Petcock lever wont turn

I searched, I PROMISE!! Just bought an 81 seca 550. Petcock valve is set to res and wont turn. Im new to petcock valves, so any help would be appreciated. Thanks.

 

It's probably gummed up. There are two little screws that hold the cover plate on. Then there is a wave washer, then the valve, then a rubber disc.

Make sure your tank is empty before you pull it apart.

 

Took it apart and it wasnt gummed up or anything. Took the whole assembley off and took the whole thing apart. Now the lever wont go back in with the o-ring. Could the o-ring have expanded? Im thinking thats what it was so im in the process of finding a new o-ring.

 

I keep a couple of complete petcocks and individual repair parts in stock:


PETCOCKS, REBUILD PARTS & KITS:


OEM Fuel petcocks: note that although these will physically bolt up to your tank, some versions are completely different from your original petcock in every way imaginable!


fp16) OEM Yamaha replacement Complete Fuel Petcock. Brand new unit comes complete with the internal filter. This unit fits and looks "somewhat" the same as an original XJ-series petcock, but it is a completely new unit and no component (internal) parts will interchange between an original petcock and these units. Surprisingly, these units are still made by the Taiyo Giken Company, who supplied the original petcocks on the XJ era bikes....

HCP626 OEM Complete Fuel Petcock. The vacuum and fuel outlet port nipples point straight out towards the back of the bike (parallel to the front-to-back centerline of the bike). This is the most useful orientation for these outlet pipes, and the same as on original XJ petcocks. Includes the in-tank filters and the petcock-to-tank sealing o-ring. Fits all XJ550/650 (except Turbo) and all XJ750 models. NOTE: petcock mounting screws and their washers are NOT included!
$ 79.00


HCP625 OEM Complete Fuel Petcock. The vacuum outlet port nipple points directly out towards the back of the bike, while the fuel outlet port nipple faces backwards and at a 45-degree angle outwards. This is a slightly odd orientation, but it does allow for slightly more space for the fuel line to be routed clear of obstructions, especially when using an aftermarket in-line fuel filter. Includes the in-tank filter and the petcock-to-tank sealing o-ring. Fits all XJ550/650 (except Turbo) and 750 models. NOTE: petcock mounting screws and their washers are NOT included!
$ 65.00


HCP627 OEM Complete Fuel Petcock. The fuel inlet and outlet port nipples point directly out towards the back of the bike and tilted upwards at a 45-degree angle. Includes the in-tank filters and the petcock-to-tank sealing o-ring. Fits all XJ650 Turbo models. NOTE: petcock mounting screws and their washers are NOT included!
$ 118.00


HCP628 OEM Complete Fuel Petcock. The vacuum port nipple points directly out towards the back of the bike (rather than being angled as the original) and the fuel inlet port nipple is tilted upwards at about a 45-degree angle and is NOT angled towards the center of the bike (as original), nor is the fuel inlet nipple as long as on an original petcock. Surprisingly, besides these minor differences, these petcocks look exactly the the originals. Also, the changed inlet pipe orientation results in being able to install the rear petcock-to-tank mounting screw easily---on original petcocks, you basically have to almost hacksaw the screw off to remove/replace it or the fiber sealing washer! (a wonderful feat of factory engineering!). Includes the in-tank filter and the petcock-to-tank sealing o-ring. Fits all XJ700 and XJ900RK models. NOTE: petcock mounting screws and their washers are NOT included!
$ 91.00



fp17) Aftermarket Complete ON-OFF-RES FUEL VALVE. Not really a "petcock" in the XJ sense of the word. Yamaha designed their petcocks to be a very clever "automatic" fuel supply valve, meaning it has to have engine vacuum for it to function. Great idea (when it works) because it allows us to basically "set it and forget it". Bad news is that when the seals go bad, or as age wears the internal components, it can become a really bad idea, since it will leak fuel into the carbs when it's not supposed to, leading to flooded carbs, fuel in the crankcase, spun bearings, etc.

