Suzuki Fuel Petcock fix | Vinson 500 Eiger 400

If you're having trouble with the vacuum operated petcock on your Suzuki Vinson or Eiger check out this how to on how to fix the issue and get your 4 wheeler running like new!
Fuel Petcock - amzn.to/2OUeOkH
Carburetor w/o Vacuum line (Cannot be used with stock petcock) - amzn.to/35Eq8HE
Thank you guys for checking out these videos! As always I hope this video has helped you save some money and get the job done right with your own hands! To make the job even easier, here is a list of tools I use and love that will never let you down! Be sure to subscribe and I'll see you in the next one!
Milwaukee 3/8 impact - amzn.to/2JfJwBF
Milwaukee 3/8 ratchet - amzn.to/2LFX3Er
Milwaukee 1/2 impact - amzn.to/2L2YMUJ
Torque Wrench 1/4 - amzn.to/2XOCdsT
Torque Wrench 3/8 - amzn.to/2JequvB
Torque Wrench 1/2 - amzn.to/2LENfKW
Channel Locks - amzn.to/2xAa5el
BFH - amzn.to/2RYlJJ6
Socket Holders - amzn.to/2Lb5Kar

[@D45VR]

Grateful for this. I have the new one in hand ready to install. You might want to mention that when the Suzuki petcock fails you end up with fuel in the crankcase and an oil & filter change is necessary. I had 1/2 gallon pour out when I removed the oil dipstick.

[@BakersDIYLifestyle]

That's a good point. This one wasn't like that because it actually stopped flowing fuel period. It was so rusted and clogged there was no fixing it. Glad it helped!

[@jimpatterson1076]

It's worse yet.. ethanol in the gasoline attacks the adhesive on the stator magnets.

[@erictharp6095]

💯💯💯

[@aokbikelife5564]

This video and comment helped alot thanks dudes👌😎

[@Easy-vv4by]

Super glad you mentioned this. I took out my oil dipstick and gas just started pouring out of it!

[@franknapolitano9144]

With the OEM Petcock, for winter storage, the easy way is to turn the switch to OFF , start the engine until the engine quits. Start again to make sure the engine cannot fire anymore. This will purge all the fuel out of the carburetor . The PRIM on the OEM version is for a Cold engine start, it's designed to prime the engine with fuel.

[@bobbybobby2181]

this is the perfect video i needed... i have watched 33 videos and this was what i needed.. thanks alot...

[@BakersDIYLifestyle]

Awesome! I'm glad it helped you out!

[@rodneybailey5108]

Very glad you did this video because I was having trouble trying to figure out what the extra petcock fuel line was for thank you once again you should do more four wheeler videos

[@BakersDIYLifestyle]

Glad it helped! I just had the opportunity to work on this one so we got lucky!

[@davidcasey6181]

Yamaha Raptor 660 has the same dimensions as the Suzuki Eiger. I changed mine and it does great now.

[@BakersDIYLifestyle]

Awesome!

[@nicolec7290]

I have watched a million videos. I’m so glad you posted this. Ty. Big help

[@BakersDIYLifestyle]

Awesome, glad it helped!

[@tidefan8942]

Sounds exactly like the problem I am having with my Suzuki Vinson 500. Thanks for the info!

[@BakersDIYLifestyle]

Thanks for watching! Hope it will get your Vinson running too!

[@The907alaska]

I am working on this exact wheeler and that was the last thing that I was gonna replace! I'm glad I found this video. I have already been through the whole carb.

[@BakersDIYLifestyle]

Hopefully this will help fix your problem!

[@The907alaska]

Yea I hope so. It would run fine for about a minute or two then it would starve for fuel. So I'm thinking that fuel switch needs to be swapped

[@bobhix5888]

Can you run it on prime only ?

[@richardyates5321]

Really good video. I've got a 2007 500 Vinson. This was truly a helpful video. Thanks!

[@BakersDIYLifestyle]

Glad I could help out!!

[@tortillajackson7694]

Awesome video! This is my weekend project just got the part in today. Glad you went over the vacuum line because I wasn't sure what to do with it lol

[@BakersDIYLifestyle]

Hopefully you get yours going! Good luck!

