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  #1  
Old 6th March 2015
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Default Vacuum bypass petcock - which years and models?

K so while draining my tank for some winter maintenance I discover that the vacuum diaphragm on my fuel petcock is holed.


Good I thought, I wanted to replace it with a newer style petcock that bypasses vacuum when switched to reserve. I find one on eBay for a decent price, and it has the left side fuel outlet like I want instead of the down outlet normally found on Sportys. Part is delivered and it's in good shape...


BUT this one does NOT bypass the vacuum on res both holes feed the same outlet


So which models and years for sure have the vacuum bypass feature??

I'm assuming the valve body will have 4 holes instead of three like above?

P.S. - I know a Pingle is the cat's meow but I don't want to spend the money and I like the safety benefits of the vacuum feature.
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  #2  
Old 6th March 2015
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From the looks of the new unit, it does NOT have a vacuum-operated shutoff...

The pic of the open valve shows that it's quite normal for typical aftermarket models - one setting is for the tube input (inside the filter) which is the high level (normal operation) and the other setting is for the direct input (low input inside the filter) which is the reserve setting... Since it has no other auto-shutoff, when you set that petcock to reserve, it will flow fuel to the carb unless the tank is empty or until the float bowl valve shuts off flow...

I don't know of any HD models that operate on vacuum for the normal setting, but then "bypass" the vacuum shutoff when the switch is on reserve --- Did you see any official HD references that mentioned a vacuum-operated unit having a "vacuum bypass" on reserve?

Although some non-HD petcocks have a "Prime" setting (to allow flow direct from the tank to the carb), I don't know of any late-model HD models like that...

If you're happy with the new switch you have, you just need to be sure to switch it off after parking or when leaving it sit for a longer period of time...

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Old 6th March 2015
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This one has a vacuum shut-off for sure - here's a shot of the back side



I'm pretty sure my '05 Sportster had a bypass on reserve, same as the 'prime' setting on other petcocks but I never took that one apart to see what the innards look like. I have drained that tank by switching to res without the engine running. Couldn`t do that trick on my Dyna... and from looking at this petcock it won`t do it either.
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Old 6th March 2015
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Quote:
Originally Posted by JohnK View Post
This one has a vacuum shut-off for sure - here's a shot of the back side
----IMG----
I'm pretty sure my '05 Sportster had a bypass on reserve, same as the 'prime' setting on other petcocks but I never took that one apart to see what the innards look like. I have drained that tank by switching to res without the engine running. Couldn`t do that trick on my Dyna... and from looking at this petcock it won`t do it either.
I now see that the vacuum box was on the back of the petcock - Doh!

I could be wrong about the HD units - I've read other posts online claiming such a function, but I've never seen anything from HD to support that such a variation exists...

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Old 6th March 2015
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My 2004 had the vacuum feature on the petcock


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Old 6th March 2015
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Vacuum operated petcocks started in 95 and continued until the last carb model (06).
Which bypassed vacuum for reserve is the question and it may take some part numbers to research that.
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Old 6th March 2015
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The valve changed in 2002 (62169-02), but I do not know what the change was from the original in 1995. If a change was made in the reserve operation, 2002 would be the year.

http://www.harley-davidson.com/en_us...ts/-j02634.pdf
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Old 6th March 2015
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This was in a thread by Shu, Lenster and Debster in 2009:

62169-02 FUEL VALVE BODY, XL Retail Price:$26.20

62169-02A FUEL VALVE BODY, XL Retail Price:$26.20

62169-81 FUEL VALVE BODY Retail Price:$76.00

62169-86 FUEL VALVE BODY Retail Price:$50.00

62169-95 FUEL VALVE, VAC, XL Retail Price:$75.50

62169-95A FUEL VALVE, VAC, XL'S Retail Price:$63.00

62169-95B VACUUM OPERATED FUEL VALVE Retail Price:$88.00

62169-95C VACUUM FUEL VALVE KIT, XL Retail Price:$41.95

So, 3 versions of the 95 (95, 95A and 95B) and two verisons of the 02 (02 and 02A)
Some changes were positional detents.
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I do not recall ever seeing a hd model that had a vacuum reserve.. THAT IS.... one that would work without vacuum on reserve..

they either worked with the vacuum from a running engine, or did not allow flow without vacuum. which is why you have to attach a mitivac to get fuel to flow.. the loss of vacuum was to prevent a bad float from leaking gas all over the place.
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Old 6th March 2015
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If there was a petcock that flowed on reserve without vacuum, I'd have to guess it was an earlier model.
The 62169-02A was used through 2006 and my 04 uses the same, which does not flow without vacuum in any position.

But I'd also love to find one that flows on reserve without vacuum.
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