This true fuel VALVE is either ON (in either the standard "ON" or the "RES"erve positions) or it's OFF. And it doesn't depend on engine vacuum, just gravity. So it won't ever leak or pass fuel in the OFF position. That's the good news. The bad news is that you have to remember to turn it on or off manually (as in every time you start your bike up or shut it down) or, instead of blaming a faulty petcock for your resultant problems, you'll have to blame yourself!

Once installed, this unit fits and looks somewhat the same as an original XJ-series petcock, what with the chrome faceplate and selector lever. It obviously has no vacuum nipple, only a rear-ward facing fuel outlet, which means you will need to remove your petcock vacuum line from the #3 intake manifold boot nipple and replace it with a rubber block-off cap plug. This fuel valve uses the same size fuel line as original.

You also must use a adapter plate on the bottom of your fuel tank that this fuel valve screws into, and the brass-mesh, in-tank fuel filter (included with this valve) is actually larger than the opening in the bottom of the gas tank (just ever so slightly), so you'll have to grind the tank opening with a dremel tool or steel file to allow the filter to go into the opening. Our complete HCP630SET34 and HCP630SET46 kits (below) includes a bolt-on grinding template so you'll know exactly how much metal to remove.

All-in-all, this is a both a great value and a fine idea. It forever eliminates the dreaded "leaking petcock" problems associated with 20+ year old factory petcocks for a price just slightly more than what it costs to rebuild a factory petcock. On the downside, you will have to remember to turn this unit off or on every single time! And, once you modify your tank (by enlarging the petcock opening), an original petcock will never seal up properly to it again (or, not without alot of effort on your part to "shrink" the enlarged hole!).


550/650 (except Turbo)/750/1100 models:

HCP630SET34 Complete aftermarket FUEL VALVE KIT, contain everything you'll need to replace a factory XJ550/650 (except Turbo)/750/1100 petcock. Includes the HCP630 fuel valve, the HCP99 adpater plate, the HCP632 mesh in-tank fuel filter, the HCP1281 tank grinding template, a single HCP81 intake manifold nipple CAP PLUG, and a single HCP542 cap plug PINCH CLAMP.
$ 52.00

HCP630 Aftermarket FUEL VALVE ONLY, as used in the above complete kit. Includes the HCP632 in-tank brass-mesh fuel filter.
$ 25.00

HCP632 Aftermarket brass-mesh FUEL FILTER for the HCP630 fuel valve, filter only.
$ 11.00

HCP99 Aftermarket fuel valve-to-tank ADAPTER PLATE, includes the plate, plate-to-tank mounting screws, screw washers, die-cut plate-to-tank gasket, and a packet of gasket sealer/thread sealant. This adapter plate fits all XJ550/650 (except Turbo)/750/1100 models.
$ 24.00

HCP1281 aftermarket tank opening Grinding Template....a bolt-on thin aluminum plate that has a hole the exact size and placement needed to enlarge the petcock opening hole in the tank to accept the HCP630 fuel valve listed above. Takes the guesswork out of this critical task! This grinding template fits all XJ550/650 (except Turbo)/750/1100 models.
$ 7.00


700/900 models:

HCP630SET46 Complete aftermarket FUEL VALVE KIT, contain everything you'll need to replace a factory XJ700 or XJ900 petcock. Includes the HCP630 fuel valve, the HCP2981 adpater plate, the HCP632 mesh in-tank fuel filter, the HCP3013 tank grinding template, a single HCP81 intake manifold nipple CAP PLUG, and a single HCP542 cap plug PINCH CLAMP.
$ 52.00

HCP630 Aftermarket FUEL VALVE ONLY, as used in the above complete kit. Includes the HCP632 in-tank brass-mesh fuel filter.
$ 25.00

HCP632 Aftermarket brass-mesh FUEL FILTER for the HCP630 fuel valve, filter only.
$ 11.00

HCP2981 Aftermarket fuel valve-to-tank ADAPTER PLATE, includes the plate, plate-to-tank mounting screws, screw washers, die-cut plate-to-tank gasket, and a packet of gasket sealer/thread sealant. This adapter plate fits all XJ700 and XJ900 models.
$ 24.00

