Fuel Tank (petcock?): Bike stalls when switching from On to Prime and/or Reserve - KawiForums - Kawasaki Motorcycle Forums
 
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post #1 of 3 (permalink) Old 10-13-2014, 05:29 PM Thread Starter
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Fuel Tank (petcock?): Bike stalls when switching from On to Prime and/or Reserve

Bike: 2001 Concours ZG1000A16, 60,000 Miles

Problem: Fuel Tank (petcock?): Bike stalls when switching from On to Prime and/or Reserve

*** 5 Questions below article ***

The problem of the bike stalling when switching the petcock from On to Prime and/or Reserve started about 3K miles - 1 1/2 months ago immediately after the bike was serviced at the dealer. The bike was serviced for a a starter issue and the dealer replaced the starter solenoid. I don't know if the dealer removed the fuel tank to replace the the solenoid (I doubt it). Within a couple of hundred feet from the dealer the bike began to sputter so i switched to prime but it continued to sputter so i switched it to reserve. The sputtering continued for a few more seconds and i continued to switch between prime and reserve until the bike stalled. The bike pretty much started right up when put on reserve after stall. Took the bike back to the dealer and he said it was most likely air in the lines and will work it's way out.

For the next 3K miles (1 1/2 mths) there were constant similar sputtering problems but it wasn't as noticeable and without the bike stalling until last week when it died at night on a very, very busy NY parkway. At this point this issue has become a danger. During this stall the bike sputtered real heavy for about 1/4 mile, say thirty seconds, before the bike turned off. However, this time the bike wouldn't start immediately like it always had in the past. I opened the fuel tank filler cap to help vent the system and it still didn't start. I continued to try to start bike and then I got nervous that I was going to kill the battery. I waited for no more than two minutes and the bike started with petcock in reserve.

Road the next 22 miles on reserve and then filled up 6.2 gallons. Coincidently the bike needed to be switch over to reserve at 200 miles and it's been that way since the stalling initially started. Before this issue the bike would always get at least 225-250 miles before the need for reserve. Another thing, since this recent stall the bike would, at times, not immediately start and one time it was warm and would not start with or without choke open. This was only for a few seconds but I figured I mention it. In the 60,000 miles of owning and riding this bike it always immediately started. The problem has not occurred again because I have not ridden enough to switch to reserve. Tomorrow the bike should be at the need for reserve.

THE FIX:
The most obvious fix would be is to replace the petcock. Replaced petcock with genuine Kawasaki petcock three years ago at about 57K miles and find it strange it would fail again in only 3K miles and the original petcock lasted 57,000 miles. Something to note is that the bikes was ridden much over the past three years, only about 3000 miles. Also, the fuel filter has also been recently changed.

Questions:
1. Would it be the petcock or possibly some other issue?
2. Is the petcock worth rebuilding or replace with new?
3. Why is the bike only getting 200 miles before reserve instead of the normal 225-250 miles?
4. What's causing the hesitant starting issue that recently started (in fact, it only been this tankfull that the hesitation has been occurring).
5. Why have I never put more than 6.5 gallons into the tank - this is even after the bike has run out of gas. It's supposed to have a 7.5 gallon tank but i have never came close to that.

Thx for being patient reading all this & I look forward to your suggestions.

~ David
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Bike: 2001 Concours ZG1000A16, 60,000 Miles

Problem: Fuel Tank (petcock?): Bike stalls when switching from On to Prime and/or Reserve

*** 5 Questions below article ***

The problem of the bike stalling when switching the petcock from On to Prime and/or Reserve started about 3K miles - 1 1/2 months ago immediately after the bike was serviced at the dealer. The bike was serviced for a a starter issue and the dealer replaced the starter solenoid. I don't know if the dealer removed the fuel tank to replace the the solenoid (I doubt it). Within a couple of hundred feet from the dealer the bike began to sputter so i switched to prime but it continued to sputter so i switched it to reserve. The sputtering continued for a few more seconds and i continued to switch between prime and reserve until the bike stalled. The bike pretty much started right up when put on reserve after stall. Took the bike back to the dealer and he said it was most likely air in the lines and will work it's way out.

