petcock problems/swap

I'm at my wits end just about with my petcock. It just lets the gas flow like the Amazon no matter the lever position or if the bike is running or not.

I rebuilt the petcock, disassembled and reassembled several times over the last couple weeks to make sure i didn't miss anything.

I stretched out the spring to try to get the o-ring to seat better.

What the heck could be wrong with it? Should i get a super duty spring in there or something?

Does anyone have any ideas of what other petcocks (maybe a manual one) that can be swapped in? I tried searching but didn't find anything.

I included a few pictures of the disassemble, let me know if you see anything weird. specifically in the last picture, is this the correct orientation of the diaphragm, or should the other side of the diaphragm be on this side of the plastic?

TO be more specific, with the diaphragm in place in the petcock, the o-ring cannot be pushed inward any further, only pulled outward. Hopefully that make sense.

Just in case... In what position do you have the petcock lever?

PRI should flow fuel - engine running or engine off.

martin_csr wrote: Just in case... In what position do you have the petcock lever?

PRI should flow fuel - engine running or engine off.

In all three positions, it flows like the great flood.

And no offense taken, I surprise myself with my own stupidity all the time.

sometimes there just too worn. i had the same trouble. i recommend getting a pingel. much better and much less hassle. i got a cheap fleabay petcock and it leaks everytime i move the lever out the side for a split sec. i ordered a pingel and after using them on other bikes ive learned my lesson.

lushbaugh wrote: sometimes there just too worn. i had the same trouble. i recommend getting a pingel. much better and much less hassle. i got a cheap fleabay petcock and it leaks everytime i move the lever out the side for a split sec. i ordered a pingel and after using them on other bikes ive learned my lesson.

which pingle petcock fits the 440? Or will i have to fab it in. They look expensive as heck.

Get on there site and get the part number then google shop it. for my bike theres the petcock then an adapter nut. yours will likely be a base adapter which is sold seprate and yea there pricey your lookin at around 50 to 60 for the petcock then 20ish for the adapter but it worth it as i counted 4 tanks of gas i lost forgetting to turn it off and i was running 100 low lead av gas so it pays for itself considering my time and material lol

lushbaugh wrote: Get on there site and get the part number then google shop it. for my bike theres the petcock then an adapter nut. yours will likely be a base adapter which is sold seprate and yea there pricey your lookin at around 50 to 60 for the petcock then 20ish for the adapter but it worth it as i counted 4 tanks of gas i lost forgetting to turn it off and i was running 100 low lead av gas so it pays for itself considering my time and material lol

i'd still like to fix the one i have on the bike now. I don't understand what else could be wrong with it, if I rebuilt it. and it's put together correctly.

Maybe i'll just put a shut-off valve after the petcock and before the carb.

Would double-check assembly installation position of gasket 11009A.



Good Fortune!

Service Manual download

Click > home.comcast.net/~loudgpz/GPZweb/Mnls/Kz...ase99924_1018_06.pdf

See pages 47, 155 and 268.

Good Fortune!

What's the bolt hole spacing? If it's 34mm, then this topic may be of use... KZRider - Manual fuel valve option
If the Yamaha unit fits, I think they're about $20 at RonAyers.

I have rebuilt a bunch of those over the years and I found some re-build kits do not have the correct size O-ring. The diaphram will bolt right on like it is supposed to but will not seal.

yep, my spacing is 34mm, good to know that there is a 20 dollar option out there! thanks.

wait a second guys.....on the lever side of the petcock there is a metal washer/ring. Does that go in between the lever and the rubber gasket, or between the lever and the cover plate? I've been putting it in between the lever and the gasket thinking that the lever "slides" on it.

In the following image, 92055 is the O-ring, but i think I put the washer there instead. There is a ring between the plate and the lever that is unmarked. Is that the metal ring?

Could this misplacement cause a continually flowing petcock?