boulevardsuzuki.com has the float for $14.06 plus shipping.

Serowbot wrote on 06/11/10 at 17:14:47:



You are my new favorite person! I was experiencing all the same problems as drums1 and was having a hell of a time figuring it out. This trick was very easy and made my bike run like a champ. Thank you! I'll be getting a new petcock soon. I was just wondering, because my bike is my only transportation for now, is there any problem with running it this was for a couple days as long as I remember to turn the valve to "ON" rather than "PRIME" when I shut the bike off??

Also, thanks everyone who posts here, your tips, tricks and advice are great.

If you have removed and replaced your main jet, you may be missing a very small bushing that is up inside the tube above it.
This happened on my TW a couple of weeks ago and the dam little thing evaporated. It cost me 40 bucks for a new one, counting shipping charges.
Lack of it will most assuradely cause a richness of a degree that the bike will not run for crap no matter what else you do.

Phelonius

Well. I'm beside myself and I truly give up. I got it all back together again, and it's doing the exact same thing as when I started. About 1 mile into ride it starts sputtering and dying everytime I stop. It's like a choke problem on a car. I just let off the gas in 4th gear, going about 40mph, and it died. I popped the clutch back out and it wouldn't start back up until I pulled over and cranked on it for about 20 seconds. Then, it still wanted to keep dying out. I revved the piss out of it and eventually it stayed running but I had to keep revving it up when at red lights. Sounds like it's way too lean almost, but I smell gas and it's dripping out the vent tubes. And if I pull out the enrichment valve, it dies right away. Then it starts running ok for a bit, then running like crap. Back and forth. I wonder if the timing chain is jumping a tooth at random. It shouldn't be, since I had the tension adjuster replaced last summer with the "new and improved" one from the dealer, during last years fiasco. It's an '87, but only 16,000 OE miles on it. I'm about ready to put the dam thing up for sale. But who, in their right mind, would even consider buying it?

                 

As soon as the storms roll through, I'm going to the parts house to buy a little rubber cap. Golf tee's I have a thousand of, but being a mechanic, you'd think I could find one little rubber cap? No such luck. Serobots check is the ONLY thing left I haven't tried because, yes, I just rebuilt the dam petcock. I hate to think I just spent $22 for nothing. If that's the case and it is bad, it will be smashed into 1000 little pieces, right before I go and spend another $20 on the Raptor.

("I don't want a pickle....just want to ride on my motor-cycle")

And I'll be dammed if it ain't.... My sincere apologies go out to Serowbot and others who suggested his check, for not doing it sooner. I did it today and then put on 30 miles with no problems whatsoever. As I type this I just remembered I forgot to shut off the gas...................
Wow. I just ran out to garage and expected gas to be all over the floor and a full crankcase--not the case. Strange. Apparently the new needle and o-ring on the seat and the new diaphram are doing their thing. So do I need a Raptor or can I just stay with the modified OE petcock? (Being as I spent $23 on that useless diaphram 1 week ago?) Is that the difference--the Raptor has no diaphram?

The petcock from a Yamaha Raptor works manually instead of by vacuum...  This is the way petcocks have operated for nearly a century until some fool thought that a vacuum operation would be clever...
I'm glad you've found the problem,... but, bypassing it, ain't fixing it...  with it bypassed, you will no longer have a reserve, and whatever ain't right in there, will still be wrong... and, the Raptor looks better, works better, and makes tank removal easier for future maintenance...  

I know it's an irksome thought,.. but the $23.00 you wasted on the stock petcock repair is still wasted, whether you buy a Raptor or not...  


I'd strongly recommend getting a Raptor,...
This is the Raptor part no.  5LP-24500-01-00
2003 Yamaha Raptor 660 YFM660R
http://www.ronayers.com/browseparts.cfm?SearchString=5LP-24500-01-00&adv=5&kw...

PS,.. people recommend that you shut off a manual petcock when you park, but I never have... and it's never been a problem for me in 30 years...  I only shut off to pull the tank or do carb work...
... as it is,... you have know idea whether turning your broken petcock to run position when parked is doing anything anyway...

Bubba wrote on 06/18/10 at 17:51:29:



Another way to skin that cat:





I squeezed a bit of RTV into the hose first.