Petcock rebuild - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
 
LinkBack Thread Tools
post #1 of 8 (permalink) Old 11-3-2019, 6:22 PM Thread Starter
Junior Member
 
Join Date: Sep 2019
Posts: 10
 
Petcock rebuild

So I noticed when I turned me Petcock to the on position is get drip, drip drip... Of fuel coming from it onto the engine.... I tried tightening all the screws but it still happened. I called up the local place and ordered a rebuild kit, what came in was the all balls racing one. Ok, no big deal I just did it tonight and noticed a few things, one is that I have a few extra o rings. The second is that the screws that I had on the front (where you select on off or reserve) were much shorter than the ones that came with the kit.

I opted to use the old ones but of course I dropped one and can't find it now.

Does anyone have any experience with the all balls rebuild kit? Did you notice these were too long and would bottom out too?

There were also 2 o rings of similar size to the one that was on the lever. The lever is very hard to move now, bit not impossible, should I try the other one?
radiant.desigtner is offline  
Sponsored Links
Advertisement
 
post #2 of 8 (permalink) Old 11-4-2019, 5:19 PM
Senior Member
 
Kevinl7778's Avatar
 
Join Date: Mar 2018
Location: Hamilton, NJ
Posts: 449
 
Garage
I had an allballs for my ZX600E and the screws for the ffilter near the float valve's were wrong and I had to use the old ones.

1993 Teal/White EX500 6K First Street Bike
Kevinl7778 is offline  
post #3 of 8 (permalink) Old 11-4-2019, 9:10 PM
Super Moderator
 
ducatiman's Avatar
 
Join Date: Feb 2008
Location: NEW YORK
Posts: 14,170
 
Garage
Quote:
Originally Posted by radiant.desigtner View Post
Does anyone have any experience with the all balls rebuild kit? Did you notice these were too long and would bottom out too?
Can't comment on All Balls petcock kit, but have had recent issues with incorrect carb kit components (other Kawasaki, not EX500) and long ago their fork seals which weeped upon installation, forcing an instant redo using OEM seals. Will never again use their fork seals.

“Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba....” quote Hunter S Thompson

Custom Carb Service

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
ducatiman is offline  
 
post #4 of 8 (permalink) Old 11-4-2019, 9:24 PM
Senior Member
 
Saabnut's Avatar
 
Join Date: Feb 2012
Location: Santa Rosa, CA
Posts: 2,328
 
Quote:
Originally Posted by ducatiman View Post
Can't comment on All Balls petcock kit, but have had recent issues with incorrect carb kit components (other Kawasaki, not EX500) and long ago their fork seals which weeped upon installation, forcing an instant redo using OEM seals. Will never again use their fork seals.
I have actually had the same experience with their fork seals and will now only use OEM as a result. In fact, I wasn't thrilled with the last set of their bearings either and will never use the brand for anything again.

Back to the original question, I don't have any experience with the All Balls petcock rebuild kit, but I do have experience with various other aftermarket brands of such and the one thing they all have had in common in that they suck. None have compared to the fit and finish of OEM parts, most notably the vacuum diaphragm. The screws on the face plate don't bottom out, so the length doesn't really matter.
My recommendation is to bit the bullet and fork out the extra dough for either OEM rebuild parts or a complete OEM new petcock assembly. This may not have been the advice you were looking for, but in my experience, I have found this to be truly the only way to go when it comes to fuel system parts for this particular motorcycle.

1990 EX500 - 144,000 miles as of November 2nd, 2019
1993 Ducati 900SS - The real canyon carver
Saabnut is offline  
post #5 of 8 (permalink) Old 11-4-2019, 9:56 PM
bpe
Senior Member
 
bpe's Avatar
 
Join Date: Mar 2015
Location: Atlanta,GA
Posts: 5,682
 
Garage
Quote:
Originally Posted by Saabnut View Post

Back to the original question, I don't have any experience with the All Balls petcock rebuild kit, but I do have experience with various other aftermarket brands of such and the one thing they all have had in common in that they suck. None have compared to the fit and finish of OEM parts, most notably the vacuum diaphragm. The screws on the face plate don't bottom out, so the length doesn't really matter.
My recommendation is to bit the bullet and fork out the extra dough for either OEM rebuild parts or a complete OEM new petcock assembly. This may not have been the advice you were looking for, but in my experience, I have found this to be truly the only way to go when it comes to fuel system parts for this particular motorcycle.
^+1
At the very least it is the fastest and easiest way to a guaranteed 10's of thousands of miles of a trouble free fix.

2006 Ninja500R Purchased new July 2006; 0 miles. Miles as of January 2019; 102,137. It's a GO bike, not a SHOW bike.
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
bpe is offline  
post #6 of 8 (permalink) Old 11-6-2019, 2:02 PM Thread Starter
Junior Member
 
Join Date: Sep 2019
Posts: 10
 
I should have a new Petcock in the mail when I get home. Ended up getting 2 of the rebuild kits, should have just bought the whole new petcock. Of course when I ordered the second rebuild they never said that it was an aftermarket or THE VERY SAME ONE THAT I JUST COMPLAINED WAS WRONG! Oh well, ended up paying almost twice what I should have to begin with...
radiant.desigtner is offline  
post #7 of 8 (permalink) Old 11-6-2019, 2:39 PM
fog
Senior Member
 
Join Date: Oct 2006
Location: Mt home, AR
Posts: 19,071
 
A little late to this party but, you do know the petcock is vacuum operated so if the engine wasn't running. it was supposed to be off . the drip was that it was leaking

FOG

I hate PMs if you want to contact me, find my email address.Look in the for sale section.
fog is offline  
post #8 of 8 (permalink) Old 11-6-2019, 8:53 PM
Senior Member
 
po18guy's Avatar
 
Join Date: Aug 2009
Posts: 2,231
 
Garage
Try a 1980-1983 Yamaha XJ650 petcock. Bolts right on. Vacuum operated, but has a "Prime" position which fills the carbs like "real" petcocks used to - you don't have to crank the engine for 30 seconds just to fill the float bowls. Any wonder why EX starters and starter clutches cause so much trouble? The process is similar to "tickling" an Amal carb to fill the bowl. Turn it to prime, put on helmet and gloves and your carbs are full. Flip it to "On" and you're good to go.

The XJ unit has no "Off" position (Prime, On, Reserve), but if it is in good shape the vacuum valve will stop the flow just like it does on the EX. The vacuum port is facing rearward, but you can either flip it 180º or just run a longer hose to the EX vacuum spigot. Your range-to-reserve might be different, due to different tube height, but that can be changed, also.

I finally figured out why I like Ducatis: With their exhaust note and dry clutch, they sound almost like a Guzzi!

Last edited by po18guy; 11-6-2019 at 8:58 PM.
po18guy is offline  
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page



Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome