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Old March 4th, 2019, 05:25 PM   #1
ducatiman
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MOTM - Nov '18, Mar '17
carb and petcock refurb

Member sent both carbset and petcock for review....carb service went well, nothing new there....but the petcock a bit problematic.

Visible intense internal corrosion in addition to both mesh pre screens being MIA. The owner granted me permission to experiment in a last ditch attempt to save $90 or so on the cost of a new petcock. Some inventive thinking and utilization of ZX600 screens netted success. Shall we call it a "FRANKEN-cock"?

Petcock pics reveal before/after corrosion. Screens not yet fitted.
Carbs like new. I'm glad he sent the petcock, I'll be suggesting sending along with carbs in the future. Important as the carbs are dependent on clean, correct petcock function, I'll be incorporating this into future carb service.

In preparation, I've ordered petcock kits and other related components for stock to enable future petcock repairs as needed.
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File Type: jpg kyle2502.jpg (105.6 KB, 4 views)
File Type: jpg kyle2503.jpg (80.6 KB, 3 views)
File Type: jpg kyle25010.jpg (113.7 KB, 21 views)
File Type: jpg kyle2504.jpg (129.8 KB, 19 views)
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Old March 5th, 2019, 09:15 AM   #2
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Niiiice!
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Old March 5th, 2019, 10:17 AM   #3
ducatiman
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MOTM - Nov '18, Mar '17
thanky z1

here's a couple pics, Franken-cock cleaned and complete. Screens invisible....huh? Where'd they go?

But note these facts....both "alternative" main and reserve circuit pre-screens are present and secure, though different configuration, identical mesh. They are fully functional, they are removable, they are cleanable and they are reusable. If need be, cheaply, easily replaceable too. But should deliver a really long service life. Boom.
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Old March 5th, 2019, 11:05 AM   #4
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Very nice!
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Old March 5th, 2019, 11:37 AM   #5
ducatiman
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thanky, cali g.

I believe the corrosion evident in the first group of pics is indicative of a very common cause of petcock failure. The diaphragm (with important shut off valve oring installed) must be able to contract/retract as controlled by vacuum and a return spring, its motion obviously hampered by pictured corrosion. As is the ability of the oring to properly create a seal, the oring sealing surface being corroded as well.

At near $90 for a stock petcock...a refurb rather than automatic replace...may offer a viable, money saving alternative for some folks.

We've read numerous times of petcock failure here on ninjette forum, these bike are ageing! And sitting with ethanol fuel is no help, as did the lack of inlet pre screens in this particular case.
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Old March 5th, 2019, 12:01 PM   #6
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Wow, that's amazing work!

With removal of corrosion, did you end up with uneven sealing surfaces?
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Old March 5th, 2019, 12:18 PM   #7
ducatiman
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MOTM - Nov '18, Mar '17
In this instance not at all, sealing surface is ok, though I replaced the hardened vac valve oring. Though in the past, I've run into such badly corroded (water damaged) petcock sealing surfaces....demanded trashing and new replacement. Many variables, of course. Like all this stuff, component must be evaluated on an individual basis. Some petcocks will be candidates for refurb, some not.
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