KZR's Bikes of the Month for 2024

Petcock Clearance

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14 Nov 2005 11:07 #8153 by Neotrion
Petcock Clearance was created by Neotrion
About a month ago I had to switch from a set of Tekei to a set of Mikuni carbs. I of course had to get some intake boots for a 650 to fit the smaller venturi size. I guess the mikuni carbs sit a bit higher because when I bolt my tank back down, I don't have any clearance to swing the petcock lever to prime or reserve. I barely have enough room to wedge the petcock in front of the carbs. Has anyone had these problems on a 750 and can pass some knowledge on how to fix it?

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14 Nov 2005 11:20 #8155 by ltdrider
Replied by ltdrider on topic Petcock Clearance
As far as I know, everything on my bike is stock. My petcock just barely makes it past the No. 1 carb when I swing it from On to Off to Reserve. You may have to scootch your tank back a little, or orient the petcock so that the lever clears the carb.
Here's a pic that shows my petcock:

'76 KZ900 LTD (Blaze)
'96 Voyager XII (Dark Star)
'79 KZ650 Cafe Project (Dirty Kurt)
Greensboro, NC

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14 Nov 2005 11:21 #8156 by ltdrider
Replied by ltdrider on topic Petcock Clearance
I keep screwing up the picture posting.

Try this one:

'76 KZ900 LTD (Blaze)
'96 Voyager XII (Dark Star)
'79 KZ650 Cafe Project (Dirty Kurt)
Greensboro, NC

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14 Nov 2005 11:23 #8157 by ltdrider
Replied by ltdrider on topic Petcock Clearance
ARRGGH!
How 'bout now?

'76 KZ900 LTD (Blaze)
'96 Voyager XII (Dark Star)
'79 KZ650 Cafe Project (Dirty Kurt)
Greensboro, NC

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14 Nov 2005 13:26 #8161 by hat0791
Replied by hat0791 on topic Petcock Clearance
There are some aftermarked petcocks on the market that have a very low profile, and the lever moves horizontally...
It might be worth looking into.
BTW, LTDrider, that is one heck of a beautiful bike!

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14 Nov 2005 15:02 #8172 by scottwes
Replied by scottwes on topic Petcock Clearance
I have a drag specialist petcock and I have to have it angled to allow it to swing freely without interference from the carbs. Instead of rotating directly front to back it rotates from back and left (off) to front and right (res). The angle is about 30~35 degrees. There was no way that I could screw in the petcock any farther, because I tried, and it rounded off 4 of the 6 corners of the hex area above the switch. I never expected it to be made of such soft metal, but I guess I got what I paid for.

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14 Nov 2005 16:20 #8194 by The Milkman
Replied by The Milkman on topic Petcock Clearance
If it isn't hitting by a lot, why not cut the lever a little shorter. It's been done before.
Ride safe,
Les

78 650-C2, Stock engine, Jardine 4-2 Exh., 17-38 sprockets, dyna ignition and coils, coil wiring mod, carb mod.

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14 Nov 2005 16:37 #8200 by apeman
Replied by apeman on topic Petcock Clearance
On my 1980 KZ750H, the petcock is also very tight to the carbs. I did what was previously suggested, and ground off about 1/4 inch of the lever. I also made sure the rubber tank mount pad was well placed to give me the max lift at the back end of the tank. I would have added a spacer if I needed it -- but I didn't.

I did not like the idea of running out of gas in the "on" position, and being unable to switch to "reserve" on the fly, just when I am on the long stretch of the SF Bay Bridge, where everyone goes 60 mph bumper-to-bumper, and there is no place to pull over. I have come to the conclusion that almost everythiing on these motorcycles is a critical safety item, and must work as intended, or better.

Petaluma and Truckee, CA -- member since Jan. 23, 2003;
PREVIOUS KZs: 1980 KZ750H with 108,000 miles; 1980 KZ750E with 28,000 miles; and KZ750H street/cafe project, all sold a few years back.

This is what I do for fun, not for work. It is art, with a little engineering thrown in.

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15 Nov 2005 09:15 #8294 by Ron G
Replied by Ron G on topic Petcock Clearance
It's possible to reverse the action of the petcock lever on the style of petcock in ltdrider's picture so that the lever swings away from the carbs rather than into the carbs.

Remove the screw at the 6 o'clock position below the lever.
Remove the lever/core assembly.
Drill and tap a hole at the 12 o'clock position identical to the 6 o'clock hole.
Insert the lever/core assembly turned 180 degrees.
Insert the screw in the new 12 o'clock hole.

The petcock lever will now swing away from the carbs instead of into the carbs.

Ron

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