Leaking from petcock after rebuild - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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Old 06-23-2019, 05:26 PM Thread Starter
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Leaking from petcock after rebuild

I did the acid wash today to get rid of the rust in the tank, and used the rebuild kit to stop the petcock from leaking. I followed the YouTube video I found on how to salvage the old petcock without a rebuild kit as a reference. Now it will stream gas out of the fuel ports in reserve and prime. It will leak out of those ports and the vacuum line if I tilt the tank. I thought I had assembled it wrong, but after pulling it apart three times, it does the same thing. Is this normal?


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'08 Road King Classic
'86 VN750 with the following work done to it, after sitting for 19 years:
  • Blue Wire Mod
  • Two Wire Mod
  • Coil Mod
  • 2nd Coil Mod
  • Ear Shave
  • 42/142 Jets
  • Debadged
  • Rattle Can Flat Paint
  • Exhaust Coming
  • K&N Filters
  • Carbs Cleaned
  • Petcock Rebuilt (unsucessfully)
  • Coolant Flushed
  • Rear Spline Lube
REV 2:9
www.voat.co
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Old 06-23-2019, 05:28 PM
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No, something wrong, vac port should always be dry.

Wet vac port causes rich mixture and gas in the oil.

Still has a spring in it?

2003-21k mi
Shaved w/UniPK92+Stock Jets-TPE/MOSFET-Shinko Tires-AGM batt-bags-chrome-LEDs...more
__________________________________________________ ____________
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Owner's Manual: http://www.mediafire.com/file/nscb5f...ers+Manual.pdf
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Old 06-23-2019, 05:56 PM Thread Starter
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It does have the spring in it. I pulled the old gasket/diaphragm out and replaced it with the new one from the kit. I thought maybe I put it on the thick plastic piece backwards, but the two nipples that are across from each other matched up with the petcock assembly, and the two diagonal nipples went towards the selector. The selector is pretty stiff (I did try to spray paint it black), and I replaced the gasket on that. I then used the metal compression ring around the selector, but under the cover. I believe thatís how it was supposed to be assembled. What about fuel coming out of the fuel ports on reserve and prime?


Sent from my iPhone using Tapatalk

'08 Road King Classic
'86 VN750 with the following work done to it, after sitting for 19 years:
  • Blue Wire Mod
  • Two Wire Mod
  • Coil Mod
  • 2nd Coil Mod
  • Ear Shave
  • 42/142 Jets
  • Debadged
  • Rattle Can Flat Paint
  • Exhaust Coming
  • K&N Filters
  • Carbs Cleaned
  • Petcock Rebuilt (unsucessfully)
  • Coolant Flushed
  • Rear Spline Lube
REV 2:9
www.voat.co
MSattler is online now  
 
Old 06-23-2019, 06:06 PM
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Prime - fuel flows all the time, even with the engine off

Reserve - fuel only flows with engine running, or vacuum applied

I've found that sometimes you have to leave the retainer screws just snug. If you tighten them up all the way, the lever is too stiff.

It's been a while since I rebuilt mine, and I've only done it once. Maybe check a diagram. It doesn't sound like it's switching ports, just free-flowing straight through. The vac port should always be isolated from the gas.

2003-21k mi
Shaved w/UniPK92+Stock Jets-TPE/MOSFET-Shinko Tires-AGM batt-bags-chrome-LEDs...more
__________________________________________________ ____________
Repair Manual: http://www.mediafire.com/file/mj7z81..._Catalogue.pdf

Owner's Manual: http://www.mediafire.com/file/nscb5f...ers+Manual.pdf
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Old 06-23-2019, 07:11 PM Thread Starter
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I just reverified, it is not coming from the vacuum, but it is from both nipples.


