I read a post ( Fuel Off Valve
) by SRchop16 concerning the stock fuel valves on the Z400. In that post, NormalZ gave a link ( Bypass the vacuum fuel valve
) to another helpful post. I have a 2006 Z400 and a couple people towards the end of the post advised that this procedure doesn't work on 2006 models. I have had problems with my 2006 stock petcock and I wanted to thank all of you that helped out. I decided to take my petcock off to clean it and look for a way to make the mod work on 2006 models. I was able to come up with a solution to the problem. The mod is as follows.....
1- Remove the entire petcock from the gas tank.
2- Remove the "vacuum line cover" from the back of the petcock. Be careful, there's a spring inside
3- Pull out the "vacuum line plug" being careful not to damage the square rubber gasket (disregard the yellow circle in the picture)
4- Cut around the "vacuum line plug" to remove the square rubber gasket. You should have something that looks like this.
5- Keep the square rubber gasket and set aside the "vacuum line plug" and the "vacuum line spring", these won't be reinstalled.
6- Plug the small hole on the inside of the "vacuum line cover" and the exterior "vacuum line tube" to stop gas from leaking in to the vent line. Before I pluged the inside small hole......
After the plug.....
I used this stuff from Advance Auto Parts called "Quick Steel" ($4.68). It's an epoxy that sets up in 1 hour and is impervious to chemicals.
7- After the plugs that you made are dry, reassemble the "vacuum line cover" with the square rubber gasket. Don't reinstall the spring or the "vacuum line plug" that was cut off of the square rubber gasket.
8- Vacuum is no longer needed on any position on the fuel valve. The "on", "reserve" and "prime" positions are all free flowing now. Keep in mind that running with the fuel switch in the "prime" position is just like running in the "reserve" position.
9- After completing this mod, you will no longer have an "off" position. To solve this, I purchased an in-line fuel shut off valve from Tractor Supply ($6.94). It's made by Briggs and Stratton (part# 5091). To shut off all fuel flow to the carb, I simply turn this in-line valve to off.
I also hooked the rubber vacuum line back up to the back of the petcock and carb just to keep junk out of the carb. I also installed an in-line fuel filter and Tusk gas cap while I was at it.
Please excuse my dirty ride. I had to test this mod out. I have no leaks and no more vacuum problems. My ride runs good again.... and now I have "on", "reserve" and a real "off" position.