HCP3013 aftermarket tank opening Grinding Template....a bolt-on thin aluminum plate that has a hole the exact size and placement needed to enlarge the petcock opening hole in the tank to accept the HCP630 fuel valve listed above. Takes the guesswork out of this critical task! This grinding template fits all XJ700 and XJ900 models.
$ 7.00



rp3) Aftermarket Mini In-Line Fuel On-Off Valve. This 1/4" inlet/outlet fuel shutoff valve provides a fail-safe solution for leaky petcocks. Small size allows it to easily fit under the gas tank, within the petcock-to-carb fuel line. Lever handle can be set to full on or full off position. Best solution is to repair or replace a leaky petcock, but for a quick and easy solution, this valve will do the job.

HCP764 Mini In-line Fuel On-Off Valve:
$ 14.00




n) XJ's gas tank Used Original Rebuilt Petcock, for various XJ models. All units are professionaly rebuilt, and include a new inside filter, all o-rings replaced, cleaned, etc. GUARANTEED TO PERFORM CORRECTLY AND TO NOT LEAK!

NOTE: The availablity of rebuilt petcocks changes over time, so please write inquiring about your specific needs.

ALL REBUILT ORIGINAL PETCOCKS REQUIRE A $15.00 REFUNDABLE CORE CHARGE. The core charge will be refunded to you upon receipt of a complete, original XJ-series petcock.


HCPUPRB1 OEM used original Rebuilt Petcock. Correct for all XJ550 and all XJ650 (except Turbo) models. This petcock features the "short arm" fuel outlet plate. NOTE: although this petcock is "correct" only for the above listed models, it will fit and function properly on all XJ550, XJ650 (except Turbo), and all XJ750 models. Natural aluminum body finish is not correct for Midnight Maxim models, which used the same petcock, but with the body anondized black.
$ inquire

NOTE: at the present time we are out of stock of the HCPUPRB1 "short arm" version of the fuel outlet plate.

We do have the HCPUPRB2 "extended/long arm" versions available. If you have a short-arm version, you would need to re-use the fuel outlet plate off of your original petcock (just clean it thoroughly, there are no moving or "wear" parts in the outlet plate).


HCPUPRB2 OEM used original Rebuilt Petcock. Correct for all XJ750 Seca models featuring the "extended arm" fuel outlet plate. NOTE: although this petcock is "correct" only for the XJ750 Seca models, it will fit and function on all XJ550, XJ650 (except Turbo), and all XJ750 models.
$ 59.95 + $ 15.00 refundable core charge.


HCPUPRB3 OEM used original Rebuilt Petcock. For XJ650 Turbo models.
$ limited availability---inquire


HCPUPRB4 OEM used original Rebuilt Petcock. For XJ700/900 models.
$ 59.95 + $ 15.00 refundable core charge.


HCPUPRB6 OEM used original Rebuilt Petcock. Correct style for all XJ750 Maxim and 750 Midnight Maxim models featuring the front petcock drain screw as original. NOTE: although this petcock is "correct" only for the XJ750 Maxim models, it will fit and function on all XJ550, XJ650 (except Turbo), and all XJ750 models. Natural aluminum body finish is not correct for Midnight Maxim models, which used the same petcock, but with the body anondized black.
$ 64.95 + $ 15.00 refundable core charge.


HCPUPRB5 OEM used original Rebuilt Petcock. For XJ1100 models....you need to specify which side you need!
$ 39.95 each side + $ 15.00 refundable core charge.



t1) Aftermarket petcock tank opening Painting Block-off Plate & Gasket----a die-cut thin aluminum plate and matching rubber gasket, exactly the same size as the petcock-to-tank top mounting flange (or "face").

Before tank paint stripping or during actual tank painting, you'll remove your petcock and replace it with this plate, and therefore won't paint the oval petcock mounting area on the tank (which you definitely don't want to do---it should be bare metal for a proper seal). Includes a pair of mounting screws also, so you don't have to paint over your original or new petcock-to-tank mounting screws, either.

Of course, these block-off plates also works great when performing an electrolytic cleaning of the tank, since you really DON'T want to leave your petcock in the tank when performing such a process!

