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Old 02-19-2007, 01:40 AM   #1 (permalink)
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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.



valve open....


valve closed...


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.
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13 tooth front sprocket; pull choke; petcock mod; clamp on K&N air filter with outerwear and lid removed; removed screen from intake tube; Yoshimura RS-3 Full Exhaust; Dyno-Jet kit currently running a 160 main/needle-3rd clip/25 pilot/fuel screw 2.25 out/elevation 650 ft; Motion Pro Terminator clutch cable.

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Old 02-19-2007, 07:02 AM   #2 (permalink)
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Great write up but for all your work and the money it cost you you could of got a new petcock for 20 bucks.I read that a raptor-660 works.I used an old petcock off an old oversized kawi tank that I have.
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Old 02-20-2007, 01:48 AM   #3 (permalink)
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It takes about a half hour to do the mod (not including the dry time) and costs $12. Went to McDonald's with all the money I saved.
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2006 LTZ400

PERFORMANCE
13 tooth front sprocket; pull choke; petcock mod; clamp on K&N air filter with outerwear and lid removed; removed screen from intake tube; Yoshimura RS-3 Full Exhaust; Dyno-Jet kit currently running a 160 main/needle-3rd clip/25 pilot/fuel screw 2.25 out/elevation 650 ft; Motion Pro Terminator clutch cable.

REINFORCEMENTS
Tusk nerf bars; Tusk Typhoon rear rotor; Tusk billet gas cap; Tusk parking brake block off; G-Force axle; Armadillo full skid plate; Armadillo A-arm guards; Armadillo swing arm guard; Pro Armor link guard; Pro Armor Dominator bumper; Fuel ATV cooler rack; Pro Design case saver; PowerMadd hand guards; front & rear shock covers; Works Connection frame guards; Garmin Etrex GPS; Hard Looks custom warning labels; IMS 4 gallon fuel tank; Stainless steel rear brake line.
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Old 02-20-2007, 12:33 PM   #4 (permalink)
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Pinned... Good write-up, explanations, and pics. Good job!
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Old 02-20-2007, 12:35 PM   #5 (permalink)
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Other than the loss of reserve, what other advantage is there to just running on prime?

z
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Old 02-20-2007, 01:33 PM   #6 (permalink)
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Some find that the fuel flow in the "ON" position is inadequate or inconsistent. Running it on "Prime" is the same as "on" on a standard petcock.
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Old 02-20-2007, 09:16 PM   #7 (permalink)
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QUOTE (drzoo2 @ Feb 20 2007, 10:35 AM)
Quote:
Other than the loss of reserve, what other advantage is there to just running on prime?

z[/b]
You have to run on prime if you get the FCR carb. Most popular carb option.
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Old 02-20-2007, 10:19 PM   #8 (permalink)
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I havent tried it (yet) but I have heard that a 660 raptor fuel petcock will fit it.
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Old 02-23-2007, 08:18 PM   #9 (permalink)
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i have a stock carb and i noticed my bike runs like sht on the ON part, doesnt get enough fuel...i just turn it on PRI and it hasnt failed yet....



in the manuel it says to never leave the bike on the PRI position when not running, i've forgot to put it back in the ON position a couple times and left it for about a week and nothing has happened, bike started up fine...



is leaving it on PRI actually that harmful to my quad?
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Old 02-23-2007, 09:00 PM   #10 (permalink)
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QUOTE (06DVX400 @ Feb 23 2007, 08:18 PM)
Quote:
i have a stock carb and i noticed my bike runs like sht on the ON part, doesnt get enough fuel...i just turn it on PRI and it hasnt failed yet....
in the manuel it says to never leave the bike on the PRI position when not running, i've forgot to put it back in the ON position a couple times and left it for about a week and nothing has happened, bike started up fine...
is leaving it on PRI actually that harmful to my quad?[/b]

If the needle valve is good in your carburetor, then you will never have a problem with the pri position.
Pri is reserve that does not shut off when the engine does. It is manual reserve.
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Old 03-02-2007, 09:32 PM   #11 (permalink)
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so what is the real benefit to this mod?? just curious. thanks
dave
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Old 06-06-2007, 06:16 PM   #12 (permalink)
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QUOTE (mrgixxer6 @ Mar 2 2007, 08:32 PM)
Quote:
so what is the real benefit to this mod?? just curious. thanks
dave[/b]

running in the prime is just like running in reserve so when your out there is nothing left but if you mod it you can run an fcr carb in the on position and still have the reserve so you dont have to walk back to the truck to get your gas can. and trust me i've had to do it and it sucks.
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Old 09-05-2007, 04:34 PM   #13 (permalink)
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Search, there are several folks on here who use raptor petcocks.
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Old 01-15-2008, 06:25 PM   #14 (permalink)
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I had a problem with the raptor petcock. The selector was rightup against the frame so I couldn't turn it. I just did a mod similiar to this and plugged off the vacuum hole. I run the FCR thats why I had to do this.
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Old 07-31-2008, 01:33 PM   #15 (permalink)
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MYZ, what kind of problems were you having with your 06 and the petcock?? I have a 06, and it doesn't seem to want to start. I'm interested in knowing what your problems were......

Thanks!
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