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Old July 15th, 2022, 04:29 PM   #1
lordhelemt
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Red face Fuel Tap/Petcock rebuild still flows when off???

The fuel tap isnít completely shutting off the fuel when the bike is of and the petcock is in the on position. It was more than a drip but not a steady stream. So brilliantly I decided to rebuild the unit. Purchased a K and L brand kit off eBay, cleaned all the components then replaced all the gaskets.

Doing this actually made it worse! Anyone know if that brand is any good or should I have only used genuine parts?
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Old July 16th, 2022, 01:06 PM   #2
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K&L has been reliable, in my experience. Very careful reassembly tactics called for, in any case, assembly errors will result in leakage. Your diaphragm return spring is present?

I've sourced softer (than stock) diaphragm shaft orings as well. Work fine. Size is, of course, critical.
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Old July 16th, 2022, 03:43 PM   #3
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The diaphragm spring is installed but Iím not sure how that would cause leakage. That said, the new gasket that toggles the on/prime switch appears to be thinner than the original gasket (which I assume is already compressed). Will order a genuine part and see if that corrects the issue
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Old July 16th, 2022, 04:54 PM   #4
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which kit did you get?
K & L part#?

Some components are shared between pre-gen & new-gen, but there's some that's different.

Also it's not just swapping parts, but also inspecting existing passageways. The seat where plunger sits is important for sealing. Every rebuild I've done has required that area to be cleaned along with resurfacing to remove deposits and pits.
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Old July 16th, 2022, 07:03 PM   #5
lordhelemt
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Part number KL-763. The housing was dissemble then cleaned in the ultrasonic cleaner. All the surfaces appeared to be good, no scratches, residue, etc.
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Old July 16th, 2022, 08:20 PM   #6
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Here's kits from K&L:


Where is yours leaking?

1. The gaskets you're holding would cause external leakage at dial. Thickness won't make difference because dial is pressed on with spring. It looks like thin washer, but it's wavy and pushes on dial to seal against gasket. It's #2 part from left that sits between outside plate and dial. If it's completely flat, it's worn-out and you need new spring to push dial onto gasket.



2. If you're getting internal leakage through fuel-hose, that's function of diaphragm and plunger.

Did you get new diaphragm and plunger?
https://www.amazon.com/Supply-Fuel-P.../dp/B001KO4L0A


Make sure plunger tip seals with hole in body of petcock fully. Usually you can stretch spring by about 1/4" and get a little more sealing pressure. Second from right in photo above.


Gordon @ https://customcarbservices.com does extremely good job of rebuilding petcocks and refurbishing carps. Send it to him and you'll be guaranteed brand-new part coming back.
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Old July 17th, 2022, 05:35 AM   #7
lordhelemt
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It's not leaking. It is flowing when on the on position when the bike is not running. Yes, I replaced the diaphragm and spring but I'll stretch to the spring and see if it helps.

The reason I thought it was the gasket in the pic I showed isn't that how the on/prime switch is valved? In other words, if in the on position the gas flows through the vacuum diaphragm? In the prime position it bypasses the vacuum switch?
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Old July 17th, 2022, 07:56 AM   #8
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"Usually you can stretch spring by about 1/4" and get a little more sealing pressure. "

hence my choice of substituting softer than stock diaphragm shaft sealing orings....thus assuring positive seal.
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Old July 17th, 2022, 11:34 AM   #9
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Quote:
Originally Posted by lordhelemt View Post
It's not leaking. It is flowing when on the on position when the bike is not running. Yes, I replaced the diaphragm and spring but I'll stretch to the spring and see if it helps.

The reason I thought it was the gasket in the pic I showed isn't that how the on/prime switch is valved? In other words, if in the on position the gas flows through the vacuum diaphragm? In the prime position it bypasses the vacuum switch?
Yes, dial does flow selection. In PRI flow bypasses diaphragm completely.

In ON, flow goes to diaphragm port 1st, and is blocked by it. Vacuum then pulls plunger away from seat. If fuel is flowing in ON without vacuum, then diaphragm plunger isn't sealing. Inspect the seating surface very closely. Test push the plunger onto seat and verify it seals all around.

Might also want to try ducatiman's softer O-ring idea.
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Old July 17th, 2022, 04:09 PM   #10
lordhelemt
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So I stretched out the new spring a bit and boom it's working properly.

Thanks all!
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