HCP634SET petcock block-off plate and gasket set. Fits all XJ550 models, all XJ650 (except Turbo) models, all XJ750 tanks, and all XJ1100 models.
$ 6.95

HCP3010SET petcock block-off plate and gasket set. Fits all XJ650 Turbo models, all XJ700 models, and all XJ900RK Seca tanks.
$ 7.90


t2) Aftermarket tank fuel sender opening Painting Block-off Plate & Gasket----a die-cut thin plastic plate and matching rubber gasket, exactly the same size as the petcock-to-tank top mounting flange (or "face").

Before tank paint stripping or during actual tank painting, you'll remove your fuel sending unit and replace it with this plate, and therefore won't paint the sender mounting area on the tank (which you definitely don't want to do---it should be bare metal for a proper seal). Includes a set of four mounting screws also, so you don't have to paint over your original or new sender-to-tank mounting screws, either.

Of course, these block-off plate also works great when performing an electrolytic cleaning of the tank, since you really DON'T want to leave your sending unit in the tank when performing such a process!

HCP2738SET fuel sending unit block-off plate and gasket set. Fits all XJ550 Seca, all XJ750 Seca, 1982 XJ750 Maxim, and XJ1100 tanks.
$ 8.95

HCP6371SET fuel sending unit block-off plate and gasket set. Fits all XJ700 tanks.
$ 8.95

HCP6373SET fuel sending unit block-off plate and gasket set. Fits all XJ900RK tanks.
$ 9.95





INDIVIDUAL PETCOCK REPAIR PARTS AND KITS:


fp13) Petcock fuel position Selector Lever O-Ring. These are usually worn out and need to be replaced whenever you go into the petcock. This o-ring found into the groove along the outside of the selector lever.

HCP108 OEM petcock Selector Lever O-Ring. Fits all XJ550, XJ650 (except Turbo models), XJ750, and XJ1100 models using the original petcock.
$ 5.00

HCP1383 Aftermarket petcock Selector Lever O-Ring, made from a soft, long-lasting Buna-N material. Fits all XJ550, XJ650 (except Turbo models), XJ750, and XJ1100 models using the original petcock.
$ 2.95

HCP5884 Aftermarket petcock Selector Lever O-Ring, made from a harder, better-sealing Viton material. Fits all XJ550, XJ650 (except Turbo models), XJ750, and XJ1100 models using the original petcock.
$ 3.95





HCP2339 OEM petcock Selector Lever O-Ring. Fits all XJ650 Turbo, and all XJ700 and XJ900 models using the original petcock.
$ 5.00

HCP5869 Aftermarket petcock Selector Lever O-Ring, made from a soft, long-lasting Buna-N material. Fits all XJ650 Turbo, and all XJ700 and XJ900 models using the original petcock.
$ 2.95

HCP5885 Aftermarket petcock Selector Lever O-Ring, made from a harder, better-sealing Viton material. Fits all XJ650 Turbo, and all XJ700 and XJ900 models using the original petcock.
$ 3.95



fp12) Petcock fuel position Selector Lever Distribution Valve. This is the hard plastic molded disc with the 4 holes in it that fits below the selector lever. These are usually worn out and need to be replaced whenever you go into the petcock. A worn valve will cause your petcock to leak fuel while in the RUN position.

HCP109 OEM Selector Lever Distribution Valve. Fits all XJ550, all XJ650 (except Turbo models), all XJ750, and all XJ1100 models.
$ 9.00

HCP1384 aftermarket Selector Lever Distribution Valve. Fits all XJ550, all XJ650 (except Turbo models), all XJ750, and all XJ1100 models. Same as the HCP109 above but at a better price!
$ 5.00


HCP2338 OEM Selector Lever Distribution Valve. Fits all XJ650 Turbo models, and all XJ700 and XJ900 models.
$ 9.00

HCP2930 aftermarket Selector Lever Distribution Valve. Fits all XJ650 Turbo models, all XJ700 and XJ900 models. Same as the HCP2338 above but at a better price!
$ 5.00



fp11) Petcock fuel position Selector Lever Wave Washer. These are usually worn out and need to be replaced whenever you go into the petcock. This spring washer fits in-between the selector lever and the outer faceplate, and provides the proper spring-pressure against the selector lever to properly engage the distribution valve.

