Question about 1996 Yamaha XV 535 Virago DX

3 Answers

No fuel getting to fuel pump

Pump doesn't **** fuel even with petcock on.

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  • rthomasdawso Jul 22, 2009

    I have a Clymer manual that doesn't mention an internal filter, but there is one located on top of the tank.
    I am curious about the petcock. a) can it be removed w/o taking the tank out of the frame?
    b) are there any electrical devices incorporated with it? Thanks


  • rthomasdawso Jul 22, 2009

    To MNFisherman

    You said I should change the internal filter. My Clymer manual does not mention an internal filter in the fuel tank. There is a filter located on top of the fuel tank. Is this the filter you are referring to?

    If there really is an internal filter, how do I gain access to it?

    Thanks
    Tom Dawson



  • rthomasdawso Jul 23, 2009

    Hi, Rockitmam 187

    Thanks for the info. If I run into more problems I'll get back to you.

    Tom



  • rthomasdawso Jul 23, 2009

    Hi, MNfisherman

    Thanks for the help, I'll see if that fixes my problem.

    Tom


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You do need to remove the tank to access this filter. should be 4 screwes holding this p-cok to the tank. If you take off the hoeses to the carbs and open the cok fuel should run out. Take off the tank and invert it to drain into a clean bucket. take the cok off and becarful of the gasket. You shouls see a plastic screen there and some turn and screw out some held in with a clip. Check that then repost.

Posted on Jul 24, 2009

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Inside the portion of the petcock that goes into the tank is a mesh filter,This may be the problem,But you can test it by unhooking the fuel line and if gas flows,the mesh filter is clear,Also you can check the inline filter just before the pump the same way but unhooking the line after the filter this time.

Also try the fuel pump with the gas cap off,It may be faulty and not allowing it to vent which will cause it to vapor lock and no gas will flow if it is vapor locked.

Posted on Jul 23, 2009

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The filter inside the fuel tank will need to be removed.

Posted on Jul 22, 2009

  • Nate Stansfield
    Nate Stansfield Jul 23, 2009

    Where the pitcock is located, there should be two screws. If you remove that piece, it will have two tubes with a paper screen.

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1 Answer

Fuel tank petcock vacuum operated


What exactly is the problem with the petcock? If it is a vacuum operated petcock and it is no longer allowing fuel to the engine check the following:

First, did you work on the bike prior to the problem occuring, and was the bike running properly before this? On bikes I've owned with vacuum petcocks, the petcock has two rubber hoses attached to it. One is the vacuum line the other is the fuel line. On one of my bikes these hoses were nearly identical in size and I managed to swap them a couple times after having the tank off the bike. Simply double check that the hoses are connected properly. If they are not, the bike will run until the fuel is run out of the float bowls then die.

Second, do you have an inline fuel filter on the fuel line between the petcock and carb? If so check it to make sure it is not clogged.

Third, remove the tank and check the entire length of the vacuum line for the petcock. Is it kinked, pinched, cracked, cut, detached, etc.? Look for anything which would prevent the line from providing vacuum to the petcock.

Fouth, test the petcock to see if it is working properly. To do this you will need a handheld vacuum pump, such as a Mityvac (you may be able to get a free loaner from some autoparts stores). remove the vacuum line from your petcock and attach the vacuum pump to it. It should only take one or two pumps to create enough vacuum to open the petcock valve. If fuel begins to flow the petcock is good, if it doesn't you could have a clogged filter screen in the tank, but most likely the petcock's vacuum diaphram is damaged. The Baha is a Chinese made bike and it's possible the rubber parts in the fuel system are not compatible with the ethenal fuel blends here in the U.S. The dealers who sell these bikes are really hit and miss when it comes to being able to provide replacement parts. Even with the internet, it may take some work to locate a correct replacement petcock for the bike. On the bright side, if you are able to get a new petcock, they are very easy to replace.

Good luck!

Nov 29, 2013 | 2011 Bajaj Pulsar 150

1 Answer

No fuel getting to carbs


If you have a vacuum operated fuel petcock, it should also have a "prime" position. That should let the fuel flow without vacuum from the engine. If this solves your fuel starvation problem, I would double-check to see whether the the replacement petcock gasket(s) may have shifted just enough to block some little pinhole that's required for vacuum equalization. That has happened to me--the replacement gaskets aren't exactly the same as what was originally in there.
You can also test the vacuum release of the fuel petcock without taking anything apart. Put a mity-vac (a hand-pumped vacuum pump) on the vac line to the fuel petcock and see whether you can get the fuel to flow. Harbor Freight sells a cheap mity-vac type pump for under $20 when it goes on sale (which it does regularly).
Good luck!