[@TomJones-uf5sl]

I just bought a used Suzuki Eiger that won't run off idle. The fuel petcock is this stupid vacuum operated mess. This video clearly and cleanly shows exactly how to fix it. THANK YOU!

[@BakersDIYLifestyle]

Thanks! Glad it helped!

[@moosemcguirk1640]

ALWAYS clean out your tank when installing new filters, petcock, and carburetors. It’s where the problem usually lies.

[@BakersDIYLifestyle]

Yup they're pretty nasty after sitting for so long!

[@codycrabtree3684]

Thanks I put a jet kit in mine it makes a big difference

[@BakersDIYLifestyle]

I could believe it!

[@robbalinski1606]

I dont get why suzuki didnt incorporate a shut off into the petcock. Thanks for sharing the secret to fixing that problem, im replacing mine now.

[@BakersDIYLifestyle]

Good intentions, bad design! Glad it helped!

[@kennybelcher8240]

Great video!

[@BakersDIYLifestyle]

Hope it helped ya out!

[@erictharp6095]

Good video man,helped alot

[@BakersDIYLifestyle]

Glad it helped!

[@Jjhdezjr28]

Bro I'm so glad I seen this video, thank very much for the info. Going to order mine stuff now to get mine going asap.

[@BakersDIYLifestyle]

Awesome man! Hopefully yours will run like a champ too! Glad it helped!

[@Jjhdezjr28]

@@BakersDIYLifestyle got my parts today, and bro it's running like brand new. All I had to do was a full tune up, oil change, the new carb and petcock. Started rite up!! Minor idle adjustment but that was it.

[@BakersDIYLifestyle]

@@Jjhdezjr28 That's awesome! That's all I had to adjust on mine too and it ran like a champ!!!

[@robertamaral907]

Thanks alot for the tip,I replaced the circuit jet and it ran great,before I had to run half choke.Now after sitting for 6 months it won't stay running so I'm gonna try your trick and clean up the contacts of the ignition switch. Hope that works cause I got snow to plow soon

[@BakersDIYLifestyle]

Awesome, good luck!

[@mikekotarba5828]

Thank you for the video

[@BakersDIYLifestyle]

Glad it helped!

[@hairystag]

great video bro cheers

[@BakersDIYLifestyle]

Glad it helped!

[@muherd79]

Nice video glad I found it

[@BakersDIYLifestyle]

Hope it helped!

[@DBuss-om8sh]

Thanks for the video. Great explaination and very helpful. I've ordered a cheap one for only $13 on Amazon and mounted it on a Suzuki QuadMaster 500, year 2001. But I had to fit it backward and use a longer hose. Meaning the petcock's front is not visible, though it still accessible with finger. I needed to installed it backward because the gas line that starts from the bottom of the carburetor and needs to be fit on the new petcock output, was oriented towards the left side. So, I would had to twist to hose to bring to the right side of the petcock, which would had cause the hose to fold and blocked. Also, the muffler is very close and bringing the hose on the right side would probably cause burning/metling issues. I blocked the hose used for the primer line of the original petcock (the hose that goes to the top of the carburator and oriented right side) with a simple bolt and tie wrap.

[@BakersDIYLifestyle]

Awesome! I glad it helped you out!

[@waero1960]

Thanks mine has been sitting for 3 years because of this same problem. I've ordered the petcock but the carb said for manual trans so I'll have to find another. Hopefully get running again thank you for taking time to explain this.

[@BakersDIYLifestyle]

That carb should work. I don't see why the transmission would matter. Hope you get it going!

[@waero1960]

@@BakersDIYLifestyle appreciate it. I'm going to order that carb and plastic clips also mine have been missing some for years. Thank you for this video

[@royburchfield3854]

thanks for video, sure works

[@BakersDIYLifestyle]

Glad it helped!

[@theskiviking9007]

THANK YOU! Those Suzuki-isms are infuriating. They flood the cylinder. You can't turn the fuel off. They plug up. I'm so happy to get rid of it and get a real functional petcock valve! My brothers DR650 had one of these and it was $170.

[@BakersDIYLifestyle]

Heck yeah I'm glad it helped you out! It is just a terrible design all around

[@jeffreybowman1787]

Thank you brother thank you

[@BakersDIYLifestyle]

Hope it helped!

[@MattsShop]

Good tip!

[@BakersDIYLifestyle]

Hopefully this will help some people out!

