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Gas tank petcock leaks when turned on - 1974 Suzuki GT 380

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Remove it and replace the little rubber seals inside. can get most auto parts stores

Posted on May 18, 2011

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Posted on Jan 02, 2017

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Gas going into crankcase


Hi, Hb there are three ways in which gas can get into your oil tank/system:
1. Someone deliberately pours gas into your oil tank.
2. The vacuum petcock control rubber fails, which allows gas to flow from the fuel tank through the petcock, through the vacuum line into the intake manifold, then into the combustion chamber, where it seeps past the piston rings and into the bottom end where it gets pumped back into the oil tank.
3. Nonvacuum petcocks that are not turned to the off position will patiently wait until the float needle and seat no longer function properly thus inviting gas to enter the combustion chamber eventually finding it's way to the oil tank.
For more information about your issue and valuable "FREE" downloads that you will need please click on the links below. Good luck and have a nice day.
http://www.kawasakimotorcycle.org/forum/kawasaki-streetbikes-sportbikes/130968-gas-crankcase-oil.html
Gas leaking into crankcase
Gas fuel in crankcase

Nov 12, 2016 | Motorcycles

1 Answer

Drain fuel tank


Turn fuel petcock to off. Take off fuel line coming from petcock and use that hose, or one the same size, to run from petcock to gas container. (have paper towels or something ready because fuel left trapped in fuel line will leak out even with petcock off). With hose going in container turn petcock to normal "run" position and drain until dry - lean bike side to side to get it all. *Note - it usually drains faster with fuel cap off. Then turn petcock to "reserve" setting and do the same to get the fuel out of reserve partition in tank. Most tanks are only held on by a few bolts at rear and rubber "slide on" knobs at front, so if you remove seat and the few tank bolts you slide tank backwards and it comes off. Then you can do this draining outside / away from anything.

Jan 21, 2015 | 2008 kawasaki Vulcan 1500 Classic

1 Answer

Replace petcock in 2000 heritage


I replaced the factory petcock on my 2000 FXDWG due to a friend having his stop working. The factory one is vacuum operated. If the diaphragm leaks it won't let fuel go to the engine.


You will probably have a bit of fuel leak during this so don't do it near any source of flame or ignition. Keep rags or an old towel handy and I recommend a fire extinguisher just to be safe.

Just drain the tank thoroughly into a container you can seal like a regular gas can, not an open pail. An open pail will allow gas fumes to spread out and they can be deadly. Turn the valve to off, and remove the hoses.
One for the gas and one for the vacuum.

Remove the factory petcock by turning the large nut that pinches it to the tank. Now you can slip it down out of the tank. There is bound to be some gas dripping off the strainer so expect it.

If you are replacing it with another factory petcock just do everything in reverse making certain the hoses have a good seal.

If you are installing a manual valve without the vacuum function, you will need to plug the vacuum hose or the engine could run lean and overheat. Make sure that new valve has a fuel strainer on it to prevent junk from going to the carburetor.

I recommend putting only about a gallon of gas in to check for leaks. If all is well, fill it up and go for a ride.

Note: If the reserve tube is shorter than the one on the factory valve you will not have as much fuel in the tank when you have to switch to reserve. That happened to me. My factory valve would make me switch to reserve when I had about 30 miles worth of fuel left in the tank. The new one would only leave me about 20. So beware of that until you learn where it hits reserve.

Apr 07, 2014 | 2000 Harley Davidson FLSTC Heritage...

1 Answer

2001 Triumph Legend TT engine oil flooding with petrol


Hi, Malcolm you're getting ready to go riding you pull out the dipstick to check your oil level and are greeted with the unmistakable smell of gasoline. What happens next depends on the following:
1. You have experienced this before and do not start the engine but do change your oil and filter leaving it 1 quart low until the engine reaches operating temperature then top off as necessary.
2. The amount of time your bike has been sitting since the last time the engine was running.
3. The amount of gas and contaminants in the tank.
4. The oil pump location, exterior or interior.
5. The condition of your petcock gasket/seal/diaphragm.
If your gas tank was low and you start the engine probably nothing you would notice but if your gas tank was full and you start your engine the oil/gas mixture can blow into your air filter, come streaming out of your crankcase breather hose, and launch your oil tank cap followed by a blast of oil. The mess can be minor or you need to call a Hazmat team for assistance. This will also happen if you overfill your oil tank.
Next is the how and why gas can get into your oil tank/system:
a. The vacuum petcock rubber/diaphragm fails, which allows gas to flow from the fuel tank through the petcock, through the vacuum line into the intake manifold, then into the combustion chamber, where it seeps past the piston rings and into the bottom end.
3. Nonvacuum petcocks that are not turned to the off position will patiently wait until contaminants from the gas tank build up in between the carburetor needle and seat breaking the seal thus inviting gas to enter the combustion chamber eventually finding it's way into the bottom end and the oil tank.
4. Bottom line if you're not going to ride your bike for a while turn off the petcock.
For more information about your issue and valuable "FREE" downloads that you will need please click on the blue links below. Good luck and have a wonderful day.
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Jul 05, 2017 | 2001 Triumph Legend TT

