2 New CL77 Petcocks Fail to Shut Fuel Off in Stop Position

[bjshealy]

Help!
Petcock No. 1:
I recently replaced the old petcock on my CL77 with a brand new reproduction.
Before installing the fuel tank on the bike I tested the "new" petcock for leaks.
The washer between the tank and the petcock sealed properly without any leaks.
However, in the stop position, the fuel shut-off valve did not stop gas from dripping out of the two spigots!
Since this was a brand new petcock, I returned it to the seller planning to purchase a second "new" petcock.

Petcock No. 2:
Purchased a second new petcock from a different seller with the same results.
Fuel dripped out of the spigots with shut-off lever in the stop position.
The rubber washer with 4 holes looked good on both petcocks.

Can this 4 hole washer be defective? Two of them?
This test was performed with the petcock on the fuel tank on the bench with just a small amount of fuel in the tank.
Just could not get the fuel to shut-off in the stop position.

Any suggestions?
Has anyone else experienced a similar situation?

Thank you.

[stratone]

Did you take the petcocks apart and lubricate the parts? I use a dab of good old vasoline.

[Tim Allman]

If the washer appears to be good then it must be in the body. Perhaps the casting is poor. Sadly some reproduction parts are good and some aren't. I ended up paying $150 for a pair of shocks from Thailand that are just not usable and there's nothing I can do about it.

[deuce_7]

There are two 6mm red fiber washers that seal the 6x25mm mm petcock-to-tank mounting screws. Had to chase a similar fuel leak, following the steps you followed. Turned out to be compromised red fiber washers that allowed fuel to pass even with the petcock valve in Off position.

Parts sources:

1960s Honda CB CL CA Fuel Petcock Mounting Screw and Fiber Washer kit (for two 6mm mounting screws)
https://www.ebay.com/itm/115195280395
https://www.ebay.com/itm/115600380702

1960s Honda Dream CA series Fuel Petcock Mounting Screw and Fiber Washer kit (for three 5mm mounting screws)
https://www.ebay.com/itm/115052664546
https://www.ebay.com/itm/115599228177

[Tim Allman]

I thought that you were referring to the multi-holed seal under the part that you rotate to operate the valve. Sorry.

[bjshealy]

Installing the two fiber washers purchased from the local hardware store in place of the two lock-washers provided by the manufacturer prevented the petcock from leaking fuel out of the spigots in the "stop" position!

Appreciate all your helpful comments.
Thank you!

[deuce_7]

6mm red fiber washers were fitted on the petcock-tank mounting by Honda manufacturer when the CL77 was built. The replaced lock washers aren't original, they didn't seal correctly, hence the leak.

Good to hear that the fuel leak is fixed!

Deuce_7
1967 CL77