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Old January 20th, 2020, 06:16 AM   #1
nocturncal
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Petcock Fuel Leaking, Should I Rebuild?

Hey guys,

My petcock started leaking, I originally thought it was leaking from the fuel lines so I replaced those. It continued to leak and ended up seeing that the leak was coming from the diaphram.

Not sure if related but recently after I fill my tank up a decent amount of gas will spill out of the overflow tube. This started happening around the same time as my petcock problem. I only fill to the metal neck.

I read the ninja250faq.org page on petcocks and other threads here and helped me a bunch

Anywho I'm trying to decide if I should disassemble and see if I can clean out the vents and maybe that will be enough. But if I have it disassembled, should I just go ahead with a rebuild? Does the petcock parts usually need a rebuild or are they generally a long lasting item that needs some cleaning with the vent hoses? I've got about 33,000 mi on the ninja.

I've also considered a low mileage used part on eBay.
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Old January 20th, 2020, 06:58 AM   #2
jkv45
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Take it apart and take a look. Clean it and reassemble.

From what I've heard, a rebuild kit is about the same cost as a new petcock.

Don't go for any aftermarket non-vacuum replacement petcock - they are a pain.

A good used one might be the way to go for a replacement.
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Old January 27th, 2020, 10:37 AM   #3
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Originally Posted by jkv45 View Post
Take it apart and take a look. Clean it and reassemble.

From what I've heard, a rebuild kit is about the same cost as a new petcock.

Don't go for any aftermarket non-vacuum replacement petcock - they are a pain.

A good used one might be the way to go for a replacement.
Thanks for that. I ended up buying a used one on eBay and the petcock doesn't dribble anymore. Man once I got 33,000 mi I swear all the gaskets and o rings on my motorcycle just started to leak 🙁
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Old January 27th, 2020, 11:06 AM   #4
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A long production run...some of these 250's are certainly ageing. As you've noticed orings approaching the end of their useful service life. As such, in particular the carb fuel rail orings become imperative to replace, though requiring a "split".

I see many hardened, near crystallized, flattened, corroded carb orings. Some rail orings right on the verge of becoming intense leakers. Mikuni (used on early 2V Ducati) not immune either.
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Old January 27th, 2020, 11:21 AM   #5
nocturncal
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Originally Posted by ducatiman View Post
A long production run...some of these 250's are certainly ageing. As you've noticed orings approaching the end of their useful service life. As such, in particular the carb fuel rail orings become imperative to replace, though requiring a "split".

I see many hardened, near crystallized, flattened, corroded carb orings. Some rail orings right on the verge of becoming intense leakers. Mikuni (used on early 2V Ducati) not immune either.
Yeah those o rings have lived a hard life on my bike lol. I'll be sending my carb your way in a couple weeks just need to find a good time to get them off. Curious to see how much better they'll run to once theyre properly cleaned (they've never taken apart).

In the process of doing the equivalent of a 15,000mi service on the bike, so basically everything's being looked at
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Old January 27th, 2020, 03:35 PM   #6
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I offer you the option of sending the original petcock with the carbset.

For testing, rebuild or send back to you as scrap if beyond refurb, your call.
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Old January 28th, 2020, 03:31 PM   #7
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I offer you the option of sending the original petcock with the carbset.

For testing, rebuild or send back to you as scrap if beyond refurb, your call.
Sending you a PM
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Old January 28th, 2020, 04:36 PM   #8
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and......responding
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Old January 28th, 2020, 05:56 PM   #9
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Any more PMs flying around? Just curious.
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