1 Answer

When off gas is leaking


1. remove the hose from the carb and see if the petcock is shutting off the gas and if not clean, repair or replace the petcock.
2. look in the tank and see if it has rust in the tank even a small haze of rust as rust will cause the needle and seat to stick in the carb and make the gas leak. If the gas tank has a lot of rust it may need a tank rubber liner kit added or even a new tank to stop the leaking.
3. if the bike has been sitting for a while it may have trash in the fuel system(carb/petcock/tank). Rust or any trash can cause a leak. Properly clean out the carb and fuel system and add a new filter when done.
4. Improperly adjusted or bad needle/seat or float in the carb will cause continual leaking. Replace the needle/seat/float and adjust the new one when installed. Check your service manual for float adjustments.

Jul 22, 2012 | 2002 Honda CR 125 R

1 Answer

I need to replace the o ring (petcock) on my 2004 honda shadow aero and need to know if i need to remove tank or maybe get special tool to remove petcock


Drain the tank. You should be able to remove the petcock by simply turning the nut holding it on or turning the whole petcock assembly. It may be stuck in place by the o-ring/fuel filter inserted into the tank. Be sure the filter is in place when you put the petcock back on or you will have problems with leaking gas out the carburetor overflows (from tank rust getting into the carburetors). Chances are the leaking gas is not form the tank sealing o-ring, but from the vacuum diaphragm assembly attached to the back of the petcock. Part # 5 on the microfiche.
http://www.bikebandit.com/houseofmotorcycles/2004-honda-vt750c-shadow-aero/o/m2881#sch407448

Sep 05, 2011 | 2004 Honda VT 750 Shadow Aero

1 Answer

Petcock leaking took off gas tank alot of air build up in gas tank


Repair or replace petcock then...Lol
As leaking gas becomes mixed it becomes a dangerous item as a spark will set it alight.

Nov 09, 2010 | 2005 Honda CBR 600 RR

1 Answer

Gas is leaking from the peacock valve under my gas tank seems to be coming directly from the bottom,what could cause this?


There's a gland nut that holds the petcock into the tank and pulls it up against the seal. Try tightening the nut. But, in all probability, it's the vacuum diaphragm in the backside of the petcock.

Harley went to a vacuum operated petcock in 1996 and they've been a pain ever since. The diaphragm gets a small hole in it and leaks gasoline or quits opening leaving the rider stranded.

Now, You can repair the petcock if you wish. Get a large funnel and an empty gasoline can. Loosen the petcock and allow the fuel to run out around the nut, catching it in the funnel and directing it into the gas can. Once empty, take the fuel line and the vacuum line off the petcock. The vacuum line is the small line on the backside. Take the petcock out of the tank. Look on the backside and there are four small screws. Take them out and carefully take the back plate off the valve. You'll see a diaphragm, a spring, and needle. Take the diaphragm and hold it up to the light and gently stretch it. You'll probably find a hole. You can get a replacement diaphragm from you local dealer. Reassembly is the reverse of disassembly.

Personally, I'd rather replace the vacuum operated petcock with a high quality manually operated petcock such as Pingel. The OEM petcock will fail on you and leave you stranded with a full fuel tank and an empty carburetor. The Pingle won't. Just install it, connect the fuel hose, and plug the vacuum hose.

Good Luck
Steve

Sep 12, 2010 | 2000 Harley Davidson FXDL Dyna Low Rider

1 Answer

Leaking Fuel tap (petcock)


This sounds like a vacuum lock pet ****. 3 position? run, prime,and reserve? If you have it on pri, You will fuel running or not. If set on run, then you will only pass fuel when engine is running, and of course res. when tank is used up. Is this leak at the valve? or from the tank or internally flowing? Tis should also be a gravity feed fuel system, please correct me if I'm wrong. good luck. Long fuel lines are not prefered on gravity feed systems.

May 20, 2009 | 1986 Honda VT 500 C Shadow

3 Answers

Gas leaking from air box on 99 B12


there is not a off position i have a 1999 GSF bandit 1200 which i had the same air box gas problem. the positions are On, Reserve, and Pri. if its leaking back into the air box the petcock is not working correctly pull the tank off or disconnect the gas line and vacume line fuel should not leak out if it does the diaphram is riped replace the petcock. Also if you airfilter got soaked it needs to be replaced

Apr 14, 2009 | 1999 Suzuki GSF 1200 Bandit S

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