Yamaha Fuel Petcock & SW-MOTECH Crash Guards - Kawasaki KLR 650 Forum
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  • 2 Post By Bluehighways
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post #1 of 4 Old 07-19-2017, 02:04 PM Thread Starter
2nd Gear
Join Date: Mar 2017
Posts: 391
Yamaha Fuel Petcock & SW-MOTECH Crash Guards

I have the SW-MOTECH Crash Guards on my 2007 KLR which work extremely well. I can speak from multiple personal experiences on this matter.

I also replaced the original Vacuum managed Fuel Petcock with the Yamaha 100% manually operated Fuel Petcock Part Number 5LP245000100

The challenge is that these two items are not 100% compatible. With the MO-TECH Crash Guards installed the Fuel Petcock Lever will hit the Crash Guard.

The solution seems simple enough. Cut/Grind/File (your choice) the Petcock Lever to clear the Crash Guard. Unfortunately having done so, the remaining Petcock Lever is now rather difficult to turn by hand. Due to its now limited size and position next to/behind the Crash Guard.

So, my solution to the solution, as it were, was to drill a hole through the Petcock Lever and install a Key Ring Loop as shown. This works perfectly!
DPelletier and Diddyklr like this.

Last edited by Bluehighways; 08-31-2018 at 02:21 AM.
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post #2 of 4 Old 07-20-2017, 01:48 PM
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Location: Texas
Posts: 1,261
I buy those key rings in 5-packs. They come in handy for replacing broken zipper pulls on various bags, jackets and other uses.
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post #3 of 4 Old 07-21-2017, 06:23 PM
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Better than a twist-tie (my current field expedient) for a broken zipper pull, I reckon!
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post #4 of 4 Old 02-14-2018, 02:23 PM
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Join Date: Mar 2015
Location: Colorado mountains
Posts: 76
I just stumbled across this ingenious fix, having the same set-up, but without the interference problem. I just couldn't rotate the petcock lever with gloves on, and had been pondering bolting a dogleg extension of sorts on. Thanks bluehighways; simple and cheap solution!

Conrad Long
'08 KLR 650
'96 R1100RT
'94 R1100RS
'75 XS650B
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