Petcock rebuild - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
 
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post #1 of 14 (permalink) Old 6-14-2019, 10:25 PM Thread Starter
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Petcock rebuild

I recently realized my bike will run with the fuel switched off, so I figured I'd better rebuild the petcock. I replaced every piece of rubber in the system, but fuel still comes out with vacuum when the switch is in the off position. Does anyone know what could cause this?
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post #2 of 14 (permalink) Old 6-17-2019, 4:33 PM Thread Starter
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I replaced every bit of rubber in the petcock, and fuel started coming out of the tank when the switch was in any position, including off. I then stretched out the spring to make it stiffer, and it fixed the leak, but when i suck on the vacuum line when the switch is on off, fuel still comes out at full force. From what i was able to find online this is not normal. Does anyone know if possibly i need a stiffer spring? I have no idea what else could cause this issue.
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post #3 of 14 (permalink) Old 6-17-2019, 4:49 PM Thread Starter
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Also does anyone know what this circled part is? I don't believe that i have that. I read online maybe it's a spring to apply pressure on the switch? If anyone knows please share the knowledge. Thanks a lot
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post #4 of 14 (permalink) Old 6-17-2019, 6:25 PM
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That is in fact a "washer" that is warped to act as a spring. A must have item. Won't be found in a rebuild kit, nor can you get it from a dealer.

2006 Ninja500R Purchased new July 2006; 0 miles. Miles as of January 2019; 102,137. It's a GO bike, not a SHOW bike.
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post #5 of 14 (permalink) Old 6-17-2019, 6:31 PM Thread Starter
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Ah hah, thank you so much. That was my guess. That info was surprisingly hard to find. The forum support has been great for this bike so far
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post #6 of 14 (permalink) Old 6-17-2019, 6:38 PM
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Thumbs up

And it always will be.

2006 Ninja500R Purchased new July 2006; 0 miles. Miles as of January 2019; 102,137. It's a GO bike, not a SHOW bike.
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post #7 of 14 (permalink) Old 6-17-2019, 7:15 PM
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its commonly called a "wave washer"....its absence will likely allow a poor seal in the ports behind the lever as it preloads the lever versus the rubber diaphragm washer.....enabling its sealing capacity.

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Last edited by ducatiman; 6-17-2019 at 7:17 PM.
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post #8 of 14 (permalink) Old 6-17-2019, 7:36 PM Thread Starter
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Yeah that makes total sense. The PO replaced it with an o ring which quickly broke, and the rebuild kit came with no replacement. I'll keep the thread updated if that doesn't fix it
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post #9 of 14 (permalink) Old 6-17-2019, 7:44 PM
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as @bpe posted, the wave washer is not included in a rebuild kit. You may need to pick up a junker petcock somewhere.

PS there IS a sealing oring around the circumference of the actual lever which should be included in the kit.

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post #10 of 14 (permalink) Old 6-17-2019, 7:45 PM
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If you can't find that replacement wave washer, let me know, I've got plenty of junk petcocks and they all still have that washer.

A note on the diaphragm. Make sure to go OEM. I've never had good luck with the aftermarket ones, regardless of brand or country of origin. They work at first, but quickly develop a tear allowing fuel to leak.

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post #11 of 14 (permalink) Old 6-20-2019, 8:50 PM
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I just recently picked up this rebuild kit which does include that washer and more.


https://www.ebay.com/itm/Kawasaki-Ni...rd!60608!US!-1

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post #12 of 14 (permalink) Old 6-21-2019, 4:03 AM
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^ Nice find. I don't remember those 2 small nylon O-rings, were those used? Did the kit end up working good?

2006 Ninja500R Purchased new July 2006; 0 miles. Miles as of January 2019; 102,137. It's a GO bike, not a SHOW bike.
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post #13 of 14 (permalink) Old 6-24-2019, 8:41 AM Thread Starter
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Quote:
Originally Posted by Shogun View Post
I just recently picked up this rebuild kit which does include that washer and more.


https://www.ebay.com/itm/Kawasaki-Ni...rd!60608!US!-1
Wow, I wish i would have seen this sooner, that is much nicer that the rebuild kit I found, and almost the same cost.
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post #14 of 14 (permalink) Old 6-27-2019, 3:41 PM
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Quote:
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^ Nice find. I don't remember those 2 small nylon O-rings, were those used? Did the kit end up working good?
The nylon washers are for the large bolts. I wasn't able to use them due to the shape of the petcock. Everything else went in fine with the only issue I have being that it is impossible to turn by hand. I have a pare of flat pliers in my jacket to turn the petcock. I'm hoping doing this for a little while will make it easier over time.

1997 Kawasaki Ninja 500R<br />FOG Mod<br />15t & 44t Sprockets<br /><br />2006 Scion tC Release Series 2.0 #498 of 2600<br />TRD Springs<br />Exel Daytona 18" Wheels<br />SS Clutchline<br />TWM SS Shifter bushings and Shift base bushings
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