HCP107 OEM Selector Lever Wave Washer. Fits all XJ550, all XJ650 (except Turbo), and all XJ750 models.
$ 2.00

HCP2918 OEM Selector Lever Wave Washer. Fits all XJ650 Turbo, all XJ700 models, and XJ900 models.
$ 1.50



fp4) OEM petcock Lever Rebuild Kits. These kits contain the plastic distribution "valve", the fuel position lever o-ring, and the fuel selector lever wave (spring) washer.

HCP945 petcock Lever Rebuild Kit, fits all XJ550, all XJ650 (except turbo), and all XJ750 original petcocks.
$13.00



fp10) Petcock fuel position Petcock-to-Tank O-Ring. These are usually worn out and need to be replaced whenever you remove the petcock. This rubber o-ring fits onto the top of the petcock.

HCP117 OEM Petcock-to-Tank O-Ring. Fits all XJ550, all XJ650 (except turbo), and all XJ750 original petcocks. Molded into a oval shape as original.
$ 3.50

HCP1385 Aftermarket Petcock-to-Tank O-Ring. This is a large o-ring and is NOT molded like original; however, it will fit and seal correctly. Fits all XJ550, all XJ650 (except turbo), and all XJ750 original petcocks. Each
$ 2.50



HCP2340 OEM Petcock-to-Tank O-Ring. Fits all XJ650 Turbo models, all XJ700 and XJ900 models. Molded into a oval shape as original.
$ 3.50

HCP1659 Aftermarket Petcock-to-Tank O-Ring. This is a large o-ring and is NOT molded like original; however, it will fit and seal correctly. Fits all XJ650 Turbo models, all XJ700 and XJ900 models.
$ 2.50


HCP6190 Aftermarket Petcock-to-Tank O-Ring. This molded oem replacement sealing ring is correct for the HCP625 and HCP626 replacement petcocks only, Correct molded oval seal with cross-bars fits and seals correctly. Fits the replacement HCP625 and HCP626 petcock only!
$ 3.95



Petcock Hardware and Fasteners:


fp8) Petcock-to-Tank Mounting Screw. The heads on these are usually stripped and need to be replaced whenever you remove the petcock. NOTE: original Yamaha screws feature a small, integral shoulder flange. All aftermarket screws have an overall head diameter that is similar to the original screws, but do NOT have a flange.


HCP118 OEM petcock-to-tank MOUNTING SCREW, grey-phosphate coated alloy steel. Fits all XJ550, XJ650, XJ750, and XJ1100 models. Each.
$ 1.50

HCP118SET2 OEM petcock-to-tank MOUNTING SCREWS, set of two.
$ 2.50 pair



HCP2922 Aftermarket petcock-to-tank MOUNTING SCREW, bright zinc-plated steel with phillips drive, pan-headed design. Fits all XJ550, XJ650, XJ750, and XJ1100 models. Each.
$ 1.00

HCP2922SET2 Aftermarket petcock-to-tank MOUNTING SCREWS, set of two.
$ 1.50 pair



HCP2923 Aftermarket petcock-to-tank MOUNTING SCREW, bright 18-8 stainless steel with phillips drive, pan-headed design. Fits all XJ550, XJ650, XJ750, and XJ1100 models. NOTE: these screws are slightly longer (2mm) than stock but it makes no difference in fit and function. Each.
$ 1.50

HCP2923SET2 Aftermarket petcock-to-tank MOUNTING SCREWS, set of two.
$ 2.50 pair



HCP2924 Aftermarket petcock-to-tank MOUNTING SCREW, black-oxide coated 18-8 stainless steel with phillips drive, pan-headed design. Fits all XJ550, XJ650, XJ750, and XJ1100 models. NOTE: these screws are slightly longer (2mm) than stock but it makes no difference in fit and function. Each:
$ 1.50