[@MattsShop]

@@BakersDIYLifestyle Yea, it will

[@jennyh9062]

I’m new to these repairs, but trying to get it right. Why did you block off the vacuum line? What did you do with it? Doesn’t it need that? When I pulled my vacuum line off there was fuel dribbling out. Don’t know if that’s right? Great video, thanks.

[@GarnettM]

I've got the Quadmaster 500 made just before yours, I thought it was the petcock too, What I found out what it was is there's a filter on the needle seat of the carb remove the seat by taking off the screw holding it in on the bottom is a yellow filter with a E clip remove the clip throw it in the bush the machine problem is solved instantly runs like new, Mine left me in the bush I. Took it back the machanic couldn't find the problem, We'll I found it or walk home it never done it again.

[@jimpoletti1696]

fuel was probably being drawn thru the vacuum line and flooding the carb, that's what happens. its easy to test this. U fixed it anyway.

[@BakersDIYLifestyle]

Ran like a champ!

[@ernielemay2490]

Great info on the petcock retro fit from a yamaha. The suzuki petcock is a pain in the a @ss. Thank you for the part number.

[@BakersDIYLifestyle]

Glad it helped you out!

[@t.s.racing]

RESERVE, not reservoir. Hope that helps. Good video. In the future be sure to use a ETHANOL fuel conditioner or ETHANOL free fuel. It's worth the extra money in the long run, I guarantee it, good luck.

[@BakersDIYLifestyle]

It's not my four wheeler so I couldn't tell you what fuel he uses.

[@The_Warrior526]

I had mine in the shop for the last time a couple years ago. They had either not payed attention or left the throttle cable so tight that it was holding the butterfly open and rendering the idle adjustment screw useless. Then last year the pilot screw litterally fell out of the carb. I'm doing my own stuff now. (2003 Vinson 500 and 2000 KingQuad 300)

[@BakersDIYLifestyle]

Thats the best way to do it! There isn't a whole lot to the job and getting rid of all the Suzuki stuff just makes them run so much easier.

[@JRYDER13]

I own a Suzuki motorbike and it has the same exact fuel petcock, it is a pain in the back side as personally the petcock should be a more simple design with ON, OFF and RESERVE but nooooo!! 😬😬 Suzuki made a more complicated design than actually should be 😤😤 nice video 👍

[@BakersDIYLifestyle]

Hope it helped!

[@romi_3lk520]

Got a quad and I'm hoping mine is the same issue as this, I've got a leaking petcock so fingers crossed it runs properly when i change it

[@BakersDIYLifestyle]

Hopefully that's all it is!

[@gambietti]

Great video. I have a 94 quadrunner and I have gas in my oil. It runs surprisingly well but I think the petcock is clogged. It want to swap the prime petcock out for one with a off switch. I hope this yammi part fits!

[@BakersDIYLifestyle]

Hope it worked for ya!

[@kennethshook2564]

The Percocet is for a raptor 660

[@HectorMartinez-xl8ul]

Do you have a video on changing out the carburetor? I just bought my first used quad and it’s the same one in your video. Haven’t been able to ride it yet because it keeps stalling out.

[@BakersDIYLifestyle]

I don't but it's as easy as pulling off the 2 boots on each side, vacuum lines, and throttle cable then just putting it back on

[@partoflife6283]

So did you have two vacuum lines going to the petcock or just one and if you had to what did you do with the other one ?

[@BakersDIYLifestyle]

On the new carb you shouldn't have any lines. If you use the stock carb with the new peacock I believe there is only one that you have to plug.

[@t.s.racing]

Bud, before you crank it after a repair as that, loosen the float bowl drain screw and allow a few c.c. of fuel to run out or into a container. It will fire up instantly.

[@BakersDIYLifestyle]

The carburetor wasn't drained before I started so it wasn't empty when I tried to fire it. Also, if you watched till the end I said the carb had to be replaced anyway because it was as corroded as the petcock was. No fuel was going to make it through anyway.

[@lambda4931]

Good video. One question: if the diaphragm fails why doesn’t shifting it to pri solve the problem.

[@BakersDIYLifestyle]

Normally it would, but this one was so clogged up nothing would come out. The second issue is since there is no actual off, you can't drain the carb for winter storage or anything without completely draining the tank which can be a hassle in itself.

