Petcock Rebuild III 86-89 TRX350 - Honda ATV Forum
Honda FourTrax Discussions for the FourTrax Rincon, Foreman, Rancher, Recon

 12Likes
Reply
 
LinkBack Thread Tools Display Modes
post #1 of 14 (permalink) Old 07-08-2018, 03:55 PM Thread Starter
Gold Supporting Member
Supporting Member
 
Goober's Avatar
 
Join Date: Jan 2014
Posts: 3,011
Liked: 1335 times
Petcock Rebuild III 86-89 TRX350

Update of petcock rebuild procedure 86-89 TRX350; this is my seventh one—sofar I have only found one oddball with a lever that was slightly larger diameter.

You can buy a set of seals on fleabay that includes the 4-hole packing, an oring lever seal, 2 tank seals and 2 screws. It will help greatly to use a small jewelers drill press and a set of oring probes.

Two things about this kit is that 1) I can’t find the right tap for the kit screws (3mm x 0.5mm?), so I use 6x32x3/8” screws; 2) the original petcock lever uses a quad seal instead of an oring–I haven’t followed up on the right sized quad seal because the oring fits.

I use a wooden jig to hold the petcock (with screws/nuts) while I’m drilling–it gets hot and this will help you concentrate on bit placement. I started with a #45—fits perfectly in the rivet head dimple–use cutting oil and small depths so you don’t weld the bit to the rivet. Drill all the way thru the ear of the petcock backshell.

Next use a #36 bit to enlarge the hole for the 6mmx32 tap. Take short strokes and plenty of cutting oil; back out the tap often to clear the shavings. Lastly cut the head off the rivets using a #20 bit and very shallow stroke–you want to leave a bit of the old rivet bodies as alignment pins. You can pop off the top shell cover with a flathead screwdriver–be careful not to damage the fiber shim underneath.

Replace all the seals, lubing with a petroleum compatible grease. Reassemble by seating the 4-hole packing on the backshell, then lever with seal, compression spring, fiber shim and topshell. Run the screws down firmly, but not too tight or will be hard to operate lever–no gasket sealer is needed. Took me an hour.

Oh that little piece? A rivet head.
Attached Thumbnails
Click image for larger version

Name:	F1BE4AA8-3ACF-4FE1-AAA5-666823E166B7.jpeg
Views:	58
Size:	770.5 KB
ID:	127226   Click image for larger version

Name:	171A975D-6482-4382-A11C-455D1F4440A3.jpeg
Views:	56
Size:	599.7 KB
ID:	127228   Click image for larger version

Name:	0AC17F3A-B37D-4900-8400-6517C7F3A974.jpeg
Views:	57
Size:	538.6 KB
ID:	127230   Click image for larger version

Name:	37C72A36-8C2B-4DDA-B022-49FC32766AA3.jpeg
Views:	67
Size:	766.4 KB
ID:	127232   Click image for larger version

Name:	B3083350-497B-47F8-8D8E-AF3C01FA4E28.jpeg
Views:	55
Size:	710.3 KB
ID:	127234  


_________________
Click link for Honda service manuals! 👀 see, right here👇🏻 Click it 👇🏻
https://drive.google.com/drive/mobil...13&direction=a

https://www.rockymountainatvmc.com/oem-parts

https://www.partzilla.com/catalog/honda
__________________

Last edited by Goober; 11-01-2018 at 07:20 AM.
Goober is offline  
Sponsored Links
Advertisement
 
post #2 of 14 (permalink) Old 07-08-2018, 10:41 PM
Super Moderator
Supporting Member
 
retro's Avatar
 
Join Date: Mar 2017
Location: Ojibwe Gichigami
Posts: 5,549
Liked: 2976 times
This repair procedure is adaptable to most other Honda petcocks as well. Great writeup (and pics!) Goober, this will be a very useful sticky. Thanks!
Goober likes this.


retro is offline  
post #3 of 14 (permalink) Old 07-09-2018, 12:25 AM Thread Starter
Gold Supporting Member
Supporting Member
 
Goober's Avatar
 
Join Date: Jan 2014
Posts: 3,011
Liked: 1335 times
Thanks Retro followed your guidance from last time–I did all the drilling and brushed the shavings away before removing the top shell. This keeps shavings out of the petcock body–important because a small piece of shaving will cut the seals–and there’s a LOT of shavings with this job!!

I use an old Grobet Vigor DR-615 jewelers drill press, bought at auction, and a set of oring probes bought on fleabay for $12.

I saved all my parts to later compare sizes and condition. Only one petcock I had leaked from the lever seal; the others wouldn’t shut off the fuel–seems common failure was caused by rust particles cutting the packing seal.
Attached Thumbnails
Click image for larger version

Name:	E27D0DCE-E079-437C-8AC3-89B5CD1315FB.png
Views:	50
Size:	1.59 MB
ID:	127236   Click image for larger version

Name:	16BD61C8-4B46-4A96-896E-C508548A86E8.jpeg
Views:	45
Size:	3.23 MB
ID:	127238   Click image for larger version

Name:	EA5883D4-4A17-4E0E-BC91-E856E5497549.jpeg
Views:	46
Size:	2.21 MB
ID:	127240  
retro likes this.

