Can't get the petcock back together!

[Kigsby]

I removed the piece with the little propeller looking thing on top but slipping a small flat head screwdriver in the notch and popped it up. Then I took out the rubber piece below that, put in a new rubber piece (thought I'd try the rubber piece first instead of the cork), slid the lever in over the rubber piece and put the piece with the propeller and the other new rubber piece with the new fuel tubes on top of that, but its loose. It won't go down all the way. Is it because it's new? When I took it apart, it was pressed down much further. Will that happen after I put the screws in or is it supposed to be on there tight before I screw it back on?

Thanks!
Keri

[brewsky]

Check to make sure the fuel tube is not sticking out past the rubber portion.

[ironangel]

also double check the first rubber part to make sure it is fully seated

[Kigsby]

I checked the fuel tube and it's not sticking out past the rubber. There are slight ridges on the holes in the bottom of the petcock that the rubber piece sits on that make it not sit flat. The holes in the rubber piece are smaller than the raised metal holes in the bottom of the petcock. It rocks back and forth over those raised holes. I could make the holes in the rubber piece slightly bigger to fit around those ridges, but would that effect the seal? Maybe it would be safer to try the cork one and just keep pressing down hard on it so the ridges dig into the cork to make it sit flat. When I look at the old piece I took out, it looks slightly indented around those ridges.

[brewsky]

The ridges should fit into the holes.
I use some motor oil on the washers to ease installation......may try heating with a hair dryer if necessary

[KellieLyyne]

Hi Keri, my hubby and I rebuilt our petcock like 8 times! It worked great for the first few weeks then it would start leaking really badly, or it would restrict the fuel so much that my bike would "cough" like it was constantly starving for fuel when traveling above 30 mph. After the 8th time of this happening, we just swapped out the petcock for a late model harley petcock. It has worked perfectly without all the issues. I hated to put on a non stock petcock, but I do have to admit, riding my bike is MUCH more enjoyable when it isn't leaking gas, or "coughing" lol. Good luck with your rebuild. : )

[Kigsby]

Thanks all! I'll try some oil to try to squeeze the ridges through the holes. Just didn't know if there was a trick to it. I had a very small leak, but thought I'd bite the bullet and just rebuild it. I want to get it ready for this weekend....there's a vintage bike show near my house and I would really love to bring the Dream there. I was going to seal the tank too, but I cleaned it out pretty well so I think I'll leave that fun job for the winter. Don't want to rush that one. Did the screw holes work for the Harley petcock or did you have to redrill holes? Still having fun riding around town with your 'old dude' magnet Kellie???