Raptor 660 Petcock Gray Ghost 421 Amazon and Weird tank tang fix

[Kawtriplefreak]

The last romp on the Gray Ghost I was running pretty hard on a long straight and it felt like I was running out of gas at the top of 4th. I got out of it and noted there was 60 miles on that tank of gas. I usually get about 25 MPG so far since the build. Rode easy 5 miles to the gas station and it held 3.2 gallons, so it had about 2 gallons left (20.3 MPG = THIRSTY). I filled it up and ran the 12 miles home quite briskly with numerous 10K shifts and no recurrences. After consulting M in SC as noted in a previous post, I decided to order a 660 Raptor petcock with the intent of doing a dual outlet mod and installing it in an effort to make sure adequate fuel is reaching the PWK35s.
I got on Amazon and ordered what was advertised as a direct replacement for the Yamaha part number with an 8MM fuel outlet $16.99 shipped. Since they were so cheap I elected to order two and rob the fuel outlet pipe out of one for the dual outlet conversion and keeping the rest of the 2nd petcock for spares. Mark told me he had been burned before in a similar situation, so I hoped for the best.
Upon arrival I started measuring and comparing it to the RD400 petcock currently installed. The supposedly 8MM outlet was actually 4.7 MM (3/16 inch) which is smaller than the 400 petcock. Both stand-pipes were also smaller than the 400 petcock. I sent that shit back.
I got on Partzilla and ordered a factory Yamaha Raptor 660 petcock for $63.41 shipped 2-day UPS Air and since MLK day clogged that up it should be here Wednesday. After further consultation with M in SC and a lesson on flow characteristics and T-Fittings VS Y-fittings no dual outlet mod will be necessary. After scouring the local auto parts stores and finding only plastic Y-Fittings I got back on good old Amazon and ordered a 5/16 brass (7.9MM) Y-fitting and it will be here tomorrow $5.99 and free shipping with Prime.



Someone in the Gray Ghost's past life decided it was a good plan to weld a tang with a hole in it on the bottom seam on the RH side of the gas tank. I have not a clue why. I do know it made getting the gas tank on and off a challenge and its' close proximity to the positive battery post resulted in unwanted sparks on more than one occasion including today.



I was afraid to cut it off before in case it might have been some kind of strange leaky tank repair but enough is enough and I broke out the cut-off wheel staying well away from the seam. 2 minutes later no more tang. I hand filed the cut smooth and sloshed the little remaining fuel in the tank over to the right side and no leakage was noted.  I also verified the gas cap vent hole is open by blowing air in the key slot and watching the bubbles in the gas can from the fuel lines




More to follow:
 
 

[m in sc]

there you go 

[1976RD400C]

The way the batteries are mounted is kind of sketchy. You can't get it out without lifting the gas tank. The positive post is so close to the tank that if the battery holding strap breaks it could slide over and hit. You can't get to the positive post, to charge it, unless you lift the tank and support it. I connect the charger to the main fuse under the seat.

[Kawtriplefreak]

I have battery maintainers on all my bikes so I run the harness down the frame rail and it plugs in. And I agree they should have done better on the arrangement.

[Kawtriplefreak]

 
We had a heat wave in Northern VA today 38 degrees and some sun so the temperature in the shop was nearly 50 for the 1st time since the storm. I got the 400 petcock off, found my 21 year old can of Gasoila petroleum pipe sealer and got to work on the Raptor petcock.

Gasoila never really dries so the fiber washers came right off and were reused.
Install completed with no issues.

Next I cut the carb fuel hoses to fit the brass Y and with the help of some WD40 got them installed. I used 5/16 hose on the petcock feed line to the Y clamped with a cable tie for ease of tank removal in the future.

I did my best with routing in an effort to take full advantage of gravity and not restrict the flow.

[Kawtriplefreak]

The temperature climbed to a balmy 55 degrees here yesterday in the frigid tundra formerly known as Northern, VA. The ice and snow melted sufficiently for me to get the Gray Ghost 421 out for a test ride after the petcock change. I am pleased to report that the fuel starvation issues appear to be solved. I rode about 30 miles with numerous 10K shifts and several long pulls in top gear up to 7000. Overall response feels stronger than before but that may just be my imagination. I do know if shifting at 10K from 2nd into 3rd it will lift the front wheel just above the pavement at 60. Thanks M in SC for the recommendation and advice as always.

[85RZwade]

"  I do know if shifting at 10K from 2nd into 3rd it will lift the front wheel just above the pavement at 60."

Hay-soos, that's a lot stronger than my RZ!

[Kawtriplefreak]

It really runs good. It is considerably stronger than my White RZ with Spec 2 stage 1 porting, Zeeltronic, Wicked Head, VM30s and FPPs.
 

[m in sc]

when i rode it it def would float the front wheel in 3rd easily.

[1976RD400C]

Here's mine with a 5.5 ah battery. 

[Kawtriplefreak]

I am running a slightly smaller battery.