Sent from my iPhone using Tapatalk

'08 Road King Classic
'86 VN750 with the following work done to it, after sitting for 19 years:
  • Blue Wire Mod
  • Two Wire Mod
  • Coil Mod
  • 2nd Coil Mod
  • Ear Shave
  • 42/142 Jets
  • Debadged
  • Rattle Can Flat Paint
  • Exhaust Coming
  • K&N Filters
  • Carbs Cleaned
  • Petcock Rebuilt (unsucessfully)
  • Coolant Flushed
  • Rear Spline Lube
REV 2:9
www.voat.co
MSattler is online now  
Old 06-23-2019, 07:44 PM
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Maybe it's been modified? I recall someone doing that. Drilled it out to eliminate the need for vacuum.

The only settings are on, prime, and reserve, correct? Been a while since I saw one of these.

2003-21k mi
Shaved w/UniPK92+Stock Jets-TPE/MOSFET-Shinko Tires-AGM batt-bags-chrome-LEDs...more
__________________________________________________ ____________
Repair Manual: http://www.mediafire.com/file/mj7z81..._Catalogue.pdf

Owner's Manual: http://www.mediafire.com/file/nscb5f...ers+Manual.pdf
Spockster is offline  
Old 06-23-2019, 07:54 PM Thread Starter
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Thank you for your help. Reserve, prime and on are the settings. I just donít want to be dumping fuel, if I ever get this thing up and running, or flooding the carbs with gas.


Sent from my iPhone using Tapatalk

'08 Road King Classic
'86 VN750 with the following work done to it, after sitting for 19 years:
  • Blue Wire Mod
  • Two Wire Mod
  • Coil Mod
  • 2nd Coil Mod
  • Ear Shave
  • 42/142 Jets
  • Debadged
  • Rattle Can Flat Paint
  • Exhaust Coming
  • K&N Filters
  • Carbs Cleaned
  • Petcock Rebuilt (unsucessfully)
  • Coolant Flushed
  • Rear Spline Lube
REV 2:9
www.voat.co
MSattler is online now  
Old 06-23-2019, 08:04 PM
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Quote:
Originally Posted by MSattler View Post
Thank you for your help. Reserve, prime and on are the settings. I just don’t want to be dumping fuel, if I ever get this thing up and running, or flooding the carbs with gas.


Sent from my iPhone using Tapatalk
Assuming it's assembled correctly, sounds like you need another petcock.

It would be fine the way it is, unless a float happens to stick open some time.

2003-21k mi
Shaved w/UniPK92+Stock Jets-TPE/MOSFET-Shinko Tires-AGM batt-bags-chrome-LEDs...more
__________________________________________________ ____________
Repair Manual: http://www.mediafire.com/file/mj7z81..._Catalogue.pdf

Owner's Manual: http://www.mediafire.com/file/nscb5f...ers+Manual.pdf
Spockster is offline  
Old 06-24-2019, 10:50 PM Thread Starter
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Leaking from petcock after rebuild

I took it 5 blocks to get gas... and 3 to lose it all
Tomorrow I will reassemble the petcock step by step and see what I missed. It was on on, but was just pouring out. Any advice would be appreciated

Sent from my iPhone using Tapatalk

'08 Road King Classic
'86 VN750 with the following work done to it, after sitting for 19 years:
  • Blue Wire Mod
  • Two Wire Mod
  • Coil Mod
  • 2nd Coil Mod
  • Ear Shave
  • 42/142 Jets
  • Debadged
  • Rattle Can Flat Paint
  • Exhaust Coming
  • K&N Filters
  • Carbs Cleaned
  • Petcock Rebuilt (unsucessfully)
  • Coolant Flushed
  • Rear Spline Lube
REV 2:9
www.voat.co

Last edited by MSattler; 06-24-2019 at 11:24 PM.
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Old 06-25-2019, 08:52 AM Thread Starter
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Quote:
Originally Posted by Spockster View Post
Assuming it's assembled correctly, sounds like you need another petcock.

It would be fine the way it is, unless a float happens to stick open some time.
Please forgive my ignorance, but how does a petcock assembly go bad? Isn't it just an aluminum body? I didn't find any videos that showed exactly how it was reassembled, because i took it apart before my rebuild kit arrived. The back side of the diaphragm was definitely misshapen though.
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