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Thread: Fuel Delivery Issue Reply to Thread
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  Topic Review (Newest First)
08-13-2017 09:15 PM
Tom Schmitz Paul is right, and I pointed it out in the referenced thread. Once you go on reserve on the Raptor, GO GET GAS!

Somewhere around here I have a Raptor that MacG modified for me, extending the main tube so that the thing has the same reserve as the stock petcock. He did a nice job. It might be in my tank now; I'm not sure. I do remember modifying a Raptor when I was tinkering with putting an external pump on the IMS, and I may have installed MacG's petcock when that experiment was over.

If I have a picture, I'll post it up.
08-13-2017 09:00 PM
Originally Posted by jddens12 View Post
Thanks Tom !!! I took your advice and removed the diaphragm and it looks like my problem is solved! I'll probably order the raptor valve and replace my mod....Thanks Again!! John
If I understand the conversion correctly, you are better off with your manual 'conversion' than the Yamaha Raptor fuel valve.


Your conversion from vacuum automatic to manual Off valve still has the original One gallon reserve supply.
The Yamaha fuel valve leaves you with about 1&1/2 quarts!
Think about That!

And you can still properly repair your original fuel valve to return to automatic function!
08-13-2017 07:52 PM
jddens12 Thanks Tom !!! I took your advice and removed the diaphragm and it looks like my problem is solved! I'll probably order the raptor valve and replace my mod....Thanks Again!! John
08-13-2017 05:47 PM
Tom Schmitz You can pull the plate off of the back of the petcock and remove the spring and diaphragm, then install a solid gasket. This will turn it into a non-vacuum-operated petcock.

Or, you can install a Yamaha Raptor 660 petcock. If you chose this route, make sure you get a genuine OEM petcock rather than a Chinese copy. The OEM Yamaha should run about $25.

Review this for an overview of the Raptor petcock.
08-13-2017 03:38 PM
Fuel Delivery Issue

After a 100 mile ride last weekend my KLR wont start. I will barly fire but wont run. I replaced the plug with no improvement. I am now leaning toward fuel issues and suspect the fuel petcock....I have removed the pet cock and think it is the problem. I cant get any flow to the carb. I understand the carb creates vacuum and operates the diaphragm in the petcock allowing fuel to flow to the carb. When i put suction on the supply barb I dont get flow. It is like the petcock is off. I have same problem in off, on and reserve. I have disassembled and clean the petcock to no avail. I wanted to ask the experts before I spend the money on a new petcock.....thoughts? thanks......John

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