Dec 06, 2011 | 1982 Suzuki Gs 550 L

2 Answers

I have a 2001 XL1200 Sporster and it just died one day while riding. If it cooled off, it would run for a little while and die again.


Have you checked to see if you have fuel IN THE CARBURETOR? In 1996, Harley went to a vacuum operated petcock and they've had troubles with them. The diaphragm in the backside of the petcock gets a hole in it and it doesn't allow for a full flow of fuel. Ride the bike with the air filter off until it quits. When it quits, look into the mouth of the carb with the engine not running and crank the throttle grip to wide open throttle. There is a brass nozzle standing just inside the mouth of the carb. When you crank the throttle grip to wide open, you should see a stream of gasoline squirt into the carb. If not, the carb has no fuel in it even though the fuel tank may be full. You'll have to drain the tank and remove the petcock. Take the plate off the backside and take a look at the diaphragm. Gently stretch it while holding it up to the light and check for holes. Personally, I'd replace the petcock with a high quality mechanical petcock and plug the vacuum hose. You'll have to manually turn the fuel on and off old-school style but you won't have anymore petcock problems.

Good Luck
Steve

Aug 03, 2011 | 2001 Harley Davidson XL 1200 C Sportster...

1 Answer

Fxstb night train starts then dies like no fuel


It might not have any fuel, in the carb even with a full tank if it's carburetor equipped. In 1996, Harley introduced a vacuum operated fuel petcock. These things give problems in the fact that they get a hole in the vacuum diaphragm and will not open allowing fuel to flow to the carb. Take your air filter off and WITH THE ENGINE OFF, crank the throttle grip to wide open. When you do this, watch the accelerator pump nozzle, the brass thingy just inside the mouth of the carb, to see if it squirts a shot of fuel into the carb. If it doesn't, you're float bowl is dry.

You can repair the petcock by draining the tank and taking it out. Remove the square plate from the backside. Take note of how the parts are placed in the petcock. Remove the diaphragm and hold it up to the light while gently stretching it while looking for a hole. Personally, I'd rather replace the petcock with a high quality manually operated petcock. You'll have to turn the fuel on and off old school style but you won't have any problems with the petcock anymore. You'll have to plug the vacuum hose as well.

Good Luck
Steve

Jun 10, 2011 | 2002 Harley Davidson FXSTB Night Train

1 Answer

I've adjusted the float and checked the needle seat [found gas in my oil ] but will not start-checked for spark thinking that it has jumped timing how do I check timing? also what about vaccume on...


The timing on your bike is set automatically by the computer and cannot "jump", not even on the older models. There is a crankshaft position sensor on the left front of the engine case that senses the position of the crank. Since your bike is equipped with a carburetor, it has a fuel petcock. This petcock is operated by manifold vacuum. The vacuum line connects to the backside of the carb. Make sure it is connected at the carb and to the backside of the petcock. To check the petcock, you must have a hand operated vacuum pump. Disconnect the fuel line, connect the vacuum pump to the vacuum nipple on the backside of the petcock and apply vacuum. Fuel should run out of the fuel line. If not, you need to replace the diaphragm in the petcock. Personally, I'd replace the petcock with a high quality manual petcock like a Pingel. You'll have to turn your fuel on and off manually, old school but it won't give you any more trouble.

You can take an oil squirt can and put some fuel in it. Remove the air filter and squirt a couple of shots of fuel in the mouth of the carb. Try to start the engine. If it starts or fires a couple of times, then you know the spark is fine. If you get the engine to run long enough, it will allow the carb to fill with fuel and it may run on it's own then.

May 09, 2011 | 2006 Harley Davidson FXDLI Dyna Low Rider

1 Answer

I just picked up a peacock from dudley perkins Harley. assembled the thing and screwed it into the gas tank. I hooked up the fuel line but there isnt any gas did I do something wrong?


If your petcock is a standard replacement part, you must connect the vacuum line to the backside of the petcock. There should have been a vacuum line on your old petcock unless a previous owner has changed the petcock to a manually operated one. The vacuum line comes off the backside of the carburetor and supplies vacuum to the VOES switch and the petcock.

Still even with the vacuum line connected, you won't get fuel until you turn the engine with the starter. The engine must turn to generate the vacuum to open the petcock. If you have a hand operated vacuum pump, you can use this to check the fuel flow from your petcock.

Good Luck
Steve

Feb 04, 2011 | 2000 Harley Davidson FXDL Dyna Low Rider

1 Answer

I have a honda shadow sabre. i need to change the fuel filter. where is it on the bike? please.


Honda always has a self cleaning filter on the fuel petcock over the metal intake tube. If your model has an electric fuel pump, you can follow the fuel tube from the petcock to a second in line fuel filter between the petcock and electric fuel pump.