_________________
Click link for Honda service manuals! 👀 see, right here👇🏻 Click it 👇🏻
https://drive.google.com/drive/mobil...13&direction=a

https://www.rockymountainatvmc.com/oem-parts

https://www.partzilla.com/catalog/honda
__________________
Goober is offline  
Sponsored Links
Advertisement
 
post #4 of 14 (permalink) Old 07-09-2018, 09:12 AM
Senior Member
 
dr. feelgood's Avatar
 
Join Date: Jun 2010
Location: N Illinois
Posts: 1,373
Liked: 211 times
Garage
Surprising that Honda riveted these instead of using small screws. The round gasket goes bad often and most OEMs use them. Luckily most newer petcocks don't use rivets.

Rob
Goober likes this.

I've owned many Hondas over the years, with 2, 3 and 4 wheels.
I’m always buying and selling projects and parts
dr. feelgood is offline  
post #5 of 14 (permalink) Old 10-25-2018, 01:42 AM
Gold Supporting Member
Supporting Member
 
LedFTed's Avatar
 
Join Date: Jan 2016
Location: high grove, ky
Posts: 2,257
Liked: 444 times
just seen this an payed attention. it should be a sticky. good job
Goober likes this.

clymers manual,service manual..
"what a good giff, the good lord gee us,not to see ourselves,as others see us"
hard to talk to morons. even more so, when related..
"ya should get 3 people ta smile or laugh every day" all will feel better
"sometimes, when drinking 5 or 6 bud's, nipping JB, Jim Beam, cinnamon in between, i start thinking sideways,,i have too though, ta match the way i walk" ed
"those that dont study history, are doomed to repeat it"
"I HOPE i aint wrote nutting else stupid" "funniest comedy dont need curse words" "teach how to think, not what to" ed
"Genius can be measured,not stupid" Albert Einstein
"when you get to old to learn, then what good are you" ed
i havent done friends list,if i do, R the rest not friends?
2000 450es TRX
2 grass hog 4x4s
sum humor adds up
LedFTed is offline  
post #6 of 14 (permalink) Old 02-02-2019, 10:05 PM Thread Starter
Gold Supporting Member
Supporting Member
 
Goober's Avatar
 
Join Date: Jan 2014
Posts: 3,011
Liked: 1335 times
Quote:
Originally Posted by LedFTed View Post
just seen this an payed attention. it should be a sticky. good job
Here ya go Ted is your petcock leaking?
You have a pic of it?

_________________
Click link for Honda service manuals! 👀 see, right here👇🏻 Click it 👇🏻
https://drive.google.com/drive/mobil...13&direction=a

https://www.rockymountainatvmc.com/oem-parts

https://www.partzilla.com/catalog/honda
__________________
Goober is offline  
post #7 of 14 (permalink) Old 02-02-2019, 10:48 PM
Gold Supporting Member
Supporting Member
 
LedFTed's Avatar
 
Join Date: Jan 2016
Location: high grove, ky
Posts: 2,257
Liked: 444 times
Quote:
Originally Posted by Goober View Post
Quote:
Originally Posted by LedFTed View Post
just seen this an payed attention. it should be a sticky. good job
Here ya go Ted is your petcock leaking?
You have a pic of it?
i just got a new one from honda east, bout 3 yrs ago. while gas tank was sitting outside this year, it started leaking. it was hard for me to believe it would go bad in that short time. i will show a picture of it, and the old one, in a while. i had got a china shutoff for the gas line from tractor supply, for the old gas shutoff. it was junk. did i say some things made in china are junk?
i had removed the gas tank prior to winter setting in, this year so i dont think any gas made it to the oil, but i will check, maybe change it anyway. stuff from japan aint what it used too be, unless you remember the 60's, maybe some of the 70's.. them toy's they made in the 60's, plastic junk.
well, i said enough for now. i'll get back with the pictures.. thanks
the leak is coming out the gas line.

clymers manual,service manual..
"what a good giff, the good lord gee us,not to see ourselves,as others see us"
hard to talk to morons. even more so, when related..
"ya should get 3 people ta smile or laugh every day" all will feel better
"sometimes, when drinking 5 or 6 bud's, nipping JB, Jim Beam, cinnamon in between, i start thinking sideways,,i have too though, ta match the way i walk" ed
"those that dont study history, are doomed to repeat it"
"I HOPE i aint wrote nutting else stupid" "funniest comedy dont need curse words" "teach how to think, not what to" ed
"Genius can be measured,not stupid" Albert Einstein
"when you get to old to learn, then what good are you" ed
i havent done friends list,if i do, R the rest not friends?
2000 450es TRX
2 grass hog 4x4s
sum humor adds up