HCP2924SET2 Aftermarket petcock-to-tank MOUNTING SCREWS, set of two.
$ 2.50 pair




HCP2341 OEM petcock-to-tank MOUNTING SCREW. Fits all XJ700 and XJ900 models. NOTE: the original petcock screw has an integral flanged washer under the head, and this flanged head makes is VERY hard to remove, as the the petcock body and the fuel outlet port "traps" the flanged washer when trying to remove the screw. These replacement tank screws HAVE NO FLANGED WASHER ATTACHED, so it "fits" onto the petcock body much easier, while still providing the sealing surface necessary. Each.
$ 1.50

HCP2341SET2 OEM petcock-to-tank MOUNTING SCREW, set of two.
$ 2.50 pair



fp7) Petcock-to-Tank Mounting Screw WASHER. These washers are made from a fuel-resistant hard fiber material and need to be replaced every so often, and certainly every time you remove the petcock from the tank.

HCP2743 OEM Petcock-to-Tank Mounting Screw WASHER. Fits all XJ550, XJ650, XJ700, XJ750, XJ900RK, and XJ1100 models. Each.
$ 1.00

HCP2743SET2 OEM Petcock-to-Tank Mounting Screw WASHERS, set of two.
$ 1.75 pair




fp19) Petcock chrome selector lever faceplate MOUNTING SCREW, the tiny phillips-headed screws that secure the chrome ON-FUEL-RES-PRI faceplate to the petcock body. Originals normally have stripped heads after one or two on-and-off sessions!
Fits all XJ550, XJ650, XJ700, XJ750, XJ900RK, and XJ1100 petcocks. Use 2 per petcock.


HCP104 OEM petcock faceplate MOUNTING SCREW, each:
$ 1.25

HCP104SET2 OEM petcock faceplate MOUNTING SCREWS, set of 2:
$ 2.00


HCP2907 Aftermarket petcock faceplate MOUNTING SCREWrew, zinc-plated alloy steel, each:
$ .75

HCP2907SET2 OEM petcock faceplate MOUNTING SCREWS, set of 2:
$ 1.25


HCP105 Aftermarket petcock faceplate MOUNTING SCREW, 18-8 stainless steel, each:
$ 1.50

HCP105SET2 OEM petcock faceplate MOUNTING SCREWS, set of 2:
$ 2.50


HCP2908 Aftermarket petcock faceplate MOUNTING SCREW, black-oxide coated steel, each:
$ 1.00

HCP2908SET2 OEM petcock faceplate MOUNTING SCREWS, set of 2:
$ 1.75



fp29) Petcock vacuum diaphram cover plate SCREW,, flathead phillips-headed screws that secure the vacuum diaphram cover plate to the petcock body. Fits all XJ550, XJ650 except Turbo, all XJ700 models, all XJ750 petcocks, XJ900RK, and the XJ1100 vacuum diaphram unit. Use 4 per petcock or vaccum unit.

HCP5895 aftermarket vacuum diaphram cover plate SCREW, zinc-plated alloy steel, flathead phillips-drive, with a natural finish, each:
$ 1.00

HCP5895SET4 aftermarket vacuum diaphram cover plate SCREWS, zinc-plated alloy steel, flathead phillips-drive, with a natural finish, set of 4:
$ 2.50


HCP5897 aftermarket vacuum diaphram cover plate SCREW, 18-8 stainless steel, flathead phillips-drive, with a bright finish, each:
$ 1.50

HCP5897SET4 aftermarket vacuum diaphram cover plate SCREWS, 18-8 stainless steel, flathead phillips-drive, with a bright finish, set of 4:
$ 5.00



fp31) Petcock fuel outlet cover plate SCREW,, flathead phillips-headed screws that secure the fuel outlet cover plate to the petcock body. Fits all XJ550, XJ650 except Turbo, and all XJ750 petcocks. Use 2 per petcock or vaccum unit.

