Honda 350/450 petcock leak
This looks to be a simple fix but is starting to become an annoyance. The fuel petcock leaks pretty much on any setting. I ordered a new interior four hole rubber fuel gasket and replaced the two valve screws (stripped heads).
Inside, I found it already had a brand new rubber gasket. Evidently installed by the previous owner, he stripped the screw heads putting it back together.
I'm beginning to see why.
The system itself seems a masterpiece of simplistic engineering. The rubber fuel gasket seats into the receseed valve body. The valve itself doesn't press up uo against the rubber gasket but up against the valve body the gasket is recessed into. This keeps the valve handle from wearing against the rubber gasket when it's rotated.
Pressure is applied to the valve handle by a "warped" spring washer placed between it and the outer faceplate. Screw down the faceplate and the warped washer applies pressure to the valve handle, bringing its surface flat to the four hole fuel gasket.
The previous owner tried to fix the leak with a new gasket but it still leaked on "Reserve". In his attempt to increase pressure on the valve, he stripped the screws.
Well! I've now had it apart about forty times now and nothing seems to change. It leaks at the valve and not at the drain bowl or tank compression fitting. It leaks at its worst when turned.
I have felt with my finger to see if the four hole gasket is seated all the way in. It seems to be but this remains my biggest suspicion. I've tested a rubber "O" ring in place of the warped washer for more pressure and this does stop the leak but that "O" is too thick and I know it won't last long with that valve turning against it.
So what's the trick here? What obvious thing am I missing?