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1200 sportster gas leak

I have a leak at the bottom of the petcock. It looks like a small breather hole.

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  • teksus May 02, 2009

    I have a 1997 Harley 12 Sportster that also has a similar gas leak. The gas comes out of the little petcock behind the fuel line and it only leaks when the engine is on and running. I thought it was becuase there should be a hose attached to it so that it would leak on the ground. Not really sure what to do, I think it may be an easy fix.



  • teksus May 11, 2010

    97 1200 sportster gas coming out of the petcock while driving?

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2 Answers

Did not say whay year but hd went to a vacumn activated petcock to shut the fuel off for you when you kill the engine. the little pinhole is the pressure equalizer for the diaphram so if it leaks, the diaphram has a hole in it. not sure but hd might make a rebuild kit, if not, i would replace it with an aftermarket without the diaphram shut off. you just have to remember to manually shut the fuel. you will also have to plug the vacumn line. why i suggest this is if you are wot too long the loss of vacumn signal will shut the fuel off and cause a lean condition which will increase combustion temps.

Posted on Aug 13, 2008

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You will need a new petcock. The internal seals are gone.

Posted on Aug 06, 2008

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2 Answers

2005 Harley Sportster 1200 Custom stalls at highway speeds


The diaphragm petcock operates by vacuum.
Sometimes, the vacuum line comes unhooked, cracked or broken.

Check the vacuum line.

Also, the diaphragm petcock sometimes dies, and needs replacing.

The reserve DOESN'T operate by vacuum.

Feb 12, 2014 | 2005 Harley Davidson XL 1200 C Sportster...

1 Answer

Gas tank on off res. leaks when driving


Hi Joe, for more information about your question please visit the websites below. Good luck and have nice day.
How to fix your motorcycle petcock without rebuild kit
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Jun 26, 2012 | 2001 Harley Davidson XL 1200 S Sportster...

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Fix the petcock on sportster hugger 883 2000


Hi Anonymous, please be aware that this question has already been asked and answered. Thank you

Feb 19, 2012 | 2000 Harley Davidson XL 1200 C Sportster...

1 Answer

2005 sportster 1200 carb stops after running awhile won't start until sits for bit seems like front cyl miss firing before stopping


Sounds like the engine is running out of fuel. There could be two reasons for this. One, the vent in the gas cap could be stopped up. Try loosening the cap, but don't take it completely off unless you want a lap full of gasoline, and take gentle ride. Do this with a half tank or less of fuel for the same reason I just mentioned. See if it still does it. Secondly, in 1996, Harley started putting vacuum operated petcocks on the bikes. These do give problems. They have a diaphragm that is opened by engine vacuum allowing the fuel to flow to the carb. If the diaphragm gets a hole in it, it will not allow fuel to the carb. To repair this, you must take the petcock out of the tank. Disconnect the fuel and vacuum hoses. Loosen the large nut until fuel starts to flow out. Catch the fuel with a large funnel and an empty gas can. Remove the petcock and take the four small bolts out that hold the square plate on the rear of the petcock. Carefully remove the plate observing how the needle, spring, and diaphragm are in there. Hold the diaphragm up to the light and gently stretch it looking for holes. If you find a hole, replace the diaphragm. While you have the petcock out, clean the fuel screen.

Good Luck
Steve

May 29, 2011 | Harley Davidson Burgman 125 G Motorcycles

1 Answer

1996 1200 custom. let run to warm, and die's. gas in the tank does not matter.will fire, but not start.


In 1996, Harley went to a vacuum operated petcock and these things do give problems. Take the air filter off the carb and with the engine off, crank the throttle wide open. Watch for fuel to squirt into the carb from the brass nozzle just inside the mouth of the carb. If no fuel squirts, your float bowl is empty, no gas is getting to the carb. You'll have to loosen the petcock and drain the tank by loosening the large nut and catching the fuel with a large funnel and an empty fuel can. Once the fuel is drained, you can remove the petcock. Remove the square plate on the rear of the petcock and remove the spring, the needle, and the diaphragm. Hold the diaphragm up to the light and gently stretch it looking for holes. If you find a hole replace the diaphragm. Blow through the petcock with some low pressure compressed air to verify that it is not plugged up and reassemble the petcock. If you have a hand operated vacuum pump, test the petcock to insure that it is functioning correctly. Personally, I suggest replacing these petcocks with a high quality manually operated petcock like a Pingel or you can purchase a new OEM one from Harley.

