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| techtalk:evo:body02 [2021/02/07 05:57] – [Petcock (Fuel Outlet)] ixl2relax | techtalk:evo:body02 [2024/11/19 02:17] (current) – [Sub Documents] ixl2relax | ||
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| Generally, you can _make_ tanks interchange between '82 to '03 - Mounting holes are at the same place, but some are rigid mount & others rubber grommet mount. | Generally, you can _make_ tanks interchange between '82 to '03 - Mounting holes are at the same place, but some are rigid mount & others rubber grommet mount. | ||
| - | Screw-in Caps from 1992-later | + | Only on fuel tanks for 2001-2003 (which |
| - | All non-efi tanks use 22mm petcocks. | + | Screw-in Caps from 1992-later are generally interchangeable although some part number variations do exist for different models and years. |
| - | There are adapters available to replace the EFI pump plate with a flat-plate | + | All 86-06 tanks (non-EFI EVO engines) use 22mm petcocks. EFI models (2007-later) have fuel pumps. (Some Ironhead tanks use 22mm petcocks.) |
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| + | There are adapters available to replace the EFI fuel pump plate with a flat-plate | ||
| **Reference Threads** | **Reference Threads** | ||
| - | http:// | + | https://www.xlforum.net/ |
| - | http:// | + | https://www.xlforum.net/ |
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| ===== Petcock (Fuel Outlet) ===== | ===== Petcock (Fuel Outlet) ===== | ||
| - | {{ : | + | {{ : |
| - | The Petcock allows control of the fuel to the carburetor from the fuel tank. It has a 3-position lever to create OFF, ON & RESERVE settings. The **OFF** setting prevents fuel flow to the carb (used whenever the bike is not running). The **ON** setting allows normal fuel flow to the carb when the tank is above the reserve level. The **RESERVE** setting allows the final amount of fuel to be sent to the carb until the tank is empty. Normally, the petcock has an in-tank cylindrical mesh filter enclosing these inlets to prevent any dirt in the tank from clogging the intake of fuel. The tank and filter may be required to be cleaned from time to time. ((Pic from Carl-04XL here: http:// | + | The Petcock allows control of the fuel to the carburetor from the fuel tank. It has a 3-position lever to create OFF, ON & RESERVE settings. The **OFF** setting prevents fuel flow to the carb (used whenever the bike is not running). The **ON** setting allows normal fuel flow to the carb when the tank is above the reserve level. The **RESERVE** setting allows the final amount of fuel to be sent to the carb until the tank is empty. Normally, the petcock has an in-tank cylindrical mesh filter enclosing these inlets to prevent any dirt in the tank from clogging the intake of fuel. The tank and filter may be required to be cleaned from time to time. ((Pics from Carl-04XL here: https://www.xlforum.net/ |
| The petcock creates two levels of fuel supply in the fuel tank, the higher level being used for the ON setting and a low level being used for the RESERVE supply level. To do this, a short tube protrudes vertically into the fuel supply to create an ON level. A shorter tube (or the base of the petcock) is used to supply fuel ONLY when the petcock is set to RESERVE. By drawing fuel from the taller tube when the petcock is set to ON, a ' | The petcock creates two levels of fuel supply in the fuel tank, the higher level being used for the ON setting and a low level being used for the RESERVE supply level. To do this, a short tube protrudes vertically into the fuel supply to create an ON level. A shorter tube (or the base of the petcock) is used to supply fuel ONLY when the petcock is set to RESERVE. By drawing fuel from the taller tube when the petcock is set to ON, a ' | ||
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| This was considered a safety feature to help riders who forgot to turn the petcock to the OFF position (and to help prevent fuel spills in case of an accident or tipover). It was the recommended petcock for all optional tanks from 1992-1994. This style petcock was implemented on all stock tanks (of any size) from 1995 thru 2006 (2007-later used electrical fuel pumps). A vacuum of approximately 0.5-1.0 in. of Mercury (Hg) was needed to open the petcock for fuel flow.((2006 Factory Service Manual)) The OFF setting was still recommended whenever the engine was not running (to prevent accidental fuel flow from a faulty vacuum diaphragm). | This was considered a safety feature to help riders who forgot to turn the petcock to the OFF position (and to help prevent fuel spills in case of an accident or tipover). It was the recommended petcock for all optional tanks from 1992-1994. This style petcock was implemented on all stock tanks (of any size) from 1995 thru 2006 (2007-later used electrical fuel pumps). A vacuum of approximately 0.5-1.0 in. of Mercury (Hg) was needed to open the petcock for fuel flow.((2006 Factory Service Manual)) The OFF setting was still recommended whenever the engine was not running (to prevent accidental fuel flow from a faulty vacuum diaphragm). | ||
| - | {{: | + | {{: |
| - | {{: | + | {{: |
| Notice that the kidney-shaped cavity on the knob allows, in one position, the ON tube to flow to the outlet and, in another position, it allows the RES(erve) tube to flow to the outlet. The middle knob setting (as the switch is shown in the picture with the kidney-shaped cavity at the bottom only) is the OFF setting. If you look carefully inside the outgoing cavity of the petcock body, you can see the vacuum stud which allows fuel flow when the vacuum pulls the stud/plug open. The petcock is designed to ONLY FLOW FUEL when there is a vacuum applied. With no vacuum, the stud is in place and no fuel can flow, no matter where the knob is set. | Notice that the kidney-shaped cavity on the knob allows, in one position, the ON tube to flow to the outlet and, in another position, it allows the RES(erve) tube to flow to the outlet. The middle knob setting (as the switch is shown in the picture with the kidney-shaped cavity at the bottom only) is the OFF setting. If you look carefully inside the outgoing cavity of the petcock body, you can see the vacuum stud which allows fuel flow when the vacuum pulls the stud/plug open. The petcock is designed to ONLY FLOW FUEL when there is a vacuum applied. With no vacuum, the stud is in place and no fuel can flow, no matter where the knob is set. | ||
| - | There are a number of Petcock valves available, most using 62169-xx, where the xx is a number and revision letter. The older versions (like 62169-81) do not use a vacuum valve. Later, among the vacuum versions (such as 62169-95/ | + | There are a number of Petcock valves available, most using 62169-xx, where the xx is a number and revision letter. The older versions (like 62169-81) do not use a vacuum valve. Later, among the vacuum versions (such as 62169-95/ |
| - | ====Bypassing the Vacuum Function==== | + | **INSTALLING THE PETCOCK**\\ |
| - | If you prefer not to use the vacuum valve to control | + | These petcocks |
| - | You would need to remove | + | You must wind the nut down on the petcock before starting |
| - | If you remove the vacuum function from the petcock | + | It may take a time or two of testing to see just how close you want the petcock |
| - | + | ||
| - | There are also kits that replace the rear vacuum section of the petcock | + | |
| - | | Decman | + | |
| + | Additional References: | ||
| + | Vacuum Operated Fuel Supply Valve Kit - (Instruction Sheet ' | ||
| + | https:// | ||
| + | https:// | ||
| ====Failures==== | ====Failures==== | ||
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| So, depending on exactly how the petcock fails, you might get a too rich or a too lean condition. | So, depending on exactly how the petcock fails, you might get a too rich or a too lean condition. | ||
| - | Manual petcocks can also fail. They can leak fuel from the seals. They can collect | + | Manual petcocks can also fail. They can leak fuel from the seals. They can collect |
| **NOTE - PRODUCT RECALL:**\\ | **NOTE - PRODUCT RECALL:**\\ | ||
| - | 2005 Petcock Recall Notice - http:// | + | 2005 Petcock Recall Notice - https://www.xlforum.net/ |
| Summary: Certain motorcycles may have been produced with defective fuel shut-off valves. The functionality of the ' | Summary: Certain motorcycles may have been produced with defective fuel shut-off valves. The functionality of the ' | ||
| - | \\ | + | ====Bypassing the Vacuum Function==== |
| + | If you prefer not to use the vacuum valve to control the fuel flow, you can disassemble the petcock & reverse the spring/ | ||
| + | You would need to remove the four rear screws of the vacuum section. Remove the spring & remove the diaphragm. Then put the spring on the stud of the diaphragm (which normally operates as the plug) and reassemble the diaphragm back into place. The spring will now hold the diaphragm in an open position. Fuel should flow through the petcock without a vacuum line connected to it. | ||
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| + | If you remove the vacuum function from the petcock and you have one of the older models with a tee fitting in the vacuum line (that goes to the VOES/MAP), then remove the tee and run a straight line from the carb vacuum nipple directly to the VOES / MAP. This minimizes any leak points. If you have a 2004-2006 model (with the MAP sensor on the intake manifold) and remove the vacuum function from the petcock, you can remove the vacumm line completely and simply cap the vacuum nipple on the carb. | ||
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| + | There are also kits that replace the rear vacuum section of the petcock with a solid blank plate.\\ | ||
| + | | Decman of the XLForum said: I had this bypass kit in my tool box.\\ It's a flat plate and rubber gasket. About a week after I installed it,\\ the bike started to stall after warmed up due to no fuel.\\ \\ When I took the petcock apart it was obvious that the center\\ of the rubber gasket was stretching and being pulled into the fuel\\ cavity and shutting off the fuel. Doh!\\ \\ So I just cut a hole in the center of the gasket and all is well.\\ After a quick search on the net I found that the new kits come with\\ the hole already there now. | {{: | ||
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| ==== Troubleshooting ==== | ==== Troubleshooting ==== | ||
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| ===== Vapor Valve (Tank Venting) ===== | ===== Vapor Valve (Tank Venting) ===== | ||