HCP5891 aftermarket fuel outlet cover plate SCREW, zinc-plated alloy steel, flathead phillips-drive, with a natural finish, each:
$ 1.00

HCP5891SET2 aftermarket fuel outlet cover plate SCREWS, zinc-plated alloy steel, flathead phillips-drive, with a natural finish, set of 2:
$ 1.50


HCP5893 aftermarket fuel outlet cover plate SCREW, 18-8 stainless steel, flathead phillips-drive, with a bright finish, each:
$ 1.50

HCP5893SET2 aftermarket fuel outlet cover plate SCREWS, 18-8 stainless steel, flathead phillips-drive, with a bright finish, set of 2:
$ 2.75



fp32) Petcock DRAIN SCREW,, panhead phillips-drive screw that allows the petcock to be drained. Fits all XJ1100 petcocks. Use 2 per petcock. The HCP5374 gasket that is used with these screws must be ordered separately below.


HCP60 OEM petcock drain SCREW, zinc-plated alloy steel, flathead phillips-drive, with a natural finish. NOTE: these screws are approx. 2mm longer than stock, but will still fit correctly. Each:
$ 1.00

HCP60SET2 OEM petcock drain SCREWS, zinc-plated alloy steel, flathead phillips-drive, with a natural finish, set of 2:
$ 1.75

HCP60SET4 OEM petcock drain SCREWS, zinc-plated alloy steel, flathead phillips-drive, with a natural finish, set of 4:
$ 3.50


HCP5887 aftermarket petcock drain SCREW, zinc-plated alloy steel, flathead phillips-drive, with a natural finish, each:
$ 1.00

HCP5887SET2 aftermarket petcock drain SCREWS, zinc-plated alloy steel, flathead phillips-drive, with a natural finish, set of 2:
$ 1.50

HCP5887SET4 aftermarket petcock drain SCREWS, zinc-plated alloy steel, flathead phillips-drive, with a natural finish, set of 4:
$ 2.75


HCP5888 aftermarket petcock drain SCREW, 18-8 stainless steel, flathead phillips-drive, with a bright finish, each:
$ 2.00

HCP5888SET2 aftermarket petcock drain SCREWS, 18-8 stainless steel, flathead phillips-drive, with a bright finish, set of 2:
$ 3.75

HCP5888SET4 aftermarket petcock drain SCREWS, 18-8 stainless steel, flathead phillips-drive, with a bright finish, set of 4:
$ 6.75



fp33) Petcock DRAIN SCREW GASKET,, translucent plastic drain screw gasket, used on all XJ1100 models. Use 2 per petcock.

HCP5374 OEM petcock drain screw GASKET, clear plastic gasket used with any of the above drain screws, each:
$ 3.00

HCP5374SET2 OEM petcock drain screw GASKETS, set of 2:
$ 5.00

HCP5374SET4 OEM petcock drain screw GASKET, set of 4:
$ 9.00




fp3) Aftermarket petcock STANDARD VACUUM DIAPHRAM REPAIR KITS. This is the part that, when worn, torn, or ruptured, allows fuel to leak into the carbs all the time. Double-gasketed plunger assembly has the o-ringed plunger tip. You must save and re-use your original plastic spacer plate!


HCP110 Aftermarket petcock standard Vacuum Diaphram Repair Kit. Fits all XJ550, XJ650 (except turbo), and XJ750 models with an original o-ringed plunger tip. Order the HCP663 washer listed below if using this repair kit to repair a petcock that originally used a "d"-ring on the plunger tip.
$ 12.00

HCP1657 Aftermarket petcock standard Vacuum Diaphram Repair Kit. Fits all XJ700, XJ900, and XJ1100 models. Order the HCP663 washer listed below if using this repair kit to repair a petcock that originally used a "d"-ring on the plunger tip.
$ 14.00



fp14) Aftermarket petcock DELUXE VACUUM DIAPHRAM REPAIR KITS. This is the part that, when worn, torn, or ruptured, allows fuel to leak into the carbs all the time. Double-gasketed plunger assembly has the o-ringed plunger tip, and comes complete with the plastic spacer plate!

HCP2282 Aftermarket petcock Deluxe Vacuum Diaphram Repair Kit, complete with the plastic spacer plate. Fits all XJ550, XJ650 (except turbo), and XJ750 models with an original o-ringed plunger tip. Order the HCP663 washer listed below if using this repair kit to repair a petcock that originally used a "d"-ring on the plunger tip.
$ 19.00



fp5) Aftermarket petcock complete STANDARD REBUILD KITS. These kits contain either the HCP110 or HCP1657 vacuum diaphram repair kit (above), plus the plastic distribution "valve", the fuel position lever o-ring, and the petcock-to-tank mounting o-ring. NOTE: petcock mounting screws, mounting screw washers, faceplate screws, and selector lever wave washer is NOT included in this kit and must be ordered separately if desired.