[@6burgert]

Did you replace with an oem carb or aftermarket? If it was aftermarket, what brand? Thanks.

[@BakersDIYLifestyle]

It was just a cheap off brand eBay one. It worked great though!

[@mrbigtuna240]

Having a hard time finding the Yamaha petcock on line anyone have a link please?

[@BakersDIYLifestyle]

It's in the description

[@tonysanchez5708]

I replaced fuel valve and carb with the ones you mentioned . I can’t seem to adjust the carb my four wheeler Boggs down and shuts off when I put it into drive. Would you happen to know what may be going on with it?

[@BakersDIYLifestyle]

There should be an air/fuel adjustment on the carb. It sounds like it could be a little to rich. I got lucky and didn't really need to change anything but the idle to get mine dialed in.

[@tonysanchez5708]

Thank You I’ll try to adjust the idle as well

[@goulashbrothers3063]

Would the quad idle normal if you put it on Prime while running?

[@BakersDIYLifestyle]

It wouldn't run at all

[@Officialzavala]

should the atv should run res or on?

[@BakersDIYLifestyle]

It should run on on. Res is the reserve setting to allow you to run a little bit longer if you happen to run out of fuel

[@andrewstroh9]

I could use some help. I swapped it exactly as mentioned and plugged the vacuum line. Now the atv won’t start. It’s getting fuel to the carb but can’t figure out why it won’t start. Any suggestions?

[@BakersDIYLifestyle]

I couldn't really tell you without being there to see it. Check your spark first and go from there.

[@taylorknott400]

Thats a Yamaha ttr50 petcock. I have both bikes and tried mine by chance. Seal from the ttr is also bad on mine though so didn't work.

[@Rameus]

Is the carb that you linked in the description the correct one you put back on the atv? You say it’s set up not for the stock petcock. So can you explain what the other hose/lines are on the carb you linked in your description?

[@BakersDIYLifestyle]

It is correct, but it doesn't use the stock vacuum style fuel petcock. You will need to change the petcock out with the one in the description as well in order to get fuel from the tank.

[@Rameus]

@@BakersDIYLifestyle I changed the pet cock to the one you suggested. Now my stock carb is wanting to run extremely high rpm. I closed off the vacuum line that was leading to the old petcock. Dont know what else to do but change the carb to a new one

[@Rameus]

@@BakersDIYLifestyle I ended up buying the carburator you linked. It runs fine now except it chokes up and backfires some when I put the breather filter on it.

[@vfpaintjobs]

Does the little black plastic piece where the fuel goes in the carburetor screw out ? My Fuel is blocked right there , can't even blow air through it .

[@BakersDIYLifestyle]

I'm not sure to be honest with you. Once I figured out mine needed replaced I didn't mess with much else on it. You might be able to soak it in carb cleaner, then use a pipe cleaner to get it out.

[@cbrewis]

I just took my carb apart I could not find a way to remove that elbow, I took a piece of wire and broke the blockage loose then cleaned and blew it out.

[@cbrewis]

My carb was so bad the jets were basically welded in place I couldn't get one loose even after soaking it in carb cleaner, I bought the one he recommended it's identical to the OEM.

[@rwj3373]

Okay, so I have a question, my Vinson 500 is running, but seems to have no power too it. Doesn’t seem to be running rough per se, but when you step on the throttle, it does t have the power that it should. I was looking around the carb and noticed that that vacuum hose is missing from the car to the fuel petcock, could this be the cause?

[@BakersDIYLifestyle]

Not sure but it's probably not helping

[@acbassin4726]

You ever figure out the problem. I have the same issue

[@cranebeg]

I've cleaned the carb on my similar ATV, a Suzuki Eiger. When I give it gas it goes no problem but as soon as I let go of the throttle it will not idle, even for a second. The tank only has a little fuel in it (fresh). If I put the dial of the petcock on "Pri"/primany fuel is released and that's how I emptied the old fuel. Was yours not doing that? Trying to decide if this petcock problem is my issue or not? Thank you in advance.

