2004 DRZ400 fuel issue

Donger

Donger

Member
Just bought a 2004 DRZ400, parked it in my shop, and fuel has been dribbling out of it for two days...wtf? Now it won't start, like its flooded. It has a desert tank for extra capacity. The manual states it has a vaccum for the fuel shut-off, hence no "off position on the petcock. Help?

Don P
 
Mad Max

Mad Max

New member
Is the petcock in "prime" position or in the on or reserve? Tap the floatbowl GENTLY with something, maybe your float is stuck.Do not turn the bike over untill you pull the sparkplug and ensure your cylinder is not full of fuel or you may bend the connecting rod.
 
zokalr13

zokalr13

Member
yeah,same thing happened to mine -turns out its the cheap fuel tap "gasket/smiley face doodad'' in the fuel tap that deteriorates and lets fuel go by even when turned in the off position.luckily, I had a spare new gas tank to swap out and when I took apart the crappy fuel tap I found this out...hope this helps..ZO13
 
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Donger

Donger

Member
Thanks guys, great help. I'll try that as soon as I can. I had the fuel in the "On" position. Since there is no "Off" position, where should I leave it when parked?

Donger
 
Summitx

Summitx

New member
Since the bike is new to you check that the leaver is in the correct position. The arrow on the leaver is hard to see so you may have it in the prime position thinking its in the on position. Seems obvious but fooled me when I first got my bike. Mine stuck open in the on position once (mysteriously fixed itself) but even in the prime position it should not leak out of the carb. Something must not be right in the float bowl. You can buy a petcock on ebay for about $30 that has an off position. I bought one but have come to like the vacuum rig.
 
S

Shuswap

Member
You must also have a leak at the float valve....it will be either the rubber-tipped float needle or the tiny little o-ring that lies under the brass float needle seat. It's usually the o-ring, commonly available, fairly easy to replace.
FWIW, the vac-operated petcock that came on my bike is in the trash can. I like being able to 100% stop fuel flow....after hydro-locking twice and always just a bit on-edge waiting for the next time.

If you need more info on the o-ring, let me know
 
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Summitx

Summitx

New member
If your going to tackle the carb work it's a bit tricky to get the carb out. There are a few things that can make it go much easier. Carb removal tricks
Remove bolt to sub frame and move sub frame back.
Remove rectifier or tip out of way.
Cable brackets – thread lock nut all the way up and bracket comes out of mount – remove before unhooking cables.
When carb is detached drop down so engine port is below boot then rotate out tipping the bottom toward you.
 
Summitx

Summitx

New member
One more tid bit. Has the 3 x 3 mod been done to the bike? If not and your taking the carb out anyway DO THE MOD You'll be soooooo happy you did. I would recommend the jd jet kit. The best. Has good tuning info for all configurations. Mine is stock, including the exhaust but the 3 x 3 with the jd makes it run much better.
 
C

Can-am Kid

New member
I had the same thing happen with mine. I replaced the stock petcock with one from one of my old can-ams, then purchased one for a Yamaha Raptor. Now I have to remember to turn it off when parked for a period of time.

If you are get drips from the carb overflow, then the problem is the needle float valve. It turns out there is a little o-ring under the float valve assembly that rots out over time (thanks ethanol) and has to be replaced.

Now that I have done both of the repairs mine is drip free. I have also started using only Shell gas as it turns out that is the only gas available in Canada without ethanol.
 
Donger

Donger

Member
Thanks for all the info. Had the carb checked, found no issues, petcock is fine. Its likely I didn't leave the fuel in "on" position letting the prime flow fuel through. Lesson Learned. Bikes fine, didn't cost me a fortune... thank the stars!

DP
 
Ti welder

Ti welder

New member
Can-am Kid said:
I had the same thing happen with mine. I replaced the stock petcock with one from one of my old can-ams, then purchased one for a Yamaha Raptor. Now I have to remember to turn it off when parked for a period of time.

If you are get drips from the carb overflow, then the problem is the needle float valve. It turns out there is a little o-ring under the float valve assembly that rots out over time (thanks ethanol) and has to be replaced.

Now that I have done both of the repairs mine is drip free. I have also started using only Shell gas as it turns out that is the only gas available in Canada without ethanol.
Click to expand...

Chevron 94 for me. Best fuel on the market IMHO
 
S

Shuswap

Member
Donger, if the engine flooded you still have a problem with the float needle valve.

Having the fuel cock on either setting cannot effect the pressure exerted on the needle valve, only whether there is flow, or not.

I have to question if the carb mech actually check the o-ring under the float valve seat? Bet he didn't....most don't know of that hidden little issue. If yours is a 2004 and hasn't been changed, it is overdue, guaranteed.
The o-ring is less than a buck.....and they are becoming a pain in the butt, perhaps due to the current fuel, perhaps it's just age. There are a gazillion posts on Thumpertalk about this
 
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r_jackson

r_jackson

Member
Good to link, I usually buy my gas at the fuel dock. Not because of it being ethanol free, but just because it's close to home.
 
M

meteor59

New member
I have had a similar problem on 2 of my Suzuki bikes, check the vacuum line on the back of the petcock . They have a spring behind the diaphragm , it can corrode and puncture the diaphragm causing fuel to leak down the vacuum hose to the carburetor . Also mine had 3 positions on/reserve/prime on and reserve were vacuum operated prime manually opened the reserve , probably changed now. On the Chevron 94 I have it works good but goes bad much faster than regular fuel specially in a plastic tank .
 
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