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Rebuilding the petcock/fuel tap: Difference between revisions

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====Obtaining parts====
====Obtaining parts====


What you decide to do will likely depend on whether you can diagnose which part of the petcock is damaged. This will, of course, involve taking it apart and looking at it before you order parts. This is the cheapest way, but you'll have to wait for parts.  
What you decide to do will likely depend on whether you can diagnose which part of the petcock is damaged. This will, of course, involve taking it apart and looking at it before you order parts. This is the cheapest way, but you'll have to wait for parts.


There is a rebuild kit from K&L Supply, part #18-2723, but it is for the E series (86-87) bikes. It doesn't have the correct diaphragm for the later F (88-07) bikes. All the other parts are the right ones, but if your diaphragm is bad, plan on spending another $25 on top of the $25 for this kit, which puts you in the ballpark for a new one, already put together.
If you want to order parts from your dealer or one of the [[Where can I buy parts/tools online?|OEM online sources]], here is what you'll need:


K&L Supply part #s:
* SPRING,TAP DIAPHRAGM- 92081-1240
* DIAPHRAGM,TAP- 43028-1068
* RING-O- 92055-1664
* PACKING- 43049-1103
* RING-O,TAP LEVER- 92055-1085
* RING,TAP FLANGED- 51039-003
 
[[Image:FUEL_TANK.png|100px]]
 
 
'''A kit, sort of'''
 
There is a rebuild kit from K&L Supply, part #18-2723, but it is for the E series (86-87) bikes. It doesn't have the correct diaphragm for the later F (88-07) bikes. All the other parts are the right ones, but if your diaphragm is bad, plan on spending another $25 on top of the $25 for this kit.
 
K&L Supply part numbers:


*86-87 rebuild kit: #18-2723
*86-87 rebuild kit: #18-2723
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[[image:IMG_0044.JPG|150px]]
[[image:IMG_0044.JPG|150px]]
[[image:diaphragms.jpg|150px]]
[[image:diaphragms.jpg|150px]]
If you want to order the parts separately, here is what you'll need:
* SPRING,TAP DIAPHRAGM- 92081-1240
* DIAPHRAGM,TAP- 43028-1068
* RING-O- 92055-1664
* PACKING- 43049-1103
* RING-O,TAP LEVER- 92055-1085
* RING,TAP FLANGED- 51039-003
[[Image:FUEL_TANK.png|100px]]


====Checking the vent====
====Checking the vent====
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You should probably change your oil now, before you start it up. If the petcock has been leaking into the oil, not only will you have too much oil, what's in there will be thinned out and much less effective. You don't want to replace major engine components just because of that.
You should probably change your oil now, before you start it up. If the petcock has been leaking into the oil, not only will you have too much oil, what's in there will be thinned out and much less effective. You don't want to replace major engine components just because of that.
===Rebuilding Vs New===
If your petcock is shot, save your time, and money and get a new one, the cost of rebuilding it isn't much cheaper, due to you need two separate kits, as they for some reason don't make just one.
New one cost about $65.00
1988~00 models
http://www.partzilla.com/parts/detail/kawasaki/KP-51023-1139.html
2001~07 models
http://www.partzilla.com/parts/detail/kawasaki/KP-51023-1393.html
Also be sure to order the orings(92022-183 WASHER,6.2X11X1.5)and new bolts(92001-1091BOLT,6X20),trust me you'll be better off in the long run.
Rebuilding kits are about $60 total.
K&L Supply Diaphragm Only for Fuel Petcock Repair Kit 18-6638 https://www.amazon.com/dp/B0055DWO60/ref=cm_sw_r_awd_s1CGub1W9N3PH
K&L Supply Fuel Petcock Repair Kit 18-2723 https://www.amazon.com/dp/B001KO2JRW/ref=cm_sw_r_awd_U1CGub05DT5NT
http://faq.ninja250.org/wiki/Rebuilding_the_petcock/fuel_tap
IMHO not worth it rebuilding, also be sure to check vacuum and fuel lines for wear, holes, and cracks, if in doubt replace them. Also replace the two small O-rings on the bolts for the petcock part# 92022.
This is the time to add an inline filter filter, if you don't have one already.
K&N 81-0221 Fuel Filter https://www.amazon.com/dp/B000E2AR70/ref=cm_sw_r_other_awd_ncMwwbE333H0E
[[image:FUEL_TANK.png|450px]]
UPDATE by Ghostt: K&L SUPPLY now makes a complete kit for 88-07 models, according to their own 2016 catalog, Part # 18-2702.
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