Help - fuel petcock reassembly

[Gryphon Rider]

I am rebuilding my fuel valve with the Honda kit, and am trying to reassemble parts 2 & 3 onto part C. I can get the button for 3 to snap into place in C, but not part 2.  Any tips for this?  I don't want to tear it by using a small screwdriver to help jam it in.

[Chrisj CMA]

just enough lubrication to get that thing to squeeze in there......done it a couple times

[rmrc51]

Keep us (me, lol) posted on this. I'm going to be doing the same rebuild for the first time once the kit arrives! 

[PharmBoy]

My high tech solution was to apply a little saliva, put my thumb on the rubber, and applied pressure with a twisting motion.  Presto, chang-o, it popped right on! 

[MP]

+1 on spit!

[rmrc51]

My high tech solution was to apply a little saliva, put my thumb on the rubber, and applied pressure with a twisting motion.  Presto, chang-o, it popped right on! 

Love these 'High Tech" solutions!!!!!  Gonna definitely try this next week when I rebuild mine!!! 

[Dave Weaver]

I rebuilt mine over the winter, but can't remember exactly how I got the little bugger to snap in.  I think I used seafoam to lube it as I had it lubing the o-rings on the carb overhaul.  Say a few choice words and keep pressing.

[Gryphon Rider]

Spit worked - got it in!

Thanks folks.

Now I have to wait 'til the dealer opens Monday or Tuesday to get an air filter.  I should have though of that when I ordered the rebuild kit.  I seem to have the luxury of time, since we just got another couple of inches of snow last night.

[Normandog]

Same general topic, similar problem. Rebuilt the petcock on '03 standard. When all was re-installed bike cranked fine and ran fine for awhile. 1st time out I made just a couple miles from home and it seemed to run out of gas. Switching to reserve did not help. Pulled off the road and bumped the starter 3 times every minute until it cranked. Since then it has quit 3 or 4 more times. Got as much as 40 miles once before it stalled again and as little as 2 miles. Pulled the petcock this afternoon and removed the screen. The black rubber donut was sideways in the screen tube. I can see where this might starve it of fuel in the run position but wouldn't think it would do so in reserve.
Plan on looking inside petcock tomorrow. any suggestions?
Where exactly does the black donut (not sure what is called) need to be?

[Chrisj CMA]

Same general topic, similar problem. Rebuilt the petcock on '03 standard. When all was re-installed bike cranked fine and ran fine for awhile. 1st time out I made just a couple miles from home and it seemed to run out of gas. Switching to reserve did not help. Pulled off the road and bumped the starter 3 times every minute until it cranked. Since then it has quit 3 or 4 more times. Got as much as 40 miles once before it stalled again and as little as 2 miles. Pulled the petcock this afternoon and removed the screen. The black rubber donut was sideways in the screen tube. I can see where this might starve it of fuel in the run position but wouldn't think it would do so in reserve.
Plan on looking inside petcock tomorrow. any suggestions?
Where exactly does the black donut (not sure what is called) need to be?

Normandog...same exact thing happened on mine except it was a lon gtime between a successful rebuild and the problem returning.  When it returned I assumed (Correctly) that the fault was in the fuel valve side (non rebuildable) of the petcock so I just replaced with a pingel and all has been fine since.....I highly recommend the Pingel its a quality piece and a tad cheaper than an OEM replacement

http://www.pingelonline.com/

[hubcapsc]

 * Rebuilt the petcock on '03 standard. When all was re-installed bike
 * cranked fine and ran fine for awhile. 1st time out I made just a
 * couple miles from home and it seemed to run out of gas. Switching
 * to reserve did not help. Pulled off the road and bumped the starter
 * 3 times every minute until it cranked. Since then it has quit 3 or
 * 4 more times. Got as much as 40 miles once before it stalled again
 * and as little as 2 miles. Pulled the petcock this afternoon and
 * removed the screen. The black rubber donut was sideways in the screen tube.

 ** same exact thing happened on mine

There's a test at the end of this article:

  http://www.valkyrieriders.com/shoptalk/petcock.htm

I think if you do this test before you put stuff back together, you'll always
be able to avoid this pitfall...

-Mike

[Larry]

Same general topic, similar problem. Rebuilt the petcock on '03 standard. When all was re-installed bike cranked fine and ran fine for awhile. 1st time out I made just a couple miles from home and it seemed to run out of gas. Switching to reserve did not help. Pulled off the road and bumped the starter 3 times every minute until it cranked. Since then it has quit 3 or 4 more times. Got as much as 40 miles once before it stalled again and as little as 2 miles. Pulled the petcock this afternoon and removed the screen. The black rubber donut was sideways in the screen tube. I can see where this might starve it of fuel in the run position but wouldn't think it would do so in reserve.
Plan on looking inside petcock tomorrow. any suggestions?
Where exactly does the black donut (not sure what is called) need to be?

Normandog...same exact thing happened on mine except it was a lon gtime between a successful rebuild and the problem returning.  When it returned I assumed (Correctly) that the fault was in the fuel valve side (non rebuildable) of the petcock so I just replaced with a pingel and all has been fine since.....I highly recommend the Pingel its a quality piece and a tad cheaper than an OEM replacement

http://www.pingelonline.com/

Obviously for you this information is moot for you Chris. You can rebuild the ball valve side in a mannor of speaking. Did mine a couple years ago. There was another rider that had posted a procedure earlier that year, you just have to take apart the valve by drilling out those rivets and then digging out the o rings under the retainer plate and replacing them. I didn't go to that extent, I just used a large bit to ream the opening a bit by taking the edge off the plate where the ball seats. This allows the ball to sit a bit deeper in the seat and seal properly. You then need some small screws and nuts to hold it all together after. Just my 2c's. 

[Normandog]

bike. Did the test suggested and then to make double sure after I reinstalled the valve I set the tank up on 2 buckets and applied vacuum. Good fuel flow.  Had to pull the rear wheel and drop it off at the shop for a new cobra so it'll be a while before I can test ride it.
Thanks again for the help.

[John Schmidt]

If you're trying to move metal across/against rubber, douse it good with some ordinary alcohol and it moves quite easy. And, the alky just evaporates and leaves no residue. I've used the alky approach hundreds of times, even use it to thread a wire/wire bundle through some insulating sleeves. It makes a great lubricant for many things, dries in a few moments and hurts nothing. It's especially useful when trying to move rubber against rubber. You can stand there and try something for fifteen minutes....cussing all the time, or a few drops of alky and be done in seconds.