Easy Petcock Conversion - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 14 Old 07-14-2018, 04:18 PM Thread Starter
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Easy Petcock Conversion

Instead of buying stuff, how about just taking out the oring that sits on the vacuum diaphragm stem? That's what cuts the fuel supply without vacuum. Totally reversible, keeps everything else in place, fuel shut off lever still functions properly. I've been reading conversion stories but never seen this mentioned.

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post #2 of 14 Old 07-14-2018, 04:33 PM Thread Starter
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Before and After

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post #3 of 14 Old 07-14-2018, 05:43 PM
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I have mentioned removing the spring that pushes on the diaphragm to close that plunger with the o-ring. Without the spring the pressure of the gas above the petcock will hold it open.

I haven't tested to see if the plunger with the o-ring removed and the spring still in place would restrict fuel flow enough to cause problems at higher throttle usage.

Let us know what you find.

Last edited by GoMotor; 07-14-2018 at 05:47 PM.
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post #4 of 14 Old 07-14-2018, 07:10 PM Thread Starter
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Quote:
Originally Posted by GoMotor View Post
I have mentioned removing the spring that pushes on the diaphragm to close that plunger with the o-ring. Without the spring the pressure of the gas above the petcock will hold it open.

I haven't tested to see if the plunger with the o-ring removed and the spring still in place would restrict fuel flow enough to cause problems at higher throttle usage.

Let us know what you find.
It shouldn't restrict anything. The vacuum is still hooked up and will pull the plunger all the way recessed under throttle. It just won't seal up in an absence of vacuum from either failure or being shut off.

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post #5 of 14 Old 07-14-2018, 09:57 PM
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It really should operate exactly like any other manual petcock with plenty of fuel flow to sustain 35 miles per gallon or better at wide open throttle whether the vacuum hose fitting is capped or still connected.
Best of all, you still have about 1 gallon on the reserve side!!

pdwestman
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post #6 of 14 Old 07-14-2018, 10:07 PM
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You might have something, shaky6!

Regardless, jettisoning the O-ring might be an effective, "middle of nowhere," MacGyveresque countermeasure to a petcock failure malfunction.
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post #7 of 14 Old 07-15-2018, 01:02 PM Thread Starter
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Well, it runs. It hasn't leaked. And it flows through when the bike is off.

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post #8 of 14 Old 07-16-2018, 07:37 AM
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When you say flows through, do you mean leaks or you took off a hose clamp to see?
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post #9 of 14 Old 08-16-2018, 11:50 AM Thread Starter
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https://youtu.be/HytehmpGttw

I made a short video showing the result of taking out this o ring. Works great, and it's free.

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post #10 of 14 Old 08-27-2018, 10:56 AM
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So it looked like it didn't flow until you went to reserve and then back to on? Can you remove the oring without removing the petcock?
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