[@BakersDIYLifestyle]

The one I worked on was completely trashed. Everything was rusted and clogged shut

[@cranebeg]

@@BakersDIYLifestyle Thanks for your reply, decided to order a replacement petcock, still in transit 🤞

[@adamsquires1775]

Very tempted to go this route if I can’t get my oem carb going. The china carbs don’t have the vacuum line, and they’re also slightly too small so you have to rig them into your boots so really hoping to get the vacuum petcock working with the oem carb again. Years later, is there any issues running with a regular petcock vs vacuum?

[@BakersDIYLifestyle]

My China carb fit perfectly. You can always double check the size and make sure it matches too

[@BakersDIYLifestyle]

No issues what so ever

[@adamsquires1775]

@@BakersDIYLifestyle it’s the same size inside diameter, but the outside diameter is smaller and doesn’t seal up to my boots. Good to know you’ve had no issues running it like this

[@BakersDIYLifestyle]

Ahh, sounds like you need some duct tape then! Haha

[@adamsquires1775]

@@BakersDIYLifestyle 😂😂 I used some electrical tape, but I still want to try and get the old carb going again

[@randosmotovlogs91]

Gonna try this on my 01 Quadmaster 500, wish me luck haha. Every time I start the quad, it fires up, but when I touch the throttle it doesn't get fuel! XD

[@BakersDIYLifestyle]

Good luck!!

[@gen1canamoutlander705]

Will it run if you have the Percocet in the pri (prime position) ?

[@_-gh0st-_]

​@@gen1canamoutlander705 how do I prime a Percocet? Asking for a friend

[@marksteeves4506]

Anyone know if this would cause backfiring and hot exhaust pipe

[@BakersDIYLifestyle]

It could be running a little lean to make it do that. If it's running fine other than that I would just try adjusting the fuel mixture

[@SuperCyril2]

@@BakersDIYLifestyle check valve clearance

[@chrismelton765]

Can this cause the fourwheeler to bog?

[@BakersDIYLifestyle]

I'm sure it could if the petcock is limiting the flow of fuel to the carb. It may be something to check out.

[@klrinstinc6287]

Yamaha raptor 660.

[@ricardoreyes5513]

does anyone know if the petcock is the same for an 05 Suzuki LTZ400?

[@Saltydrew]

Did you end up finding out boss ? I need mine replaced

[@BakersDIYLifestyle]

I would assume they are pretty close if you have the same settings as this one

[@johnmorrison2093]

If you forget to turn the new non-vacuum fuel petcock off, your crankcase will fill with fuel within a week....ask me how I know.

[@BakersDIYLifestyle]

The carburetor float shouldn't allow fuel to flow past the bowl once it's full

[@caduceus33]

Can't the diaphragm be drilled or bypassed so the fuel will flow without vacuum applied?

[@BakersDIYLifestyle]

Yes it has a bypass but there is no actual off which makes it harder to empty the carb of fuel without draining the tank. This one was also so clogged up it would never work anyway

[@jsimm4587]

@@BakersDIYLifestyle I’m working on one of these now trying to see if the vacuum lines are where they should be . Not idling worth a hoot .

[@michealargyle1608]

I have an 03 Eiger that sat with a 1/2 tank of gas for about a year and a half. Draid the fuel (turpentine smell). Fresh fuel. Idles great but the minute you touch the idle it stalls. I'm sure it's the carb but I'm going to do

[@michealargyle1608]

This same thing as well

[@BakersDIYLifestyle]

The problem with those petcocks is you can't turn the fuel completely off to drain the carburetor when they sit. The carburetor on this one was completely rusted on the inside and couldn't be rebuilt because of it.

[@michealargyle1608]

Getting to it in the next few days. I'm hoping for the best. We'll see. Hoping for just plugged jets

[@bigohm306]

Micheal Argyle did you figure out the problem. I’m having the exact same issue. Idles great but can’t give it any throttle/move it

[@michealargyle1608]

@@bigohm306 I just got it started. The petcock needed to be replaced. The filters attached to the petcock are internal (inside the tank) and they broke down and plugged the petcock. I replaced it and the fuel line and added an online filter. But I rebuilt the carb. I used an AllBalls kit. My fuel was actually black (mold) so I took the same to the carwash.

[@franknapolitano9144]

If there is no Vacuum, what is controlling the opening and closing of the Fuel Diaphragm ? I think The "Prim" selection on the petcock is to help start the engine when it's cold. It Primes the Engine with fuel during a cold start. I don't think the "Prim" function is not intended to act as regular On position. the "On" position on my Suzuki Ozark is located at the 6 O' Clock Position and that is the regular position for riding.

