Apparently this is a common problem that I also have. Another website said that there is not a true reserve. This bike is designed to slow down the fuel pump when the reserve switch is on the "on" position and the fuel is low to give you the sense that you are running out of gas. My solution, reset the trip meter each time you get gas and make sure you fill up before reaching 100 miles.
SOURCE: I have a petcock rebuild kit for a 1997 gsxr
Hello the vacuum chamber is the part with the nipple for the vacuum line when you remove that there is the spring then you have the diaphragm that is on the plastic center remove the old diaphragm take note the is a small pin hole on it careful install the new diaphragm the center aluminum piece with the o-ring faces into the body of the petcock make sure the pin hole aligns with the together, remember pin hole on the plastic center piece there is a pin hole on the diaphragm membrane and a pin hole on the main body of the petcock.
one other thing make sure the surfaces do not have anything on there or your diaphragm will not seal properly any pieces of of the old diaphragm oxidation clean it off with edge of a plastic knife or wooden pop stick don' use a screw driver or metal scraper.
hope this helps.
SOURCE: suzuki gs 750 getting a constant flow of fuel out of crank vent
The breather tube may warrant re-jetting but not re-syncing.
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SOURCE: Bad petcock, rebuild?
Hi Jerry
The easiest way to get a rebuild kit is to hunt eBay. Click here There are a few options for you.
regards
robotek
SOURCE: fuel leaking into air box.
Probable best to take the carbs back, as there may be something clogging one of the float needle jets.
Although the bike is getting old, the floatlevels dont normally wear out of adjustment, as they have a neoprene end on one end of the needle and a spring loaded pin on the float end,
Unless there is damage to one of the floats.
Note ethanol in fuel can affect some carb parts like neoprene seals
SOURCE: rebuild vs replace fuel **** assembly
If it is the old style fuelcock there is a four hole washer that needed replacement on a yearly basis way back then (poor quality rubber).Just buy the washer that should be all you need unless there is other damage. than replace the assembly. With the age of the machine your only option may be to replace the worn washer as the new assembly is probably no longer available.
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