Sep 26, 2010 | 2005 Honda VT 1100 C2 Shadow Sabre

1 Answer

How do i change fuel filter


If there are no fuel filters visible between the tank and the fuel pump, the only fuel filters are in the tank. They are self cleaning and do not need maintenance. If the intake filters on the petcock are damaged they are part of the fuel petcock. The whole petcock will need to be replaced. You can always add an additional filter in line before the fuel pump, but it should not be necessary. To replace the fuel filter you need to drain the tank and replace the fuel petcock.

Sep 14, 2010 | 2003 Suzuki VS 800 Intruder

1 Answer

Bike runs for a mile then stops


You didn't tell me what year Sportster we're dealing with. So, I'll cover a few general things to check.

If your bike is running for about a mile and then stopping and it does this repeatedly, It sounds like a fuel problem. Most likely it's either the petcock or the fuel tank vent system.

First, If your bike is made after 1996, it probably has the OEM vacuum operated petcock. These petcocks are designed to open when the engine is running and close when it stops. There is a small vacuum line that plugs into the backside of the petcock. When the engine is running, this line supplies the vacuum. Check the line and make sure that it hasn't come loose or cracked. It originates behind the carb and goes upwards underneath the tank to the VOES switch and it has a "Y" in the line that reduces the size and then runs to the backside of your petcock.

If it is intact, you'll need a hand vacuum pump to test the petcock for proper operation. Connect the vacuum pump to the rear of the petcock. Remove the fuel line from the petcock. Now, apply vacuum to the petcock with the pump. Fuel should flow from the petcock. If not, the petcock is either bad or the strainer in the tank is stopped up.

Remove the petcock from the tank. Place a large funnel under the petcock and direct the funnel into an empty gasoline can large enough to hold all the fuel in the tank. Loosen the petcock enough so that the fuel runs out at a rate that you can control. When empty, finish removing the petcock from the tank. Inspect and clean the screen. Now, on the back side of the petcock is a square plate held on by four screws. Remove the screws and remove the plate. Underneath the plate you'll find a diaphragm. Hold the diaphragm up to the a light and gently stretch it and look for holes. If you find a hole, you'll have to replace the diaphragm.

Look inside the petcock where the needle is for trash. At this point you should be able to blow back up through the petcock to check for obstructions. Reassemble petcock and reinstall in the tank.

I've seen these petcocks give a lot of trouble exactly like you're experiencing. I recommend that you replace the petcock with a manually operated petcock. The Pingle petcocks are very high quality units but a bit pricey. If you'd rather stick to an OEM type unit, purchase a petcock from the Harley shop for a 1995 or earlier model. This will be a manually operated petcock. Plug the vacuum hose that you'll no longer need. You'll have to get into the habit of turning the gas on and off whenever you get on or off the bike like the old timers did. But, they'll never let you down.

Now, remove the fuel cap. Wipe it down real well with a clean cloth. Now, make sure your friends are NOT around for this test or you'll never hear the end of it. Put the threaded end of the fuel cap up to your lips and try to **** and blow through the vent. If you cannot, the vent is bad and you're not getting gasoline to your carb due to a buildup of vacuum in the tank.

Good Luck
Steve

Jul 15, 2010 | 2000 Harley Davidson XL 1200 C Sportster...

1 Answer

While driving motorcycle stalled.


Sounds like you've lost either spark or fuel. Take another set of spark plugs and plug them into your spark plug wires. Do not remove the plugs from the head. Spin the engine and watch for spark. If no spark, first check the "run/start" switch. If it's alright, you need to check the fuse for you ignition system to see if it's blown.

On fuel injected engines, you have a fuel pump. Check the fuse for the fuel pump. Listen for the fuel pump to run when the switch is turned on.

If you bike is carburated, check the petcock. In 1996, H-D went to a vacuum operated fuel petcock. These things are notorious for giving problems. Either the diaphragm gets a hole in it and shuts off the fuel or the vacuum hose comes loose. Check the vacuum hose that comes off the back of the carburetor and runs to the VOES switch and the petcock. You may have to remove the petcock to service the diphragm in it.

If you remove the petcock, there are four small bolts on the backside. Remove the four bolts, lift the plate and theres a spring and a diaphragm behind the plate. Check the diaphragm for holes. If you find hole, replace the diaphragm. If not, replace everything and test the petcock by applying vacuum to the rear of the petcock while blowing though the fuel line nipple. When you appy the vacuum, the petcock should be open. With no vacuum, petcock should be closed. Good Luck, Steve

Apr 27, 2010 | 2004 Harley Davidson FLTRI Road Glide

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