2001 EV-electric petcock wire broke

[drburt]

Had my tank off checking the air filter and replaced the fuel filter.
A wire to petcock broke off.
Better now than later.
I'm not having much luck finding another electric one.

I'm wondering what the downside to the manual petcock is.

If I forget to open the manual one, could I damage the fuel pump?
If I forget to close the manual one, am I going to have fuel filling my cylinders?
Thanks!
Brenrt

[John A]

I just leave it on unless I’m taking off the tank. It never has been any trouble .

[s1120]

You will know as soon as you start the bike that you forgot to turn on the petcock..  You will hear the fuel pump. The replacements out there are kinda cheesy..  sometimes they are hard to open, and close. You really dont NEED to close it. Your not going to fill the cyl's because its FI. Worse case if your hose from the tank to pump is bad, that may leak. Mine never really closes fully when I remove the tank... but either did the electric one..  the angle of the outlet was a little different so I needed to change the hose also. Not really a downside because I was changing all lines anyway, and it would have been changed in the next year. All in all I'm glad I changed, I just wish the manual ones were better made.

[Chuck in Indiana]

You can repair the petcock. It is just potted with epoxy, and you can (carefully) grind around the connection with a small die grinder or Dremel. Resolder the connection, repot it, and you are done. 15 minutes and zero cost. (Guzzi content) 

[n3303j]

What Chuck said.
The solenoid coil wires are relatively thick and easy to handle once you dig out the epoxy.
Repot the assembly with stress relief on the leads and Ty-wrap the leads to ths solenoid body to eliminate any future flex at the coil face.
It'll last forever.

[Wayne Orwig]

I would try to cut out some potting and tie into the wire.
Or, switch to manual and LEAVE IT ON. The only reason to turn it off is to remove the tank.

And of course, never swap the fuel light sensor connector are solenoid wires, That is a disaster.

[drburt]

Thank you for sharing your expertise and experiences.
I'm ordering the manual petcock for insurance.
I'm also ordering some of these because the sealing rings (washers/o-rings) as you might be able to see, are toast.
https://www.mgcycle.com/index.php?main_page=product_info&cPath=379&products_id=1401
Does the collar where the wires exit the petcock unscrew or come off somehow (red arrow in pic below).?





Thanks!
Brent

[bad Chad]

I don't remember if the collar unscrews.  But I did pretty much what the others did.  Simply reconected the wire, and then added some Shoe Glue, or flexible caulk of some kind, ( it was 15 plus years ago) to secure the wires so they wouldn't move, and thus not fail, it worked like a charm.   I too bought the manual petcock, I still have it, NOS in my tool box!

[Wayne Orwig]

I think the collar is glued on.

When you remove the tank don't sit it on the wires.

[drburt]

Yep. It was glued.
Lightly hit it with my small butane torch and it finally pulled off. No Threads.
The other wire was hanging by a single strand and came off too.
Good tip regarding not setting tank on the wires. Must've been previous owner(s).
They did have the wires ty-wrapped to the petcock.
I'll see if I can fix it just for fun and maybe use it if I do fix it.
I still have the manual one on the way.
Thanks again!
Brent