Last edited by LedFTed; 02-02-2019 at 10:52 PM.
LedFTed is offline  
post #8 of 14 (permalink) Old 05-27-2019, 06:02 AM Thread Starter
Gold Supporting Member
Supporting Member
 
Goober's Avatar
 
Join Date: Jan 2014
Posts: 3,011
Liked: 1335 times
A pic from the time i did four in a row. This allowed me to refine the method.
Used a homemade jig to hold the petcock.
Select a pilot bit small enough to fit inside the rivet dimple (55). Use plenty of oil a drill very slowly or the bit will weld to the rivet. You want chips not ribbons of drillings.
Then use the bit intended for the 6mm x 32 tap (29).
Use a big bit to cut off the rivet head. This time i used a 16. If bit is too small—it cuts the rivet head and pulls the top shell up.
Tap with plenty of oil and back out the tap as soon as it starts to bind. About 1/3 in and again at 2/3s—clean the shavings off with a brass brush.
This will allow you to brush all the drillings off the petcock before you open it up with a thin blade screwdriver.
Soak the metal parts in carb cleaner and remove bits of seal with a bamboo scraper
I used a film of bearing grease on the seals so they don’t drag on the cleaned metal.
Attached Thumbnails
Click image for larger version

Name:	965AE978-C1ED-443D-89F3-F0B2ED3730FB.jpeg
Views:	15
Size:	2.19 MB
ID:	136846   Click image for larger version

Name:	9D815CE6-C9F4-4B80-8A22-AF47CF8A648F.jpeg
Views:	12
Size:	2.87 MB
ID:	136848   Click image for larger version

Name:	5A6B4005-57AC-4605-AC71-0A721329A18B.jpeg
Views:	15
Size:	1.29 MB
ID:	136850  
retro likes this.

_________________
Click link for Honda service manuals! 👀 see, right here👇🏻 Click it 👇🏻
https://drive.google.com/drive/mobil...13&direction=a

https://www.rockymountainatvmc.com/oem-parts

https://www.partzilla.com/catalog/honda
__________________
Goober is offline  
post #9 of 14 (permalink) Old 05-27-2019, 09:04 PM
Gold Supporting Member
Supporting Member
 
LedFTed's Avatar
 
Join Date: Jan 2016
Location: high grove, ky
Posts: 2,257
Liked: 444 times
sorry

i subscribed to it this time, so i dont have to keep pestering you. thanks. still got to put up pictures. it's the same thing though, just i got a 450es2000. i had to hand drill mine out. i stayed close, within perimeters. i'll need some fine thread screws, nuts, washers, and lock washer's. not much sidewall, on the housing. woof!!! ->[hey, long island]
Goober likes this.

clymers manual,service manual..
"what a good giff, the good lord gee us,not to see ourselves,as others see us"
hard to talk to morons. even more so, when related..
"ya should get 3 people ta smile or laugh every day" all will feel better
"sometimes, when drinking 5 or 6 bud's, nipping JB, Jim Beam, cinnamon in between, i start thinking sideways,,i have too though, ta match the way i walk" ed
"those that dont study history, are doomed to repeat it"
"I HOPE i aint wrote nutting else stupid" "funniest comedy dont need curse words" "teach how to think, not what to" ed
"Genius can be measured,not stupid" Albert Einstein
"when you get to old to learn, then what good are you" ed
i havent done friends list,if i do, R the rest not friends?
2000 450es TRX
2 grass hog 4x4s
sum humor adds up

Last edited by LedFTed; 05-27-2019 at 09:17 PM.
LedFTed is offline  
post #10 of 14 (permalink) Old 05-29-2019, 06:34 AM Thread Starter
Gold Supporting Member
Supporting Member
 
Goober's Avatar
 
Join Date: Jan 2014
Posts: 3,011
Liked: 1335 times
Quote:
Originally Posted by LedFTed View Post
i subscribed to it this time, so i dont have to keep pestering you. thanks. still got to put up pictures. it's the same thing though, just i got a 450es2000. i had to hand drill mine out. i stayed close, within perimeters. i'll need some fine thread screws, nuts, washers, and lock washer's. not much sidewall, on the housing. woof!!! ->[hey, long island]
Good job Ted heck yeah let’s see some pics. You mentioned that petcock was only 3 years old?

_________________
Click link for Honda service manuals! 👀 see, right here👇🏻 Click it 👇🏻
https://drive.google.com/drive/mobil...13&direction=a

https://www.rockymountainatvmc.com/oem-parts

https://www.partzilla.com/catalog/honda
__________________
Goober is offline  
Reply

  Lower Navigation
Go Back   Honda ATV Forum > Honda Model Specific Discussions > Honda FourTrax

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Honda ATV Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in













Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome