Rebuilding the petcock/fuel tap: Difference between revisions

(13 intermediate revisions by 3 users not shown)

Line 14:

*Get a used one from eBay or one of the [http://faq.ninja250.org/wiki/Where_can_I_buy_parts/tools_online%3F#Junkyards.2C_err..._Used_Parts usual sources]

*Get the parts and rebuild it yourself

This illustration shows how everything goes together on the petcock.

[[image:832902.jpg|100px]]

====Obtaining parts====

What you decide to do will likely depend on whether you can diagnose which part of the petcock is damaged. This will, of course, involve taking it apart and looking at it before you order parts. This is the cheapest way, but you'll have to wait for parts.

If you want to order parts from your dealer or one of the [[Where can I buy parts/tools online?|OEM online sources]], here is what you'll need:

* SPRING,TAP DIAPHRAGM- 92081-1240

* DIAPHRAGM,TAP- 43028-1068

* RING-O- 92055-1664

* PACKING- 43049-1103

* RING-O,TAP LEVER- 92055-1085

* RING,TAP FLANGED- 51039-003

[[Image:FUEL_TANK.png|100px]]

~~There is a rebuild~~ kit ~~from K&L Supply~~, ~~part #18-2723, but it is for the E series (86-87) bikes. It doesn~~'t have the correct diaphragm for the later F (88-07) bikes. All the other parts are the right ones, but if your diaphragm is bad, plan on spending another $25 on top of the $25 for this kit, which puts you in the ballpark for a new one, already put together.

'''A kit, sort of'''

K&L Supply part #s:

There is a rebuild kit from K&L Supply, part #18-2723, but it is for the E series (86-87) bikes. It doesn't have the correct diaphragm for the later F (88-07) bikes. All the other parts are the right ones, but if your diaphragm is bad, plan on spending another $25 on top of the $25 for this kit.

K&L Supply part numbers:

*86-87 rebuild kit: #18-2723

Line 31:

Line 49:

[[image:IMG_0044.JPG|150px]]

[[image:diaphragms.jpg|150px]]

~~If you want to order the parts separately, here is what you'll need:~~

* SPRING,TAP DIAPHRAGM- 92081-1240

* DIAPHRAGM,TAP- 43028-1068

* RING-O- 92055-1664

* PACKING- 43049-1103

* RING-O,TAP LEVER- 92055-1085

* RING,TAP FLANGED- 51039-003

~~[[Image:FUEL_TANK.png|100px]]~~

====Checking the vent====

Line 48:

Line 55:

[[image:5_Diaphram vent.jpg|150px]]

[[image:6_Diaphram vent2.jpg|150px]]

[[image:4_Vacuum Routing.jpg|150px]]

====Rebuild process====

Line 73:

Line 82:

[[image:IMG_0033.JPG|150px]]

[[image:7_Front view.jpg|150px]]

The lever body pulls straight out. You might feel some resistance, since there is an o-ring on it. Once you have it out, take the o-ring off.

Line 81:

Line 91:

[[image:IMG_0035.JPG|150px]]

[[image:8_Front disassembled.jpg|150px]]

This one was a little chewed on.

Line 90:

Line 101:

[[image:IMG_0032_labeled.jpg|150px]]

Make sure everything is nice and clean. Replace the o-rings on the diaphragm and lever body, then reassemble. You should now have a clean, leak-free petcock. The kit comes with a new o-ring for the petcock-to-gas tank connection as well.

Make sure everything is nice and clean. Replace the o-rings on the diaphragm and lever body, then reassemble. Put some grease on the spring washer and valve plate when putting it back together (see photo).

[[image:7a_Front view.jpg|150px]]

You should now have a clean, leak-free petcock. The kit comes with a new o-ring for the petcock-to-gas tank connection as well.

You should probably change your oil now, before you start it up. If the petcock has been leaking into the oil, not only will you have too much oil, what's in there will be thinned out and much less effective. You don't want to replace major engine components just because of that.

===Rebuilding Vs New===

If your petcock is shot, save your time, and money and get a new one, the cost of rebuilding it isn't much cheaper, due to you need two separate kits, as they for some reason don't make just one.

New one cost about $65.00

1988~00 models

http://www.partzilla.com/parts/detail/kawasaki/KP-51023-1139.html

2001~07 models

http://www.partzilla.com/parts/detail/kawasaki/KP-51023-1393.html

Also be sure to order the orings(92022-183 WASHER,6.2X11X1.5)and new bolts(92001-1091BOLT,6X20),trust me you'll be better off in the long run.

Rebuilding kits are about $60 total.

K&L Supply Diaphragm Only for Fuel Petcock Repair Kit 18-6638 https://www.amazon.com/dp/B0055DWO60/ref=cm_sw_r_awd_s1CGub1W9N3PH

K&L Supply Fuel Petcock Repair Kit 18-2723 https://www.amazon.com/dp/B001KO2JRW/ref=cm_sw_r_awd_U1CGub05DT5NT

http://faq.ninja250.org/wiki/Rebuilding_the_petcock/fuel_tap

IMHO not worth it rebuilding, also be sure to check vacuum and fuel lines for wear, holes, and cracks, if in doubt replace them. Also replace the two small O-rings on the bolts for the petcock part# 92022.

This is the time to add an inline filter filter, if you don't have one already.

K&N 81-0221 Fuel Filter https://www.amazon.com/dp/B000E2AR70/ref=cm_sw_r_other_awd_ncMwwbE333H0E

[[image:FUEL_TANK.png|450px]]

UPDATE by Ghostt: K&L SUPPLY now makes a complete kit for 88-07 models, according to their own 2016 catalog, Part # 18-2702.

