Okay, so my petcock has had a slight leak - enough to fill the garage with a gas odor. At first, couldn't find the issue, but have determined that it's leaking around the adjustment shaft (part the **** screws to). This "side" of the petcock has the rivets holding the faceplate on, so the intent is that this side is not "user serviceable".

Here's the petcock off the tank in all its glory:


I decided I'd file off the rivet heads and service this unit myself ... and here's what I'm up against for the rebuild:


The cleanup part is a no-brainer. I'm sure folks have performed this rebuild.
1) What about the odd-shaped o-ring in the perimeter of the housing?
2) For the 2 o-rings on the valve-adjuster's snout - anything special about these ... they appear to be "square" rather than round o-rings.
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you can get a repair kit, these are on uk ebay,

1993 honda cbr1000f fuel tap repair kit | eBay
repaired mine on my 1988 with one and had to put bolts through where it had been drilled out

 

Take your pick - US Ebay

 

None of those kits appear to have the correct parts to rebuild the **** side of the petcock. The vacuum operated valve side diaphragm and check are there but not the shaft seals and such in picture 2. Anyone used these kits?

 

And I always thought you kept an oring kit for all kinds of emergencies

There's always the "i don't have time for this ****" approach

 

Yea, I knew I could spend $100+USD, and bolt a new one on, but what's the fun in that?
I enjoy tinkering, and a bit of a challenge is fun. Plus, if I can get the parts for $5, I could use the other $95 for something else on the CBR or the ST !

I'll tinker with the CBR tomorrow - gotta go in the garage and install some Angel GTs on the ST ..
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True that man, keep us in the loop on how it goes.

 

Did you ever do anything with this? Im in the same boat with my 91. I bought a used petcock to get me through last season but its leaking now too.

 

I finally (mostly because I've been busy with other things) got this finished yesterday! The cost was an o-ring and two self-tapping screws - about $2 USD.

Took the oddly-shaped "o-ring" to the hardware store, opened up the o-ring drawer and looked for a close match - incredibly, found one that fit perfect ("lengthwise" and in diameter (cross-section wise). Also picked up two self-tapping screws, about 1/4" in length, not sure of the diameter - it would be the same diameter of the original hole size for the 2 rivets.

Drilled the rivet holes deep enough to accept the self-tapping screws.

I used Permatex Permashield Fuel Resistant gasket sealant in the gasket "groove" of the petcock's body - i used the sealer mostly to hold the new o-ring in place (as the groove is not round, but more of a rectangular shape). After the sealant set (about 5+ minutes), i put the outer plate in place and turned the 2 screws in place.

No leaks!

Link to images: 1993 CBR1000F - Petcock fix

 

Great job Caldercay,

Thanks for keeping us in the loop - and I've 'filed' your pictures for future reference

Cheers, SB