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Sportster Motorcycle Air intake, Carburetor, EFI, Fuel, and Exhaust Problems, advice and/or how tos for Sporster and Buell motorcycle carburators, Electronic Fuel Injection (EFI), Air Intake, Fuel and Exhaust.

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  #1  
Old 24th March 2012
decman decman is offline
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Join Date: Jan 2005
Location: Dubois, WY
Posts: 4,025
Sportster/Buell Model: 1200S
Sportster/Buell Year: 2001
Sportster/Buell Model #2: XLH-883D
Sportster/Buell Year #2: 1988
Other Motorcycle Model: FXDXT
Other Motorcycle Year: 2001
Reputation: 3902665
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Default Vacuum petcock bypass kit failure...

Folks, just FYI in case someone else runs into this.

I had this bypass kit in my tool box and while rebuilding my FXDXT it was a good time to bypass that vacuum mechanism before it failed on the road.
My 2001 XL1200S failed last year on the way to Bubs and that was fresh in my mind.

Anyway as you can see its a flat plate and rubber gasket. After about a week the bike started to stall after warmed up due to no fuel.
When I took the petcock apart it was obvious that the center of the rubber gasket was stretching and being pulled into the fuel cavity and shutting off the fuel....
So I just cut a hole in the center of the gasket and all is well.
After a quick search on the net I found that the new kits come with the hole now.

Some folks use the original diaphragm but put the spring on the fuel side instead of the vacuum side. That's OK as long as the diaphragm is is good shape.

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  #2  
Old 25th March 2012
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DaytonaSportster DaytonaSportster is offline
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Sportster/Buell Model: XL1200c
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Good info to know!
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