Good Luck
Steve

May 23, 2011 | 2000 Harley Davidson XL 1200 C Sportster...

1 Answer

No gas flow thru fuel shut off switch/valve...what's up?


You probably have one of the vacuum operated petcocks. These came out in 1996 and have been a source of trouble ever since. Look at your petcock and see if it is square looking on the backside and has a vacuum line going to it. If so, you need to check the vacuum line. It comes of the backside of your carb and has a tee fitting in it. From the tee fitting two vacuum lines come out and one goes to the VOES switch and one goes to the petcock. You may have to replace the diaphragm in the petcock.

To replace the diaphragm, drain the tank and remove the petcock. Take the four small screws out of the plate on the back of the petcock and carefully separate it. There is a needle, spring, and a diaphragm under the plate. Hold the diaphragm up to the light and carefully stretch it looking for a hole. If you find a hole, replace the diaphragm.

To avoid future problems, I suggest purchasing a high quality manually operated petcock and simply turn your fuel off manually when you finish riding. This is old school but it doesn't give problems.

Good Luck
Steve

Apr 17, 2011 | 2005 Harley Davidson XL 1200 C Sportster...

1 Answer

2003 harley davidson sportster 1200 custom. runs fine shortly then dies with spurts of fire. the light stays on and if i pull the clutch when its still running, it goes back to normal idle and responds to...


It sounds like a fuel starvation problem since it's spitting back out of the carb. Check you fuel cap to see if the vent is working. Loosen the cap and ride and see if that makes any difference.

Also, if your bike is equipped with the original vacuum equipped petcock, there could be problem with this as well. I've seen them get holes in the diaphragm and I've seen cause a vacuum leak. Check the vacuum hose and diaphragm. You'll have to remove the petcock from the tank. Personally, I'd recommend that you change the petcock to a high quality manually operated petcock like a Pingel.

Good Luck
Steve

Oct 09, 2010 | 2003 Harley Davidson XL 1200 C Sportster...

1 Answer

How to drain a gas tank on a harley 1200 sportster


Evidently, you have the vacuum operated petcock on your bike. If you have a hand operated vacuum pump, you can unplug the vacuum line from the back of the petcock and apply vacuum with the pump.

Otherwise, use a large funnel under the petcock and loosen the petcock tank fitting until the fuel starts to flow out. The funnel will catch the gasoline and direct it into a gasoline can.

Good Luck
Steve

Aug 17, 2010 | 2000 Harley Davidson XL 1200 C Sportster...

1 Answer

My 2003 sportster 1200 sputtered this morning and quit. I tried to start it and it would turn over and sometime like a small backfire but would not stop. What could be the problem?


Sounds like it ran out of gas. Yeah, and I bet the fuel tank is full. Reach under the fuel tank to the petcock and pull the fuel line off. If you've still got the vacuum operated petcock, no fuel should flow out. But, if you try to start the engine, the vacuum should open the petcock and allow fuel to flow to the carb. Press the start button and watch for fuel to run out, catch the fuel in some sort of container.

If no fuel runs out, you've got a bad petcock. I've seen this at least a hundred times. Those petcocks are the worst thing Harley ever did in my opinion. You can take the petcock out of the tank, disassemble it and look for a hole in the diaphragm or you can replace it with a high quality manually operated petcock. I recommend a Pingle. They're pricey but well worth the money.

To check your diaphragm, take the four small screws out of the back of the petcock. Remove the plate watching for the small spring and needle thats under the plate. Hold the diaphragm up to the light and gently stretch it and look for a hole. If you find a hole, buy a replacement diaphragm at your local Harley dealer and reassemble your petcock.

Hopefully, this will help you fix your problem. If not, write back and give me some more information.

Good Luck
steve

Jul 29, 2010 | 2003 Harley Davidson XL 1200 C Sportster...

1 Answer

I recently added a kuryakyn hypercharger on my sportster


The worm clamp proly did choke off the breather. Usually when oil comes out of your breathers it means there is to much oil in your oil tank. 

Apr 16, 2009 | 2002 Harley Davidson XL 1200 S Sportster...

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