For the next 3K miles (1 1/2 mths) there were constant similar sputtering problems but it wasn't as noticeable and without the bike stalling until last week when it died at night on a very, very busy NY parkway. At this point this issue has become a danger. During this stall the bike sputtered real heavy for about 1/4 mile, say thirty seconds, before the bike turned off. However, this time the bike wouldn't start immediately like it always had in the past. I opened the fuel tank filler cap to help vent the system and it still didn't start. I continued to try to start bike and then I got nervous that I was going to kill the battery. I waited for no more than two minutes and the bike started with petcock in reserve.

Road the next 22 miles on reserve and then filled up 6.2 gallons. Coincidently the bike needed to be switch over to reserve at 200 miles and it's been that way since the stalling initially started. Before this issue the bike would always get at least 225-250 miles before the need for reserve. Another thing, since this recent stall the bike would, at times, not immediately start and one time it was warm and would not start with or without choke open. This was only for a few seconds but I figured I mention it. In the 60,000 miles of owning and riding this bike it always immediately started. The problem has not occurred again because I have not ridden enough to switch to reserve. Tomorrow the bike should be at the need for reserve.

THE FIX:
The most obvious fix would be is to replace the petcock. Replaced petcock with genuine Kawasaki petcock three years ago at about 57K miles and find it strange it would fail again in only 3K miles and the original petcock lasted 57,000 miles. Something to note is that the bikes was ridden much over the past three years, only about 3000 miles. Also, the fuel filter has also been recently changed.

Questions:
1. Would it be the petcock or possibly some other issue?
2. Is the petcock worth rebuilding or replace with new?
3. Why is the bike only getting 200 miles before reserve instead of the normal 225-250 miles?
4. What's causing the hesitant starting issue that recently started (in fact, it only been this tankfull that the hesitation has been occurring).
5. Why have I never put more than 6.5 gallons into the tank - this is even after the bike has run out of gas. It's supposed to have a 7.5 gallon tank but i have never came close to that.

Thx for being patient reading all this & I look forward to your suggestions.

~ David
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post #2 of 3 (permalink) Old 10-13-2014, 05:35 PM Thread Starter
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Re: Fuel Tank (petcock?): Bike stalls when switching from On to Prime and/or Reserve

UPDATE

The bike finally needed to switch to reserve this past Sunday night. It went from sputter to reserve with just a little hesitation but not as smoothly as when I had no problems. I did not switch to prime first; went directly to reserve. The call for reserve again happened at the 200 mile marker. This really baffles me because, like I said in the original post, the bike has always switched to reserve at appx 225 - 250 miles. The reduced mileage did't happen until the back came back from service at 57K. Again, the bike is at 60K miles (and is 13 yrs old old).

As someone posted, the dealer may have removed the tank during its last service and upon reinstalling the tank may have pinched a vacuum or fuel line. I was just about to purchase a new petcock but I am now going to hold off until I have another chance to evaluate the condition of the fuel & vacuum lines. I had the tank off last week inspecting wiring on another issue (if you like see Directional lights go on after bike is switched off - problem not yet resolved). I replaced fuel filter and didn't notice any problems with lines (fuel tank issue has been happening way before filter was replaced).

I will now proceed to remove tank again but this time a will make a much closer examination of the lines and anything else that may be the culprit. I was about 15 miles from the gas station by my home when switched to reserve and had no problem from the initial switchover sputter. The problem I now have is that I filled the gas tank to full (I knew I shouldn't have done that) and only have ridden it appx 2 miles. I told myself last time not to remove tank again unless it's pretty much empty. Too much gas makes it too heavy and I dont want to risk scratching the tank during reinstall. So I need to ride the tank down. I'm not going to ride to this weekend and hopefully I'll get to inspect the fuel/vacuum lines

Thx all for your technical support. I hope to get to look at the problem during the next week so around then I hopefully will post another update.

Hope you all had safe riding this Columbus Day weekend.

~ David
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post #3 of 3 (permalink) Old 10-13-2014, 05:46 PM
Sev
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I'd check the fuel filter as well. Bikes old enough for it to be a little gummed up now.

Of course I'm generalizing from a single example here, but everyone does that. At least I do.


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