Honda GL500i leaky petcock, July 10, 2021

So I was sitting on the bike back on June 19 & feeling that satisfied feeling that you’ve fixed just about everything and you’re ready to roll, then something else happens. The something else was that as I sat on the bike with it running, on centerstand of course, I look down and there’s a puddle of something oozing its way towards my electric bike & charger. Not knowing what this is I turn off the bike, get down and stick my finger in this puddle. Not being careful I also use my left arm instead of my right and promptly burn my arm on the exhaust pipe. duh. Hot pipe = Hot, and Hot is hotter than the Arizona sun …

Turns out the puddle is gasoline … hmm … why is there gas coming out the bottom of my engine somehwere … ? Time to call it a day & look again next week … so, that was fast. Here we are next week , July 26, 2021. Sunny day, full of oxygen and carbon dioxide in the air, wonderful morning. Start the bike up again, wait for the gas to come out hte bottom, figure out it is coming from a small diameter black tube, trace it back to the … petcock? Really? What the heck? okay, there’s an overflow on the petcock. What’s it for? When does it leak? It is there to relieve gas build up when the diaphragm in the petcock ruptures …. great.

So … turns out the diaphragm is not flat, or spherical, it is round with a knob on each side, has a metal section in the middle, and another rubber side with a knob in the middle. See pictures below. Amazon/Ebay/the entire internet do not have rebuild kits specifically listing this model so what do I do? I spend $34 buying a new compatible full petcock. Not a bad idea as once i went to install it i found out the vacuum, relief, and output all face the wrong way compared to the current install. What good news is there? Well, the replacement petcock diaphragm section is the same as the existing one from 1981 … so i take it off and put it on the original … and it fits like a glove. Problem solved, now the inputs and output face the proper direction and i have a spare section so i can peruse the internet for similar looking pieces going forwards.

Small gas leak from overflow tube at petcock
Bare petcock diaphragm parts.
old and new petcock next to each other. went with the old on the right with the diaphragm section on the left
and the installed hybrid petcock … it’s alive, it’s alive, ha ha ha ha …