Questions about petcock on 84 zn1100

My bike is a 1984 zn110b shaft drive. So, my petcock dumps fuel in every position. It will flood the carbs pretty quick regardless of setting. So i assume that something is wrong with the vacuum. I took it apart to check out the condition of the internals, and everything looks ok. There is no rips or tears, nothing is swollen. I was checking to see if maybe a previous owner reassembled it incorrectly. However, it appears that it would be impossible to do so, as everything is semetrical inside. Nothing could really be on backwards. I am at a loss as to how this thing could be malfunctioning. I ordered a new one from ebay that arrived today, and of course it doesn't fit at all. The mounting holes are different distance, and the nipples on it are smaller then the original. Any ideas or suggestions? Thanks.

All the rubber parts are likely available at your local Kawasaki dealer.
If fuel is flowing in every position with the engine off, ther is a problem inside the petcock. They can be assembled incorrectly. Check the pictures in the fsm carefully. The parts fisch on the Kawasaki or Partzilla website may also help.

www.kawasaki.com/Parts/PartsDiagram/136213/1984/KZ550-F2

Is the spring, 92081, missing?

Thanks for the quick response. Yes, that spring is missing, lol. How did you know? There was definitely no spring in there.

Another fuel related question... Any idea why my fuel gauge doesn't work? Anything I can do to possibly fix it without buying a new sending unit?

The fsm has testing procedures for the sending unit and, I believe, the guage. I am pretty sure the sender has to be removed from the tank to test it. Be sure to replace the o-ring.
Could be something as simple as a disconnected connector, a corroded connection or even a broken wire. Some careful sleuthing with your volt-Ohm meter, and some judicious cleaning with a can of Deoxit D5, may be all you need.
If the bike sat for a long time, especially outside, the sender may be rusted beyond saving.

Thanks again. I ordered the petcock spring from partszilla.

Im going through the same thing on my bike but I have the spring so thats not the problem. I just got my rebuild kit yesterday and hope that will sort things out.I remeber a while ago,someone posted a link to a tutorial on repairing vacuum petcocks.I think it was from an XS650 forum. Anyone still have that link??

Quick find

xjbikes.com/forums/threads/rebuilding-th...-valve-w-pics.25058/

Michael

Yup! That be the one. Thanks.

Update:

So i deleted the hoses coming from carb 1 and 4 and capped them. Those 2 lines originally went to a 'T' and ran up to the front top of the engine to what looks like an egr valve. I plugged that end as well. Now the bike will not idle at all. Any ideas?

You have to plug #1 and #4 at the carb separately to prevent effect each other, did you?

Take some pics of your current setup.

Yes i capped th #1 and #3 and #4 carbs seperately. Carb #2 runs to the petcock for vacuum. Do i also need to plug where carbs 1 and 4 went up to the egr valve looking thing on the top front of the motor?

Also, i received my petcock spring and installed it, petcock still leaks fuel in all positions. I guess a replacement or rebuild is in order. However replacements are impossible to find for this bike. I ordered the only one on ebay that said it fit my bike... and it wasn't even a close fit. Are there other bikes that share a similar petcock? The mounting holes are about 2 inches apart, and most i see are just over an inch apart.

The bolt hole spacing is probably 44mm. Some of the 80s models are 34mm (e.g., 81 650-CSR).
I believe the 82-2005 KZ1000-P police bike is 44mm & the petcock is still available from the dealer for about $70.
Z1Enterprises.com may have a Suzuki aftermarket petcock that is also 44mm.