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So I got my bike back from the shop about a week ago to fix an electrical issue, and I've noticed that the bike seems to have developed a fairly severe gas leak. Losing about a drop of gas every 30 seconds to 2 minutes. It appears to be coming from either above the petcock or from the knob itself.

I found and ordered a new petcock for the bike and it should be here either this weekend of early next week. What considerations are important when I'm putting in the new part? Are there any little kinks that I may find myself in?

What are the steps to follow when removing the petcock? Do I need to remove the entire tank to get to it, or should it be easy enough to work around the engine and such? Do I need anything other than the petcock? Do I simply remove the old petcock and screw this one into place?

This is the part I ordered: Amazon.com: Fuel Gas Petcock Valve Switch For HONDA CBR900RR 1996 1997 1998 1999: Automotive
 

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It will be just as easy to remove the tank, as it's only 3 bolts and the fuel line will need to be disconnected anyway. Once the fuel line, 2 breather tubes, and 3 bolts are out the tank will lift straight off. Try and have it empty of fuel before hand, but if there is still some in there be careful for it not dumping out when you take the old petcock out. Put the tank upside down to work on it, it will be way easier. You should definitely have it emptied befor you turn it upside down. :)

You will need a fairly large wrench (30mm I think) or an adjustable wrench to loosen/tighten the nut on the valve. Once it's off, there is a plastic filter screen that usually gets stuck inside the tank. It usually gets ruined when you try to remove it. Your new valve "should" come with a new one and a new o-ring as well.

Stuff the new assembly in there, orientate it properly to access the valve knob, tighten the nut and check for leaks. Then away you go. Should be pretty simple.
 

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about a week ago



But anyways... back on topic.
Glad you posted this since ill be doing the same with my 99 blade. But before just out right go buying a petcock I'm going to take mine off and apart and determine what may need to be done or replaced. Hopefully ill be able to source it locally if needed.

Also, heres a video i watched to kinda prep myself. What youre doing should be easier and less than what this guy did.

@IanDoohan

My tank isn't full but it does have some gas on it. Will it really be an issue if it's just flipped? What are the chances it will leak?
 

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The fuel cap isn't completely water/fuel tight once upside down. I would imagine fuel can leak through the internals and out the keyhole. It may also leak out the outer portion of the cap too. Just drain it into a clean container/bucket and reuse it afterwards.
 
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