Petcock leaking on my 96' 500 LTD
- Dino
- Posts: 24
- Joined: Wed Jul 25, 2012 1:05 pm
- I ride: '96 Vulcan 500 LTD
- Location: Southern California
Petcock leaking on my 96' 500 LTD
The other day I started up my bike and while I was putting on my gear I noticed that gas was leaking from the petcock.
Even after I turned off my bike, it still kept on leaking. From what I observed, it was leaking from the plastic spacer.
I took off my tank and unscrewed the petcock and I noticed one of the thin films that cover the spacer on both sides was ripped.
Does anyone know if that is the main cause of my leak? If so, I think a repair kit wouldnt really help me that much.
Should I just buy a new oem petcock? any help will be appreciated
Even after I turned off my bike, it still kept on leaking. From what I observed, it was leaking from the plastic spacer.
I took off my tank and unscrewed the petcock and I noticed one of the thin films that cover the spacer on both sides was ripped.
Does anyone know if that is the main cause of my leak? If so, I think a repair kit wouldnt really help me that much.
Should I just buy a new oem petcock? any help will be appreciated
- Triangles
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Re: Petcock leaking on my 96' 500 LTD
below is an exploded diagram of the fuel petcock assembly. I have no idea what "plastic spacer" you are referring to. There is an o-ring between the tank and petcock. You should be able to take it apart and figure out what is broken. Buy just that part and put it back together. That way you don't have to buy a whole new petcock.
- Attachments
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- petcock.JPG (24.5 KiB) Viewed 20015 times
- Dino
- Posts: 24
- Joined: Wed Jul 25, 2012 1:05 pm
- I ride: '96 Vulcan 500 LTD
- Location: Southern California
Re: Petcock leaking on my 96' 500 LTD
I removed the back plate of the petcock and everything seems to be fine except for the spacer or I guess you could call it a gasket.
it gets held on with the back plate.
The diagram doesn't seem to list the part I'm referring to.
I marked the diagram to show where this spacer/gasket goes.
I'll take a picture of exactly what Im talking about once I disassemble the petcock again.
it gets held on with the back plate.
The diagram doesn't seem to list the part I'm referring to.
I marked the diagram to show where this spacer/gasket goes.
I'll take a picture of exactly what Im talking about once I disassemble the petcock again.
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- petcock.JPG (72.55 KiB) Viewed 20010 times
- Triangles
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Re: Petcock leaking on my 96' 500 LTD
I have a better understanding now. I thought you were saying there was a spacer between the petcock and the gas tank or something. The gas valve is vacuum operated when in the on/reserve positions. I've never had one of these apart so I don't know exactly how they work internally. I'm completely speculating here... That spacer/gasket may be apart of the diaphragm that the vacuum acts against to open the valve. If that's the case it doesn't look like it's an OEM replaceable part. You might want to consider buying a used petcock from fleabay and canabalizing it for the bad parts in your petcock or simply swapping it in for your petcock.
- Dino
- Posts: 24
- Joined: Wed Jul 25, 2012 1:05 pm
- I ride: '96 Vulcan 500 LTD
- Location: Southern California
Re: Petcock leaking on my 96' 500 LTD
Yesterday I had everything assemble because I had fixed a damaged hose and everything appear to be fine. I warmed up my bike and noticed the leaking had stopped, so I took her out for a ride. When I got home and turned it off, it started dripping gas from the same spot it leaked before.
I just finished taking it apart again and included some pictures.
I could buy a used one but then I might have the risk of running into the same problem.
I was also considering buying a manual petcock but I dont know yet.
I just finished taking it apart again and included some pictures.
I could buy a used one but then I might have the risk of running into the same problem.
I was also considering buying a manual petcock but I dont know yet.
- Attachments
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- the two thin black films on both sides appear a bit worn out and loose
- Photo on 2012-10-29 at 13.56.jpg (34.46 KiB) Viewed 20003 times
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- Photo on 2012-10-29 at 13.55 #2.jpg (42.24 KiB) Viewed 20003 times
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- the o-ring appears to be fine on this side
- Photo on 2012-10-29 at 13.55.jpg (39.67 KiB) Viewed 20003 times
- Dino
- Posts: 24
- Joined: Wed Jul 25, 2012 1:05 pm
- I ride: '96 Vulcan 500 LTD
- Location: Southern California
Re: Petcock leaking on my 96' 500 LTD
Im really considering buying a manual petcock instead to avoid any future problems.
I've read that the ethanol in gasoline tends to mess up certain parts(like the petcock) on carbureted vehicles.
I'm not sure if thats true or not but since I live in California and dont have access to gas without ethanol, a manual petcock sounds hassle free.
