The XS1100 probably had vacuum pet cocks originally. The previous owner installed manual petcocks. I would have done the same thing. The petcocks are rock solid reliable. The only issue is that there are two spigots on each petcock. Since both supply fuel, and since the each carb bank of two carbs only has a single inlet, the fuel system must use a Y connector to go from two lines down to one.
This Y connector is inconvenient regardless of where it is placed. The best (of the worst) places to put it is right after the petcock. This makes reinstalling the tank a bit difficult as the Y connector hits the carb intake boots. It seems everytime I take the tank off, I end up cracking a fuel line when reinstalling the tank.
This happened recently and I did not realize it until I was riding around, my left leg covered in fuel. I was frustrated enough to finally do something about it.
First up: eliminate the Y connector. I check the operation of the petcock. Fuel only comes out the right spigot when in the ON or RES positions. Fuel only comes out the left spigot when in the PRI position. Since these are not vacuum petcots I am not sure whey they even have a prime position.
I blocked the left spigot (runs when in PRI) with JB Weld. Now the OFF or PRI position on both petcoks do not flow any fuel. ON and RES still work as expected.
Next up: install quick disconnects on the fuel lines so I don't have to pull lines off hose barbs to remove the tank. I had tried to do this previously but the avaiable quick fuel line disocnnects were too long to fit.
Now that the Y connection was out the system I had a little more room to fit the quick disconnect. I got Tusk quick disconnects. They are slightly bulkier than the Motion pro connector I got for the TS250, but they are half the price so well worth it.
All said and done, the tank is easily removed, there are no leaks. the bike is ready to ride
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| non-vacuum petcock with dual outputs |
| one output is only used in prime position, will be blocked off as its not needed |
| tusk quick fuel disconnect |
| tusk compared to motionpro. tusk is slightly larger but much cheaper |
| new fuel line route, should avoid breaking fuel lines on the Y and the carb intake boot |
| fuel line disconnected. these are not fuel shut offs so fuel will run out unless petcock off |
| still have fuel filter too |
| the left spigot is blocked with JB Weld, no leaks at all. |