[@BakersDIYLifestyle]

On the new petcock just the dial. On is on, off is off

[@franknapolitano9144]

@@BakersDIYLifestyle Where is the Vacuum to operate the diaphragm if the Vacuum line is removed ? How does the Diaphragm operate to control the fuel flow with no Vacuum ??

[@BakersDIYLifestyle]

The carburetor controls it's own flow with the float in the bowl. It doesn't rely on vacuum to run at that point just like any other carb.

[@franknapolitano9144]

@@BakersDIYLifestyle ... I thought the purpose of the Vacuum line was to suck in the outer Diaphragm which, in turn, pushes out the inner rubber valve assembly that allows for fuel to flow to the Carb. ? There is a spring in between the outer Diaphragm and the inner rubber valve assembly. However I do like the simplicity of the Yamaha Petcock. I will give it a try and see if it will work on my Suzuki Ozark 250.!

[@39knights]

Next time just put the bike up on it's side; not all the way but put an old car tire on the ground and tip it up and let it rest on it. Won't hurt and puts all the fuel in the tank away from the petcock and makes it much easier to work on.

[@BakersDIYLifestyle]

I'm hoping there isn't a next time on that one! Lol great tip tho!

[@damonhowell7401]

Very good reply thanks for the heads up on Leon lining the folder on its side

[@anthonycastro6973]

Did you get the same carburetor with the vacuum line and where did you find it?

[@BakersDIYLifestyle]

The new carburetor does not have the vacuum line because you don't need it with the new petcock. The one I used came off Ebay for about $180. A new Suzuki one was around $800

[@BakersDIYLifestyle]

I just added links to the parts I used in the description as well!

[@michaelcoleman611]

Try lifting side of fourwheeler with petcock up so gas goes other side of tank an won't run out if don't drain tank.

[@BakersDIYLifestyle]

That definitely would have been smarter!

[@ernesthurt662]

2000

[@86250rrippin]

RES means reserve ..:)

[@BakersDIYLifestyle]

Yes it does!

[@triplecranks9540]

I picked up on that too. He kept referring to it as reservoir instead of reserve.

[@BakersDIYLifestyle]

My bad!! I didn't even realize it when I filmed it lol

[@paulmanning1671]

22 LR ammo is perfect for plugging your vacuum line.

[@BakersDIYLifestyle]

I'm a .223 guy myself 🤙

[@gen1canamoutlander705]

My Eiger has a similar problem runs fine in the pri (prime) position but when I put it in on it runs with what’s in the bowl and then quits.

[@BakersDIYLifestyle]

Hopefully a petcock will fix it!

[@gen1canamoutlander705]

@@BakersDIYLifestyle for some reason it started working fine after I rolled my bike

[@BakersDIYLifestyle]

Well that's one way to do it haha

[@chrismelton765]

Had cleaned my carb out and everything still bogs

[@BakersDIYLifestyle]

The carb could still need adjusted or there could be something wrong with a jet that didn't get caught. Hope you get it running!

[@fourbyfourer]

The "Res" does not stand for "reservoir", it stands for "Reserve".

[@BakersDIYLifestyle]

Yes you're not the only one who pointed out my mistake thank you

[@MagicRoosterBluesBand]

Sounds like my problem with my Suzuki Ozark 250.

[@BakersDIYLifestyle]

It's really just a terrible design overall

[@tylerpalmer6615]

Removing the gas tank would have saved you the mess ;)

[@BakersDIYLifestyle]

Probably so but that's just not as fun haha

[@codyweien4513]

It's RESERVE, prime, on. Good video tho

[@BakersDIYLifestyle]

Thank you again for pointing out the same thing 10 other people have!

[@phillipmarsh73]

Where the spark plug at

[@BakersDIYLifestyle]

Front left right behind the petcock

[@phillipmarsh73]

NoBSAutoRehab I don’t see it

[@ricksmith5019]

RES is reserve not reservoir

[@BakersDIYLifestyle]

Yes I know..... sorry!

[@anymouse1073]

Reserve! Not reservoir.

[@BakersDIYLifestyle]

Thanks!