1980 KDX250 Petcock Replacement

Discussion specific to the various air-cooled KDX models sold in the USA
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worley_craig
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1980 KDX250 Petcock Replacement

Post by worley_craig »

Hi, I'm new the forum. Thanks for the add. Working on a 1980 KDX250 (dual shock). Does anyone know where I can get a replacement petcock? Or, one from a different bike that will work? It's the plastic type with no reserve and the tube is in the middle. Thanks.
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Re: 1980 KDX250 Petcock Replacement

Post by KDXGarage »

Welcome. Thanks for joining.

https://www.partzilla.com/catalog/kawas ... -kdx250-a1

Here's the other bikes it came on. You may be able to just buy an aftermarket petcock.

This Kawasaki 51023-4002 COCK ASSY,FUEL fits the following models and components:

Kawasaki Motorcycle 1979 KDX400 - KDX400-A1 Fuel Tank

Kawasaki Motorcycle 1980 KX250 - KX250-A6 Fuel Tank

Kawasaki Motorcycle 1981 KX420 - KX420-A2 Fuel Tank

Kawasaki Motorcycle 1980 KDX400 - KDX400-A2 Fuel Tank

Kawasaki Motorcycle 1980 KLX250 - KLX250-A2 Fuel Tank

Kawasaki Motorcycle 1979 KLX250 - KLX250-A1 Fuel Tank

Kawasaki Motorcycle 1981 KDX420 - KDX420-B1 Fuel Tank

Kawasaki Motorcycle 1980 KX420 - KX420-A1 Fuel Tank

Kawasaki Motorcycle 1980 KDX250 - KDX250-A1 Fuel Tank

Kawasaki Motorcycle 1981 KX250 - KX250-A7 Fuel Tank

Kawasaki Motorcycle 1982 KDX450 - KDX450-A1 Fuel Tank

Kawasaki Motorcycle 1981 KDX250 - KDX250-B1 FUEL TANK ('81KDX250-B1)

Kawasaki Motorcycle 1982 KDX250 - KDX250-B2 FUEL TANK ('81KDX250-B1)
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worley_craig
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Re: 1980 KDX250 Petcock Replacement

Post by worley_craig »

Thanks for the cross reference! I'll try searching aftermarket for those models as well. So far, all I've seen are ones with reserve or an offset single tube.
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Re: 1980 KDX250 Petcock Replacement

Post by KDXGarage »

Check for a MX version of aftermarket. I don't think they have a reserve.
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Re: 1980 KDX250 Petcock Replacement

Post by worley_craig »

Appreciate the suggestions. I found one from K&S. The bolt holes are correct, but the tube is offset to one side. https://www.denniskirk.com/k-and-s/fuel ... 186904.sku
I'm thinking about trying that one and breaking off the tube.
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Re: 1980 KDX250 Petcock Replacement

Post by KDXGarage »

Here's a dumb question.

Can one just slot out the current hole so a double intake petcock can be used?? It is a trail bike after all.

Is the stock one not rebuildable?
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Re: 1980 KDX250 Petcock Replacement

Post by worley_craig »

Good idea slotting out the hole in the tank. Would rather alter the petcock though if possible. It comes apart easy enough, but it is not a normal petcock design. It has a cone shaped plastic piece with a hole running through it. The lever is attached to the cone and a spring keeps it tight against the rubber lined inner body of the petcock. Never seen anything like it.
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Re: 1980 KDX250 Petcock Replacement

Post by Slick_Nick »

I had an old Suzuki that had a petcock like that. Even after rebuilding it time after time the damn thing would always start leaking again.
'00 KDX 220R
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Re: 1980 KDX250 Petcock Replacement

Post by KDXGarage »

WOW! That's even before my time. Yeah, replace instead of repair on that one.

How much of a gambler are you? Some deep in the heart of Chiner models on eBay for $10 shipped.

Here's a K&L for less.

https://www.ebay.com/itm/272322297276?h ... Sw-jhUB3zj



Here's one you may want to dig around to see about spacing. The earlier YZ petcock.

It says made in Japan.
https://www.ebay.com/itm/141549240144?e ... SwvclgAJxu

K&L version:
18-4173
by K&L Supply
Description


#KL-18-4173 Yamaha Petcock

OEM#2K5-24500-00

FITS

YZ80G/H/K/K/L/N (80-85)

YZ100E/F/G/H/J/K (78-83)

YZ125E/F/G/H/J/K/L/N (78-85)

YZ250D/E/F/G/H/J/K/L/N (77-85)

YZ400D/E/F (77-79)

YZ465G/H (80-81)

YZ490J/K/L/N (82-85)
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Re: 1980 KDX250 Petcock Replacement

Post by worley_craig »

Thanks for the links! I messaged the guy on eBay about the YZ petcock and the bolt spacing is the same, 34mm. I'm going to give that a try. Will let you know how it turns out.
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Re: 1980 KDX250 Petcock Replacement

Post by KDXGarage »

Cool! Please let us (and future readers) know how it works out.
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Re: 1980 KDX250 Petcock Replacement

Post by kjmarshall »

Did you ever find a usable replacement? I'm in the same situation, 1980 KLX 250, completely restored. Petcock leaks. I couldn't find replacement head light bulb either, not critical.
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Re: 1980 KDX250 Petcock Replacement

Post by worley_craig »

The eBay vintage YZ petcock above worked! I had to make the hole in the tank slightly larger. I also had a hard time keeping it from leaking. I figured out that the brass inserts protrude a little from the tank preventing the base from pressing down far enough on the o-ring. So I drilled an indent so that it could cinch up tighter. Plastic petcock didn't have that problem. Used Permatex Ultra Copper to seal up the bolts with some plastic washers. Not sure if that will hold up for gasoline though. Here are some pics. Thanks again for all of the suggestions.
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Re: 1980 KDX250 Petcock Replacement

Post by KDXGarage »

Cool. I am glad you git it working. Check Versachem. I bought some of their black "goop" that was gasoline tolerant to seal the airbox junctions.
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Re: 1980 KDX250 Petcock Replacement

Post by London_KX250A7 »

https://www.ebay.co.uk/itm/324810937297
Sorry a little late , mine failed on my '81 Kx250-A7
I used this to replace the plastic one .. fits exactly.
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