Is it Possible to Divert OEM Parts for Other Models? Challenging to Overhaul the Fuel Cock

OD01b.jpg How to

The recessed area is pushed out with a stick from the inside of the tank, and the entire tank is polished to develop a base for the re-chrome plating process. After the sheet metal treatment was completed, the gasoline tank was asked to be re-chromed and after the re-chroming process was completed, it was painted with the manufacturer's stock approximate color. The completed gas tank was fitted with the YAMAHA emblem and knee grip rubbers, but unfortunately, the commonly known "Rincon" gasket that goes inside the fuel cock was not available. So are there any parts for other models that I can use?

Full restoration to achieve the finest finish.

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A full restoration is a process of taking a beat-up motorcycle and bringing it back to a beautiful and well-running condition. This motorcycle is a 1962 Yamaha YA5 Deluxe. All Yamaha 2-stroke models developed before 1963 were of the "mixed gasoline" type.

Gasket for Suzuki with matching port dimensions

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The genuine Yamaha gasket commonly known as "Rincon" is a part that was discontinued a long time ago. The Yamaha YDS fuel cock, which had a similar body design, also used the same specification Rincon gasket. It was difficult to find a gasket that matched, but we were able to find a gasket that was slightly smaller in outside diameter but was "for Suzuki" (for the early Hustler 250 in the left photo?). The gasket on the right is a genuine Yamaha gasket. The gasket on the right is a genuine Yamaha part from that time. The gasket for Suzuki has been used for several years, but there is no fuel leak at all. This is an example of the success of using the OEM parts for other models.

Other functional components are also self-made

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I was able to get several different thicknesses of gasoline resistant rubber sheets. Buy a brass net and cut it with precision scissors. The brass net is sandwiched between the gasket and the brass net, and the gasket is cut into ring shape. To prevent the gasket from breaking, rubber grease was applied thinly when tightening the bowl. The feeling of tightening the gasket is very smooth.

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The brass pipe that plugs into the gas tank has to incorporate a brass net, bar-shaped cover to keep out debris. The brass net rod which had turned black with necho was revived beautifully after soaking it in carburetor cleaner. If there is a broken part, it can be repaired with solder, so let's practice it. After completion, install it in the tank, fill it with gasoline and check if it functions correctly as the lever is switched. This net rod can be made by yourself by cutting brass net, rounding it, and fixing it with solder.

All inner parts are handmade parts

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A full restoration of an old motorcycle can be a challenge depending on the parts you are looking for. If you don't want to look for genuine parts, you can use your own parts like this. As long as there is no malfunction such as gas leak, the self-made parts should be enough. If you find the genuine parts later, you can keep them as spare parts.

After assembly is complete, check for gas leaks

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After installing the inner parts to the fuel cock body, whether it is a homemade part or a genuine part, let the gasoline flow into the tank and check the lever positions of ON, OFF, and RES. Does it work well without any gas leak? The most important thing is to check it with real gasoline. Soak it for a while, and take your time to make sure that the swelling caused by the gasoline does not make the lever switching heavy and hard.

POINT
  • Point 1: There are some cases where it is possible to use genuine parts for other models even if the parts are no longer sold, and in such cases, it is basic to match the actual parts.
  • Point 2: It is possible to use self-made parts instead of OEM parts that are no longer sold. Don't give up and try to make your own!
  • Point 3: When fuel system parts are repaired, be sure to check the function for gasoline!

 

There are a surprising number of old motorcycles that have gasoline seeping or leaking from the fuel cock. What is the cause of the leaking fuel? You need to find out and fix it at the same time. Rarely do we hear about problems such as a motorcycle catching on fire but the majority of cases are caused by gasoline leaks. Many of the old motorcycles, no matter what the ignition type (battery ignition), often use points to control the timing. In the case of points control, the points and the capacitor are used at the same time, and at the moment the points are opened, the electricity stored in the capacitor flows to the primary side of the ignition coil, which is then boosted and flows to the secondary side, where it flows to the spark plug through the plug cord and sparks the electrodes. In the process of this ignition system, small sparks fly at the moment the points open, and in a surprisingly large number of cases, these sparks ignite gasoline.

In the late 70's, battery ignition motorcycles evolved to transistor ignition, and flamag point ignition motorcycles evolved to CDI ignition motorcycles. At the same time as this evolution of the ignition system, the points function was abolished and the ignition signal was controlled by a signal from a "non-contact pickup coil". When people hear about transistor ignition and CDI ignition, they tend to focus on the "improvement in ignition performance.

If you know the above facts, you will understand how terrible gas leak is. I'm sure you can understand. This time, I was lucky to find a genuine Rincon gasket, but in the past, I made my own parts with NBR rubber sheet and fluorine rubber sheet, which are known as gasoline resistant rubber sheet, but they don't seem to be compatible with modern gasoline. However, it seemed to be incompatible with modern gasoline, and the gasoline swelling made the seal too strong, and sometimes it was impossible to turn the fuel cock lever smoothly. The ethanol content of modern gasoline is increasing due to environmental issues, and this seems to be having a negative effect on the rubber parts. Considering this environment, we would like you to make your own parts and check for leaks before use. This time, I installed the fuel cock into the gas tank after all the inner parts were installed, and left it for a while (several weeks) after filling it with gasoline, but there were no gas leaks or the switching lever stopped moving heavily.

 

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