Were is the petcock - 1997 Suzuki GSX-R 600

What exactly is the problem with the petcock? If it is a vacuum operated petcock and it is no longer allowing fuel to the engine check the following:

First, did you work on the bike prior to the problem occuring, and was the bike running properly before this? On bikes I've owned with vacuum petcocks, the petcock has two rubber hoses attached to it. One is the vacuum line the other is the fuel line. On one of my bikes these hoses were nearly identical in size and I managed to swap them a couple times after having the tank off the bike. Simply double check that the hoses are connected properly. If they are not, the bike will run until the fuel is run out of the float bowls then die.

Second, do you have an inline fuel filter on the fuel line between the petcock and carb? If so check it to make sure it is not clogged.

Third, remove the tank and check the entire length of the vacuum line for the petcock. Is it kinked, pinched, cracked, cut, detached, etc.? Look for anything which would prevent the line from providing vacuum to the petcock.

Fouth, test the petcock to see if it is working properly. To do this you will need a handheld vacuum pump, such as a Mityvac (you may be able to get a free loaner from some autoparts stores). remove the vacuum line from your petcock and attach the vacuum pump to it. It should only take one or two pumps to create enough vacuum to open the petcock valve. If fuel begins to flow the petcock is good, if it doesn't you could have a clogged filter screen in the tank, but most likely the petcock's vacuum diaphram is damaged. The Baha is a Chinese made bike and it's possible the rubber parts in the fuel system are not compatible with the ethenal fuel blends here in the U.S. The dealers who sell these bikes are really hit and miss when it comes to being able to provide replacement parts. Even with the internet, it may take some work to locate a correct replacement petcock for the bike. On the bright side, if you are able to get a new petcock, they are very easy to replace.

Good luck!

If it's a stock petcock, it should be one of the vacuum operated types. You can get rebuild parts from Harley as far as I know. You'll have to remove the petcock, disassemble, and replace the parts inside. Since these petcocks are prone to problems of not allowing fuel to flow to the carb, I usually recommend that owners having problems with them simply replace their stock petcock with a high quality aftermarket manually operated petcock. I prefer the Pingle petcocks but they are pricey but they are very high quality that you can feel when you turn your fuel on or off. No more problems with one of those.

Good Luck
Steve

You didn't say what year or model your bike was so I'll just take a guess here. In 1996 and later, Harley started putting vacuum operated petcocks on their bikes that are equipped with a carburetor. It should have a small vacuum line running to the backside of it unless someone has changed the petcock to a manual operated one. The vacuum line comes off the backside of the carburetor and supplies vacuum to the VOES switch and the petcock.

If it is a vacuum operated petcock, it will have a square plate on the backside with four small screws holding it on. Take the screws out and carefully remove the plate. Notice how the stuff in there comes out. There is a spring, a needle, and a diaphragm in the petcock. Hold the diaphragm up to the light and gently stretch it while looking for a hole. If you find one, put a new diaphragm in the petcock. Upon reassembly, connect the vacuum hose and turn the petcock to the normal run position. Leave the fuel hose off and spin the engine. Fuel should flow from the petcock. If you have a hand operated vacuum pump, you can connect it to the petcock and apply vacuum to get the fuel to flow.

Personally, I suggest changing the petcock to a high quality manually operated petcock and turn your fuel on and off manually. Old School style. Pingel makes a very high quality petcock. They aren't cheap but you'll never have another petcock problem.

Good Luck
Steve

Your bike is equipped with a vacuum operated petcock. To check the petcock out, you must remove it from the tank. I usually use a large funnel and an empty fuel can. Loosen the petcock enough to allow the fuel to run out and use the funnel to collect the fuel in the empty can. Once the tank is empty, disconnect the fuel hose to the carb and the vacuum hose. Remove the petcock from the tank.

On the backside of the petcock, there are four small screws. Remove the screws and the diaphragm and needle in the petcock will come out. Hold the diaphragm up to the light and gently stretch it while looking for holes. If you find a hole, replace the diaphragm.

Personally, I've seen enough problems generated by these petcocks to warranty replacement with a high quality manually operated petcock. I like the Pingle petcocks. They're pricey but they WORK. I've seen too many people stranded with a whole tank of fuel and none in the carb because of these petcocks.

Good luck
Steve

You didn't tell me what year Sportster we're dealing with. So, I'll cover a few general things to check.

If your bike is running for about a mile and then stopping and it does this repeatedly, It sounds like a fuel problem. Most likely it's either the petcock or the fuel tank vent system.

First, If your bike is made after 1996, it probably has the OEM vacuum operated petcock. These petcocks are designed to open when the engine is running and close when it stops. There is a small vacuum line that plugs into the backside of the petcock. When the engine is running, this line supplies the vacuum. Check the line and make sure that it hasn't come loose or cracked. It originates behind the carb and goes upwards underneath the tank to the VOES switch and it has a "Y" in the line that reduces the size and then runs to the backside of your petcock.

If it is intact, you'll need a hand vacuum pump to test the petcock for proper operation. Connect the vacuum pump to the rear of the petcock. Remove the fuel line from the petcock. Now, apply vacuum to the petcock with the pump. Fuel should flow from the petcock. If not, the petcock is either bad or the strainer in the tank is stopped up.