Its also less expensive than buying a new oem petcock.
I've read that the ethanol in gasoline tends to mess up certain parts(like the petcock) on carbureted vehicles.
I'm not sure if thats true or not but since I live in California and dont have access to gas without ethanol, a manual petcock sounds hassle free.
Its also less expensive than buying a new oem petcock.
- Dino
- Posts: 24
- Joined: Wed Jul 25, 2012 1:05 pm
- I ride: '96 Vulcan 500 LTD
- Location: Southern California
Re: Petcock leaking on my 96' 500 LTD
On the contrary to my last post, Im going to get the oem petcock instead.
I couldnt really find a manual one and I wouldnt want hassle with one from a different bike.
I do realize my bike is a bit old and a brand new petcock should hold up for a good while.
I couldnt really find a manual one and I wouldnt want hassle with one from a different bike.
I do realize my bike is a bit old and a brand new petcock should hold up for a good while.
- Triangles
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Re: Petcock leaking on my 96' 500 LTD
Looks like the gasket/diaphram or whatever that is, is bad. I'd assume this has what you need since the pictures from the other kits looks similar to your problem part. scroll down to Kawasaki - 2763 $27 bucks I would think is cheaper than a new petcock. Also available on amazon.com You can find others by googling "K&L 18-2763"
- Dino
- Posts: 24
- Joined: Wed Jul 25, 2012 1:05 pm
- I ride: '96 Vulcan 500 LTD
- Location: Southern California
Re: Petcock leaking on my 96' 500 LTD
Thanks for your insight.
I'm going to buy the repair kit instead since my budget is a bit low to begin with, hopefully this will solve my problem.
I'm going to buy the repair kit instead since my budget is a bit low to begin with, hopefully this will solve my problem.
- Dino
- Posts: 24
- Joined: Wed Jul 25, 2012 1:05 pm
- I ride: '96 Vulcan 500 LTD
- Location: Southern California
Re: Petcock leaking on my 96' 500 LTD
I rebuilt the petcock about a month ago already and a few weeks after I noticed that it still dripped a little bit of gasoline, not as much as before though.
What else would cause it to leak?
I feel I should mention that the previous owner put a set of harley pipes on the bike, but I think he didnt rejet the carbs becuase I get some backfire if I let go of the throttle quickly. I dont know if any of this would contribute to the problem....
What else would cause it to leak?
I feel I should mention that the previous owner put a set of harley pipes on the bike, but I think he didnt rejet the carbs becuase I get some backfire if I let go of the throttle quickly. I dont know if any of this would contribute to the problem....
- Triangles
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Re: Petcock leaking on my 96' 500 LTD
I don't know what else the problem could be. I can tell you the bike "backfires" (technically it's an afterfire) when you let off the throttle sort of by design. Thanks to the eco-nazis, Kawasaki has a system that dumps air into the exhaust to burn up any unburned gas that makes it to the exhaust pipes. Google Kawasaki Clean Air System. Also changing the mufflers won't throw off the carbs enuff to require rejetting and the Harley mufflers would have no effect on your problem.
- Dino
- Posts: 24
- Joined: Wed Jul 25, 2012 1:05 pm
- I ride: '96 Vulcan 500 LTD
- Location: Southern California
Re: Petcock leaking on my 96' 500 LTD
I took my bike out for a ride early today, it had been about a week since i rode it.
I rode it a little faster than usual to see if the petcock would interfere at all but it didn't.
Now surprisingly it hasn't dripped anymore fuel, even after checking it a few hours later.
Hopefully the problem has gone away.
I rode it a little faster than usual to see if the petcock would interfere at all but it didn't.
Now surprisingly it hasn't dripped anymore fuel, even after checking it a few hours later.
Hopefully the problem has gone away.
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- Posts: 38
- Joined: Tue Sep 10, 2013 12:13 pm
- I ride: 06 red Vulcan 500
- Location: Round Rock,Tx
Re: Petcock leaking on my 96' 500 LTD
Are the barbs on the petcocks removable?
VRA 1-68 President
Round Rock Vulcan Riders
Round Rock Vulcan Riders
- Triangles
- Site Admin
- Posts: 819
- Joined: Sun Dec 27, 2009 10:35 pm
- I ride: '94 Black Cherry Vulcan 500, '06 Candyfire Red Vulcan 500 LTD
- Location: Toledo Ohio
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Re: Petcock leaking on my 96' 500 LTD
they are not supposed to be removable. I don't remember which bike it was but I had one come out that wasn't supposed to. JB Weld fixed that
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- Location: Round Rock,Tx
Re: Petcock leaking on my 96' 500 LTD
How long did that hold up for you?and would you do it again?
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Round Rock Vulcan Riders
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