HCP124 petcock standard Complete Standard Rebuild Kit. Fits all XJ550/650 (except Turbo models)/750 models with an original o-ringed plunger tip. Order the HCP663 washer listed below if using this repair kit to repair a petcock that originally used a "d"-ring on the plunger tip.
$ 26.00


HCP1661 petcock standard Complete Standard Rebuild Kit. Fits all XJ700/900 models with an original o-ringed plunger tip. Order the HCP663 washer listed below if using this repair kit to repair a petcock that originally used a "d"-ring on the plunger tip.
$ 27.00


HCP1662 petcock standard Complete Standard Rebuild Kit. Fits all XJ1100 models. Includes 2 each of the selector lever o-ring, the petcock-to-tank mounting o-ring, and the fuel distribution valve. Also comes with the vacuum diaphram used in the external fuel distribution unit. One kit does both petcocks and the external unit. Order the HCP663 washer listed below if using this repair kit to repair a distribution unit that originally used a "d"-ring on the vacuum plunger tip.
$ 27.00



fp22) Aftermarket petcock complete DELUXE REBUILD KITS. These kits contain everything you'll need to do a complete rebuild and replacement of your factory petcock, including mounting screws and washers and a fuel filter!


HCP6060 aftermarket petcock deluxe Complete Rebuild Kit: contains everything you'll need to repair an original petcock: the HCP2822 deluxe diaphram repair kit (with the plastic spacer plate); the selector lever o-ring, wave washer, and distribution valve; the petcock-to-tank o-ring, two stainless faceplate screws, two petcock-to-tank mounting screws and their sealing washers, the fuel outlet plate gasket, and the in-tank filter!Fits all XJ550/650 (except Turbo models)/750 models with an original o-ringed plunger tip. Order the HCP663 washer listed below if using this repair kit to repair a petcock that originally used a "d"-ring on the plunger tip.
$ 52.00



HCP5870 aftermarket petcock deluxe Complete Rebuild Kit: contains everything you'll need to repair an original petcock: the diaphram repair kit; the selector lever o-ring, wave washer, and distribution valve; the petcock-to-tank o-ring, two stainless faceplate screws, and two petcock-to-tank mounting screws and their sealing washers, and the in-tank filter! Fits all XJ700 and XJ900RK models with an original o-ringed plunger tip.
$ 52.00



HCP5871 petcock deluxe Complete Rebuild Kit: contains everything you'll need to repair both original petcocks and the vacuum pod control unit: the HCP2822 deluxe diaphram repair kit (with the plastic spacer plate); two each of the selector lever o-ring, wave washer, and distribution valve; two of the petcock-to-tank o-ring, four stainless faceplate screws, four petcock-to-tank mounting screws and their sealing washers, two of the petcock drain screws and their sealing washers, two each of the vacuum diaphram pod short and long screws with lockwashers, and two of the in-tank filters! For all XJ1100 models with the original dual petcocks and separate vaccum control unit.
$ 99.00



fp6) HCP663 petcock vacuum diaphram spring SHIM WASHER. Order this washer to be able to use any of the diaphram repair kits on a petcock that originally used a "d"-shaped rubber ring on the plunger tip. This washer goes behind the plunger spring and acts as a tension shim to allow the spring to put more pressure on the replacement-style o-ringed plunger tip, and thus allowing it to seat and seal properly. The key is this: if you are using an "o-ring" vacuum diaphram repair kit (NOTE: all of the replacement vaccum diaphram repair kits are only available with an o-ring tipped seat plunger!) to replace an original "d-ringed" plunger, then you'll need to use this shim! Used on all XJ550, XJ650 except Turbo, XJ700, XJ750, XJ900, and XJ1100 petcocks (or vacuum module for 1100's).
$ 1.00