Gas leak in fuel shut off valve ON/OFF positions

Hey guys. First issue with my new (to me) '81 KZ1000 CSR. When the fuel shut-off valve is in the ON or OFF positions, fuel leaks out. I can rock the bike back and forth and it will practically splash out. When I put it in RES, everything's fine. No fuel leaks, even when I rock the bike. What would cause this? Do I need a new shut-off valve? How difficult would this be to fix? Never worked on motorcycles before, but I'm fairly decent with a wrench and can figure things out. And my Clymers manual is on the way as I type.

Any help is greatly appreciated.

Here you go, start here and find your rebuild kit. I strongly suggest really looking that bike over before an order is placed, sure you'll miss something, but get the spare oil filters, a new fuel filter, brake pads, and it'll save you in the short and long run.
www.z1enterprises.com/catalog.aspx?pid=KZ1000J

Do you know if the bike has the stock petcock? If so, you ought to be able to get a rebuild kit for it - oem or K&L. The Kaw dealer or Z1Enterprises.com. Another alternative is to get a new unit. I believe the one from a late model Kaw police bike will work... 2005 or so & assuming the bolt hole spacing is the same. I think it is but not 100% sure... just going by the cross-reference & supersession info at Kawasaki.com.

Also, it might be a good idea to get a Kawasaki factory service manual.

Oh, and Howdy.

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Thanks gentlemen.

@Motor Head: Good idea on stocking up. And thanks for the link.

@JMKZHI: I'm pretty sure it is stock. Motor Head also suggested a factory service manual. Where would I find one of those? Kawasaki.com? ebay?

@H1Vindicator: It may be RES-PRI-ON, I'll have to double-check. Thanks for the link. $120 does sound like alot, but it looks exactly like the one on the bike.

www.kawiworld.com/index.php?option=com_c...icle&id=77&Itemid=99
pdf copy for download.

Sweet! Thanks MH!

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Gotcha. And it does have RES-PRI-ON. Besides the parts, is there any special considerations for a repair/rebuild on one like that? Thanks.

open up petcock, some have O Rings which you could get a some hardware stores (Lowes, Home Depot etd), might get you going until rebuild kit arrives, worked for me,

apearson wrote:

Gotcha. And it does have RES-PRI-ON. Besides the parts, is there any special considerations for a repair/rebuild on one like that? Thanks.

Disassemble, clean, & inspect the stock unit to see what kind of condition it's in. It shouldn't be pitted or anything. I used brass wool to polish the surfaces that come in contact w the rubber. Make sure the replacement kit is made in Japan (I'd guess some are made in China & Taiwan).

and if all else fails, I have a factory petcock off my 82 CSR that I rebuilt that I wll let u have for 10 plus postage.I put Pingel on mine and eleiminated all my fuel delivery worries.I think thats a good deal.Let me know.bj