2000 King Quad 300 4x4 -- Fuel Petcock leaking

This is a discussion on 2000 King Quad 300 4x4 -- Fuel Petcock leaking within the Repair and Maintenance forums, part of the Suzuki ATV Technical Discussions category; OH no...my fuel petcock is leaking. Can smell fuel in the garage...and go take a close look. The screws are wet from the gas. Thinking ...

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Old 05-09-2013, 02:15 PM   #1
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Arrow 2000 King Quad 300 4x4 -- Fuel Petcock leaking

OH no...my fuel petcock is leaking. Can smell fuel in the garage...and go take a close look. The screws are wet from the gas. Thinking it might just be loose...I get my screwdriver and attempt to tighten. One screw was a little loose, but the other screw is stripped out.

This weekend...I'll have to drain the tank. Then...I'll be waiting for new OEM parts to arrive. Ordered new petcock and screws...plus a lot of other fuel related stuff. I'll post pics of the new .vs the old petcock.

If going to do it...do it right. Hoping anyway!


biz
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Old 05-09-2013, 02:24 PM   #2
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I would think the screws would come with the new fuel petcock, but i could be wrong. Anyhow, while you're waiting if you want to read up on the vacuum operated fuel petcock check this out: (Vacuum operated fuel tank valve (Petcock)) This thread was created by our forum member Tim and gives a pretty good breakdown of the fuel petcock and how it works.
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Old 05-09-2013, 02:51 PM   #3
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Arrow

Oh yeah. Was just reading up on that thread. Funny coincidence...that you mention it. Heck...I even subscribed to it!

Figure I'll remove the tank and clean it out while I am at it. Plus...pull the Mikuni carb...and give it a good cleaning. Varnish build-up...probably?! I purchased a carb kit...so I will add all new jets, needle, O-rings, and gaskets. Install new spark plug too.

Have new air filter. Plus...will do an oil change with fresh 10W-40 oil and oil filter.

New meats are coming with Kenda Bear Claws (originals) along with new front and rear shocks.

Fun project!
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2000 King Quad LT-F300FY 4x4 Green
UNI Air Filter
Venom 2000HD Hardcore Series Winch
Kenda Bear Claws - Frt 24x9-11 & Rr 25x10-12
Differential Lock Mod
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++++++++++++++++++++++++++++++
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Old 05-12-2013, 11:54 AM   #4
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Well...I did some reading...and NO way...do I want to pull the fuel tank. According to the instructions...they say to pull the motor?!?!

The tank comes out the bottom...and does not pull upwards. So...that is off my list...unless absolutely necessary.

The fuel petcock can be replaced with fuel tank in place! Some good news out of this...I was able to verify the fuel petcock is functioning normally as intended. I verified this during the process of draining the fuel tank. Turn it to 'ON' and 'RES' position...and no fuel comes out. Put it to 'PRI'...and out comes the fuel. So...it's really just the gasket that needs replacing. But...I am replacing the entire petcock with OEM new. I'll either keep this as a spare...or sell on the Bay! Pretty cool...

Removed the carb yesterday (tight space)...but have not torn it down yet. Still waiting for carb rebuild parts. Hoping to have carb done by next weekend.

...more to come...with Project KING!


biz
__________________
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2000 King Quad LT-F300FY 4x4 Green
UNI Air Filter
Venom 2000HD Hardcore Series Winch
Kenda Bear Claws - Frt 24x9-11 & Rr 25x10-12
Differential Lock Mod
++++++++++++++++++++++++++++++
++++++++++++++++++++++++++++++

Last edited by biz4two; 05-12-2013 at 12:06 PM.
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Old 05-22-2013, 12:08 AM   #5
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YES...finally received the new OEM fuel petcock. Also...super glad that I ordered the 2 screws that are required to install it. At least this one...did not come with screws.

This is going to be a tough job...but hoping it goes well. As mentioned...one screw is totally stripped right now. I'll just have to take it slow...and work it off...this weekend.

I'll try and take pics of the new and the old removed from machine. Just for a side-by-side comparison.


biz
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2000 King Quad LT-F300FY 4x4 Green
UNI Air Filter
Venom 2000HD Hardcore Series Winch
Kenda Bear Claws - Frt 24x9-11 & Rr 25x10-12
Differential Lock Mod
++++++++++++++++++++++++++++++
++++++++++++++++++++++++++++++
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Old 05-22-2013, 05:03 PM   #6
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Take step by step pics if you can and post them up. The pics might come in handy for someone looking to replace one and who is looking for a step by step walkthrough on how to do so. And if they are like me, pics and videos are always a welcome bonus.
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Kenda Bear Claws (Rear 25X10-12) - (Front 24X9-11)
Differential Lock Mod
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Old 05-24-2013, 02:03 AM   #7
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If the screw is long enough, you might be able to put a nut on the inside with a bit of trial and error figuring out a way to hold the nut. If it's not long enough, most hardware stores stock small metric bolts and nuts. I'd use a nyloc self locking nut.

Quote:
According to the instructions...they say to pull the motor?!?!
I just looked in the service manual and it says the tank will slide back and down with the engine in the ATV.

Last edited by oldeerslayer; 05-24-2013 at 02:07 AM.
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Old 05-24-2013, 06:35 AM   #8
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I was looking at pulling my tank a while back too and I got to the same part and said what the Heck, what idiot designed a machine where you have to remove the engine to get the tank out.
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Old 05-24-2013, 07:21 AM   #9
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OOPS, I re-read the manual and in small print step 3 says "Remove engine", I never noticed that before. There has to be some way to do it. What if you just pulled the head? I guess you have to clean and flush it in place.
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Old 05-25-2013, 12:34 AM   #10
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Quote: Originally Posted by KingQuadRunner View Post
I was looking at pulling my tank a while back too and I got to the same part and said what the Heck, what idiot designed a machine where you have to remove the engine to get the tank out.

Yeah...I'm thinking it has to do with the design of the levers...and the location they are placed.

Definitely...not cool.


biz
__________________
==============================
2000 King Quad LT-F300FY 4x4 Green
UNI Air Filter
Venom 2000HD Hardcore Series Winch
Kenda Bear Claws - Frt 24x9-11 & Rr 25x10-12
Differential Lock Mod
++++++++++++++++++++++++++++++
++++++++++++++++++++++++++++++
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