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Discussion Starter #1
My 2002 Katana will not turn and I am trying to figure out why.

I first drained the Gas tank and found a lot of rust in there. I cleaned out the tank and got it coated.

I would now like to check to see if the petcock was damaged. To do so, while the tank was removed, I put some gas in there (1 gallon) and set the petcock to PRI. I was expecting to see fuel fuel flow out of the petcock in this situation, but nothing happened.

Would I be correct in expecting the gas to flow out of the tank on its own when the petcock was set to PRI?
Whats the next step a new petcock or a rebuild kit?

Thanks.
 

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Did the petcock have a vac line attached to it, or just a fuel line? Does it have a 'prime' position? If so set it to prime and see if fuel flows.

Some bikes have a vaccum operated petcock that stop fuel flow when the engine is off (no vaccum). The prime position bypasses that. Not sure if your kat has this setup or not.
 

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I put some gas in there (1 gallon) and set the petcock to PRI.

Whats the next step a new petcock or a rebuild kit?
Next step would be removing it from the tank to see if the screen is just plugged up.
PLEASE tell me that the petcock was OUT when the tank was coated. :shock:

Your test and expected result was correct.
BUT.....if the engine is not turning, you are looking in the WRONG place.

Does it have a 'prime' position?
Time to check your glasses ?? :whistle:
 

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Discussion Starter #4
Thank you for your replies.Yes, I did remove the petcock before I coated it... I am not as dumb as I sound :)The filter is rust colored... it doesn't appear to have any blockages - my current thinking is that fine rust particles or varnished gas might have gone thru the filter and fouled up the petcock. Does that make sense?Also would I need a rebuild kit or a new petcock?I went online and looked for a petcock rebuild kit for my make/model/year but didn't find any kits for my year. The rebuild kits stopped being available for katanas after 1998 (if memory serves correctly). Does anyone know why, did Suzuki change something that made them non-servicable?Could I use a rebuild kit for a different Suzuki model I.e. is the petcock shared accross multiple Suzuki models of the same year?
 

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. I am not as dumb as I sound :)

Does anyone know why, did Suzuki change something that made them non-servicable?
Have a look at it. If it is STAKED or RIVETED together instead of assembled with screws that should give you a clue. :mrgreen:

You might want to try some carb cleaner carefully sprayed into all the holes (except the vacuum hose one) and then some low pressure compressed air. You might be able to remove a blockage that way.

Probably should wear goggles for that.......as the probability of "blow back" getting stuff into your eyes is highly likely !! :shock:

I think a new one would be best.....if you can get one.
A new one for my Honda was $75, IIRC.
 
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