Remove the petcock from the tank. Place a large funnel under the petcock and direct the funnel into an empty gasoline can large enough to hold all the fuel in the tank. Loosen the petcock enough so that the fuel runs out at a rate that you can control. When empty, finish removing the petcock from the tank. Inspect and clean the screen. Now, on the back side of the petcock is a square plate held on by four screws. Remove the screws and remove the plate. Underneath the plate you'll find a diaphragm. Hold the diaphragm up to the a light and gently stretch it and look for holes. If you find a hole, you'll have to replace the diaphragm.

Look inside the petcock where the needle is for trash. At this point you should be able to blow back up through the petcock to check for obstructions. Reassemble petcock and reinstall in the tank.

I've seen these petcocks give a lot of trouble exactly like you're experiencing. I recommend that you replace the petcock with a manually operated petcock. The Pingle petcocks are very high quality units but a bit pricey. If you'd rather stick to an OEM type unit, purchase a petcock from the Harley shop for a 1995 or earlier model. This will be a manually operated petcock. Plug the vacuum hose that you'll no longer need. You'll have to get into the habit of turning the gas on and off whenever you get on or off the bike like the old timers did. But, they'll never let you down.

Now, remove the fuel cap. Wipe it down real well with a clean cloth. Now, make sure your friends are NOT around for this test or you'll never hear the end of it. Put the threaded end of the fuel cap up to your lips and try to **** and blow through the vent. If you cannot, the vent is bad and you're not getting gasoline to your carb due to a buildup of vacuum in the tank.

Good Luck
Steve

It may indeed be out of gas. You can have a full tank of fuel and be "out of gas" in the carb. The culprit could be the vacuum operated petcock. The petcock has a diaphragm in it that is opened by engine vacuum. If that diaphragm is not functioning as it should, no gasoline gets to the carb.

To test the petcock, reach around behind it and feel for a small vacuum hose. Unplug this hose and replace it with a hose you can **** on. Using your mouth, **** on the hose with the fuel line disconnected. You should see fuel flow out of the petcock. If not, you must drain the tank by loosening the petcock and allowing the fuel to run out of the loose petcock. Use a large funnel and an empty fuel container to catch the fuel. Once the fuel tank is empty, remove the petcock. Take the plate on the back of the petcock off by removing the four small screws. You'll find a diaphragm, a small spring, and a needle. Hold the diaphragm up to the light and stretch it gently. If you find a hole in the diaphragm, replace it. Check the petcock for obstructions by blowing through it. Reassemble the petcock and test it again.

Check the hose that supplies the vacuum to the petcock. It comes from the backside of the carb and runs upwards to the VOES switch and then reduces in size and goes to the petcock. Make sure it's connected and has no holes or cracks in it.

If everything looks alright, replace the petcock, connect the hose and try to start your bike again.

These petcocks are notorious for giving problems. I always recommend that the vacuum operated petcock be replaced with a high quality manually operated petcock such as a Pingle. They're expensive and require you to manually turn the gas off like the "old school bikers" do but they won't leave you stranded out of gas with a full tank of fuel.

Good Luck
Steve

Do you have a petcock on the bottom of the gas tank? If so, if you have a "reserve" the petcock will have three positions, off, regular and reserve. If you only have a two position petcock you have no reserve function. Petcocks work by taking the gas in the petcock tube higher up in the gas level, once the gas level drop below a certain level on the gas tank pickup tube, the petcock has to be switched to reserve where the tube picks up gas at a lower level. Hope this is not too confusing.

The petcock on your bike is supposed to be one of the vacuum operated type petcocks. When the engine is started, the vacuum from the engine is supplied to a diaphragm on the backside of the petcock open the fuel valve. It may have been changed since these valves were notorious for problems.

Your petcock should be labeled "ON", "OFF", and "RES" if it's a manual petcock. There should be and arrow on the lever on the petcock as well. This is the best advice I can give without being able to look at the petcock. I hope it helps. GOOD LUCK and ride safe.

Sounds like you have a hole in the vacuum diaphragm that opens and closes the petcock. This is one of the problems with the vacuum operated device. The other problem is that sometimes they don't open and you're left stranded with a full tank of gas and not a drop in the carburetor. I changed to a manual operated petcock. Personally, I'd rather have a Pingle petcock than another vacuum operated Harley petcock. If you do change to a manual operated petcock, don't forget to plug the small vacuum hose.

If you want to keep your vacuum operated device, I think you can buy a replacement diaphragm. You will have to drain the tank and remove the petcock. There are four small screws on the backside. Remove the screws and the backplate will come off. The diaphragm and a sping is all that is in that section of the petcock.

You're bike may be equipped with a vacuum operated petcock. See if the fuel valve has a "prime" position on it. If so, put it in this position. If you still don't get any fuel to the carb, you'll have to remove the petcock from the tank and clean the screen or unstop the petcock. I'd put a manual petcock in and block the vacuum line.

If you already have a manual petcock and you're not getting fuel, remove the petcock, clean the screen, and blow air through the petcock in both the "On" postition and the "Res" position.