow. Think how small your jets are and even at full flow they don't move very much volume of fuel.
do you need to plug the hose too? or just the hole on the carb?
Not sure what you are referring to? If you are talking about the vacuum port on the carb, yes that needs to be plugged. not sure what "hose" you are talking about.
The one that goes into the vacuum port originally
Rodrigo Munoz The hose that you pulled off the vacuum port on the carb.
Rodrigo Munoz Yes, I answered that. If you do not plug the vacuum port on the carburetor you will have a massive vacuum leak directly into the intake and an extreme lean condition. The bike may not even start. I believe I state this in the video and if you went to my website (link in the description) it explains this as well along with more information.
There Is a hose that you pulled off the vacuum port. Do I need to clamp Off the hose. Or do I just leave the hose sitting there
My 1996 Suzuki Quad runner LT-F250 has been sitting in my basement for over 10 years. I have removed the carb, air filter, and fuel shut off valve under the tank. Should I just replace the shut off valve or should I tear it down and rebuild it? How does one clean out the gas tank? It may sound like an easy answer until you read the service manual and it tells you to remove the engine and yes the motor is in the way. I do not want to remove the tank. Any suggestions would be grateful. Peace, Mo
Please ask your question in the comments at this link. www.thejunkmanadv.com/fuel-shut-off-conversion.html I hate G+ and this commenting system. It is much easier for me to respond there. Plus I have a lot more videos over there that will help you out.
thejunkman Thanks anyway. By the time it took you to type your answer, I could have gotten your suggestions. I went to your site and it required me to sign in. Another pain in the butt. I got enough passwords as it is. I guess if you do not want people to ask you questions on you tube you should block the reply section so you don't have to spend so much time re-directing people to your site. Peace
Maurice Gundrum No need to register for comments on my site. I have a hard time keeping up with comments here, I just hate G+/RUclips comments after the change and I can better manage them on my site and I have more information written over there than in this video. Your comment is fair though. Replace the valve, cleaning the tank you must remove it to do it properly. I wouldn't think you would need to remove the engine to remove the tank, but I am not intimately aware of the LT250. Thanks for the comment.
Thank you for your reply. I will try again but signing in was the first thing when I pulled up your page.
I too did not think you had to remove the engine and thought it was a joke when I read this in the manual. When I went back in the basement and looked at it some more saw that the tank was molded under the frame rail sticking out too far to be pulled up and out the top. It has to be lowered and pulled out from the center/side of the framed and not the top. In order for it to be pulled out from the side, you have to have the engine out of the way. Someone needs to be shot for that one. Peace.
Can you bypass a kawi ninja 250 vacuum petcock? I'm guessing yes but wanna make sure of any problems in the future.
Yes you can.
@@thejunkman worked for about 10 min. Then started spitting and bogging. Put the original petcock back on ran fine...
Just curious. Did you block off the vacuum port on the intake? But whatever makes it work.
@@thejunkman yes
Did you have to plug vaccum port on carb?
+Eric cooling Yes, I went over that in the video.
Do you need a diaphragm in the manual petcock kit?
+GuitarWholesale not sure what you are asking
thejunkman
Let me explain myself better.
I've heard (I don't know anything about bikes) that the fuel petcock needs a diaphragm so it doesn't leak gas or something.
Then I was reading about this manual petcock that somehow doesn't need it.
Sorry if I can't explain myself better.
I kind of explain that in the video. It is not needed as long as you turn the fuel off each time you stop for long periods of time.
What do you do with the vacuum hose.
Just cap it off.
@@thejunkman Is that something I can buy at my auto or motorcycle supply shop?
Yes, auto parts stores will sell an assortment. However a length of hose and a machine screw will work as well. doesn't look pretty, but anything to plug the orifice into the intake is what you are trying to achieve.
what do you plug the vacuum port on the carb with????
+Essie decent a vacuum port plug, they sell assortments at the autoparts stores
thejunkman thanks
Sweet
What about fuel filter?
Most bikes don't have them but this would be a good time to add one.
lots of non info, vacuum routing?
There is no vacuum routing. This video is about eliminating the vacuum component in the petcock. The only thing to note, and this is said in the video, is to cap off the vacuum port on the intake.
good lord its the same as my bandit 1200