kz400 Dual to single outlet petcock swap

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20 Jan 2016 09:24 #707380 by padgett
kz400 Dual to single outlet petcock swap was created by padgett
I have a gravity fed petcock on there that is dual outlet, but one of the outlets is loose and leaking terribly. Would there be any danger in just closing off (jb weld) that leaky spout and running a single fuel line from the petcock to the carbs?

Thanks

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20 Jan 2016 11:25 #707391 by martin_csr
Replied by martin_csr on topic kz400 Dual to single outlet petcock swap
What year is your KZ400? Does it have a manual fuel valve or a vacuum petcock?

You might be able to repair the leak. The fuel port on my 81 650 got pulled out, so I re-sealed it with Permatex liquid metal. I also used the stuff to repair a leaky low fuel switch. Seal-All would be another product that should work (Lowes or HomeDepot).
1981 KZ650 Competition Sports and Road

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20 Jan 2016 11:27 #707392 by padgett
Replied by padgett on topic kz400 Dual to single outlet petcock swap
its a 74 but a mishmash of parts.

The petcock I have does not have a vacuum. Its just the two spouts coming straight out for fuel. So if I removed the one spout i'd starve for fuel probably?

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20 Jan 2016 13:13 #707410 by floivanus
Replied by floivanus on topic kz400 Dual to single outlet petcock swap
Probably not, but if you are sealing with epoxy any way, pull the tube out, smear the epoxt around the tube (keep it off the very tip of the tube) and stick it back in the hole. That will keep your dual outlet setup like it is now
my bikes; 80kz1000(project), 77 gl1000, 74 h2 (project)
Past; 78 kz1000, 83 kz550
Andrew

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20 Jan 2016 14:19 #707420 by Nelson
Replied by Nelson on topic kz400 Dual to single outlet petcock swap
have u taken it apart? no chance of a repair? I was able to stop the leaks on mine by bending the wavy washer (spring) so it puts more pressure on the rubber thing.
Restoring and customizing a KZ1000. Click here to read about it.
Plated KTM, DR650, KZ1000, Former MC mechanic (eons ago). 40 yrs. of dirt and street.

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20 Jan 2016 14:21 #707421 by padgett
Replied by padgett on topic kz400 Dual to single outlet petcock swap
yea had it apart, but its leaking from the outlet itself, the brass is loose,

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21 Jan 2016 02:09 - 21 Jan 2016 02:11 #707476 by martin_csr
Replied by martin_csr on topic kz400 Dual to single outlet petcock swap
A leaky fuel valve port isn't uncommon. an epoxy repair is a simple fix. I did mine several years ago.
1981 KZ650 Competition Sports and Road
Last edit: 21 Jan 2016 02:11 by martin_csr.

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23 Jan 2016 05:00 #707711 by jdvorchak
Replied by jdvorchak on topic kz400 Dual to single outlet petcock swap

martin_csr wrote: A leaky fuel valve port isn't uncommon. an epoxy repair is a simple fix. I did mine several years ago.


+1 I've repaired them with JB Weld but epoxy would work as well. Try not to tear it up pulling the brass nipple out.Gentle twisting and pulling should free it.
Don't fix it until it's broken.
John

83 KZ550M1
83 KZ1100LTD

Also own:
2010 Harley Ultra Classic Limited, 2008 Harley low rider 71 CB350/sidecar

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23 Jan 2016 05:04 #707713 by jdvorchak
Replied by jdvorchak on topic kz400 Dual to single outlet petcock swap
Just had another thought. If you put some fuel line on that fitting with a tight screw type clamp you can use your pliers on the rubber hose for twisting and pulling and not touch the brass part. If it doesn't pull right out I'd also use my heat gun to heat the aluminum part.
Don't fix it until it's broken.
John

83 KZ550M1
83 KZ1100LTD

Also own:
2010 Harley Ultra Classic Limited, 2008 Harley low rider 71 CB350/sidecar

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23 Jan 2016 07:06 #707731 by Nelson
Replied by Nelson on topic kz400 Dual to single outlet petcock swap
that's a great idea! the rubber hose becomes sorta like a strap wrench.
Restoring and customizing a KZ1000. Click here to read about it.
Plated KTM, DR650, KZ1000, Former MC mechanic (eons ago). 40 yrs. of dirt and street.

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23 Jan 2016 07:47 #707738 by pete greek1
Replied by pete greek1 on topic kz400 Dual to single outlet petcock swap
When I had that problem I just cleaned the area around the nipple without removing it, & just put a bead of JB Weld around where the nipple inserts into the petcock, & it never leaked again
Pete
1980 LTD 1000..,1976 LTD 900, have the 1000&900 now. the rest are previous= 1978 KZ 650 B.., 1980 Yamaha XT 500..,1978 Yamaha DT 400.., 1977 Yamaha yz 80..,Honda trail ct 70.., Honda QA 50...5-1/2 hp brigs & straton CAT chopper mini bike...3-1/2 hp mini bike (WHEN GAS WAS ABOUT 45 CENTS A GALLON)!!!!

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23 Jan 2016 19:23 - 23 Jan 2016 19:24 #707832 by jdvorchak
Replied by jdvorchak on topic kz400 Dual to single outlet petcock swap

pete greek1 wrote: When I had that problem I just cleaned the area around the nipple without removing it, & just put a bead of JB Weld around where the nipple inserts into the petcock, & it never leaked again
Pete


That could work. I'd make sure I used JB Weld not JB Quick. JB Weld seems to hold up better in the presence of gasoline. If the brass tube doesn't come out easily I'd try a bead of JB Weld.
Don't fix it until it's broken.
John

83 KZ550M1
83 KZ1100LTD

Also own:
2010 Harley Ultra Classic Limited, 2008 Harley low rider 71 CB350/sidecar
Last edit: 23 Jan 2016 19:24 by jdvorchak.

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