@@ Line 14: / Line 14: @@
 *Get a used one from eBay or one of the [http://faq.ninja250.org/wiki/Where_can_I_buy_parts/tools_online%3F#Junkyards.2C_err..._Used_Parts usual sources]
 *Get the parts and rebuild it yourself
+This illustration shows how everything goes together on the petcock.
+[[image:832902.jpg|100px]]
 ====Obtaining parts====
 What you decide to do will likely depend on whether you can diagnose which part of the petcock is damaged. This will, of course, involve taking it apart and looking at it before you order parts. This is the cheapest way, but you'll have to wait for parts.
+If you want to order parts from your dealer or one of the [[Where can I buy parts/tools online?|OEM online sources]], here is what you'll need:
+* SPRING,TAP DIAPHRAGM- 92081-1240
+* DIAPHRAGM,TAP- 43028-1068
+* RING-O- 92055-1664
+* PACKING- 43049-1103
+* RING-O,TAP LEVER- 92055-1085
+* RING,TAP FLANGED- 51039-003
+[[Image:FUEL_TANK.png|100px]]
-There is a rebuild kit from K&L Supply, part #18-2723, but it is for the E series (86-87) bikes. It doesn't have the correct diaphragm for the later F (88-07) bikes. All the other parts are the right ones, but if your diaphragm is bad, plan on spending another $25 on top of the $25 for this kit, which puts you in the ballpark for a new one, already put together.
+'''A kit, sort of'''
-K&L Supply part #s:
+There is a rebuild kit from K&L Supply, part #18-2723, but it is for the E series (86-87) bikes. It doesn't have the correct diaphragm for the later F (88-07) bikes. All the other parts are the right ones, but if your diaphragm is bad, plan on spending another $25 on top of the $25 for this kit.
+K&L Supply part numbers:
 *86-87 rebuild kit: #18-2723
@@ Line 31: / Line 49: @@
 [[image:IMG_0044.JPG|150px]]
 [[image:diaphragms.jpg|150px]]
-If you want to order the parts separately, here is what you'll need:
-* SPRING,TAP DIAPHRAGM- 92081-1240
-* DIAPHRAGM,TAP- 43028-1068
-* RING-O- 92055-1664
-* PACKING- 43049-1103
-* RING-O,TAP LEVER- 92055-1085
-* RING,TAP FLANGED- 51039-003
-[[Image:FUEL_TANK.png|100px]]
 ====Checking the vent====
@@ Line 48: / Line 55: @@
 [[image:5_Diaphram vent.jpg|150px]]
+[[image:6_Diaphram vent2.jpg|150px]]
+[[image:4_Vacuum Routing.jpg|150px]]
 ====Rebuild process====
@@ Line 73: / Line 82: @@
 [[image:IMG_0033.JPG|150px]]
+[[image:7_Front view.jpg|150px]]
 The lever body pulls straight out. You might feel some resistance, since there is an o-ring on it. Once you have it out, take the o-ring off.
@@ Line 81: / Line 91: @@
 [[image:IMG_0035.JPG|150px]]
+[[image:8_Front disassembled.jpg|150px]]
 This one was a little chewed on.
@@ Line 90: / Line 101: @@
 [[image:IMG_0032_labeled.jpg|150px]]
-Make sure everything is nice and clean. Replace the o-rings on the diaphragm and lever body, then reassemble. You should now have a clean, leak-free petcock. The kit comes with a new o-ring for the petcock-to-gas tank connection as well.
+Make sure everything is nice and clean. Replace the o-rings on the diaphragm and lever body, then reassemble. Put some grease on the spring washer and valve plate when putting it back together (see photo).
+[[image:7a_Front view.jpg|150px]]
+You should now have a clean, leak-free petcock. The kit comes with a new o-ring for the petcock-to-gas tank connection as well.
 You should probably change your oil now, before you start it up. If the petcock has been leaking into the oil, not only will you have too much oil, what's in there will be thinned out and much less effective. You don't want to replace major engine components just because of that.
+===Rebuilding Vs New===
+If your petcock is shot, save your time, and money and get a new one, the cost of rebuilding it isn't much cheaper, due to you need two separate kits, as they for some reason don't make just one.
+New one cost about $65.00
+~00 models
+http://www.partzilla.com/parts/detail/kawasaki/KP-51023-1139.html
+~07 models
+http://www.partzilla.com/parts/detail/kawasaki/KP-51023-1393.html
+Also be sure to order the orings(92022-183 WASHER,6.2X11X1.5)and new bolts(92001-1091BOLT,6X20),trust me you'll be better off in the long run.
+Rebuilding kits are about $60 total.
+K&L Supply Diaphragm Only for Fuel Petcock Repair Kit 18-6638 https://www.amazon.com/dp/B0055DWO60/ref=cm_sw_r_awd_s1CGub1W9N3PH
+K&L Supply Fuel Petcock Repair Kit 18-2723 https://www.amazon.com/dp/B001KO2JRW/ref=cm_sw_r_awd_U1CGub05DT5NT
+http://faq.ninja250.org/wiki/Rebuilding_the_petcock/fuel_tap
+IMHO not worth it rebuilding, also be sure to check vacuum and fuel lines for wear, holes, and cracks, if in doubt replace them. Also replace the two small O-rings on the bolts for the petcock part# 92022.
+This is the time to add an inline filter filter, if you don't have one already.
+K&N 81-0221 Fuel Filter https://www.amazon.com/dp/B000E2AR70/ref=cm_sw_r_other_awd_ncMwwbE333H0E
+[[image:FUEL_TANK.png|450px]]
+UPDATE by Ghostt: K&L SUPPLY now makes a complete kit for 88-07 models, according to their own 2016 catalog, Part # 18-2702.