SUZUKIPictures of how I modified the fuel petcock valve for "unrestricted" fuel flow on my 89-09 Suzuki GS500 motorcycle.

But first, lets pay some bills:

  1. This is a petcock from a pre 2001 GS from ebay.

  2. I pried off the metal face cap with a flat screwdriver. Glad I took these pictures first, they helped me remember how to put it back together.
    pry off plate

  3. Here's the back of the petcock. Behind these screws is the vacuum operated ON valve.

  4. Here are all the parts of the petcock. Vacuum on the left and selector on the right.
    exploded petcock

  5. I drilled out the fuel channels. The aluminum petcock body drills easy. I don't remember what size drill bit. But if you are man enough to drill your own petcock, you don't need me picking your bits.
    drilling    drilling

  6. Drilled out the plastic selector valve guts. I wrapped it in a paper towel to hold with the pliers as not to scratch the outside seal surface. If I was just a bit more drunk I would have drilled through the plastic straight through or sideways into the next channel, thus making the part useless.

  7. Here is a view of the inside of the plastic selector valve piece, which clearly shows you how drunk I was.

  8. Reserve, Main, Carb.

  9. Reassembled valve this way. The plastic groove pointing like so with the selector knob like so.

  10. Next I sold out to make 02ยข so I can fulfill my lifelong dream of owning a 1986 944 with blown head gaskets.

    But no minivans!

  11. Then I finished my beer.


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Last modified: 11/22/2014