Sylvie Willis
The Suzuki DR650 is a popular motorcycle model, and its fuel tank is a common topic of discussion among owners and enthusiasts. The stock fuel tank has a capacity of around 3.4 gallons, but many owners opt for larger aftermarket tanks to increase their riding range and reduce the frequency of refuelling. The Acerbis and IMS brands are popular choices for replacement fuel tanks, offering capacities of up to 6.6 gallons and addressing some of the issues with the stock tank, such as limited range and the need for frequent refuelling. This paragraph introduces the topic of operating the fuel tank of a Suzuki DR650 motorcycle, with a focus on the available options for replacement fuel tanks and the process of installation and maintenance.
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What You'll Learn
Fuel tank capacity and range
The fuel tank capacity of the Suzuki DR650 can vary depending on the type of fuel tank installed. The stock tank capacity is reported to be around 3.4 gallons, while some users have mentioned larger capacity options such as the 5.3-gallon Acerbis tank and the 4.9-gallon IMS tank.
The 5.3-gallon Acerbis tank is a popular upgrade, providing a significant increase in fuel capacity and allowing riders to comfortably travel over 200 miles without worrying about fuel. The IMS 4.9-gallon tank is also recommended by some users, offering slightly less capacity but a sleek design that complements the look of the bike.
For older DR650 models (pre-1996), the 6.6-gallon Acerbis tank is an option that can be fitted with brackets and minor adjustments. This larger tank provides even more fuel capacity, potentially extending the range of the bike.
Additionally, there are smaller capacity options available, such as the Clarke 3.7-gallon tank, which can increase the range by about 20 miles compared to the stock tank.
The choice of fuel tank depends on the rider's preferences and needs. While larger tanks offer increased fuel capacity and extended range, they may also impact the handling and aesthetics of the bike. Smaller tanks, like the Clarke 3.7-gallon option, can provide a lightweight alternative while still offering improved range over the stock tank. Ultimately, the decision should consider factors such as intended usage, desired range, and personal preferences for the bike's appearance.
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Fuel tank materials
If you prefer the look of a metal tank, you can opt for an aluminium or steel tank. Metal tanks offer a more rugged appearance and are often favoured by those who want their bike to stand out. Metal tanks are also more durable than plastic tanks and can withstand impacts and scratches better.
Another option is the Clarke 3.7-gallon tank, which is almost 5 lbs lighter than the stock tank and holds close to 1/2 gallon more fuel, increasing your range. The IMS fuel tanks are also a popular choice, made with polyethylene crosslink for extra strength and durability, and designed to enhance the appearance of your motorcycle while providing greater riding distance per tankful.
When it comes to aesthetics, some riders prefer to paint or coat their fuel tanks. However, it is important to note that fuel vapours can pass through plastic fuel tanks, causing paint to bubble or peel. One alternative to painting is to use a spray-on bedliner, which can add colour, texture, and protection to your tank. Additionally, you can customise your tank with various accessories, such as tank grip pads, decals, stickers, or graphics.
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Fuel tank maintenance
Fuel Tank Selection
When choosing a fuel tank for your DR650, you have several options. The stock fuel tank is typically made of steel or plastic polyethylene, and you can opt for different capacities depending on your needs. The Clarke 3.7-gallon tank is a lightweight option that increases your range, while the IMS 4.9-gallon tank offers even more capacity and is available in various colours. If you're looking for an even larger capacity, the Acerbis 5.3 and 6.6-gallon tanks are excellent choices, providing an exceptional range of over 200 miles.
Installation and Compatibility
When installing a new fuel tank, it's important to ensure compatibility with your DR650 model. For instance, the 6.6-gallon Acerbis tank can be fitted to 1996 and newer DR650SEs with minor adjustments and brackets. You may need to fabricate adapters using a grinder, drill, and welder. Additionally, consider the compatibility of the petcock; for instance, the stock petcock may not fit the Acerbis tank, requiring a conversion to a gravity-fed system.
Preventing Clogs and Leaks
Proper maintenance of your fuel tank includes taking steps to prevent clogs and leaks. If you have a plastic tank, ensure that you thoroughly rinse it before use to remove any plastic shavings left over from the manufacturing process. These shavings can clog your carburetor inlet filter if not removed. Additionally, pay attention to your petcock; if it leaks or won't shut off, consider replacing it with a manual one, especially if your bike will be parked for extended periods.
Tank Customization and Aesthetics
Customizing the look of your fuel tank is also part of its maintenance. You can attach various items to a tank cover, such as tank grip pads, pockets, reflective tape, lights, or even rhinestones. If you're artistic, you can also paint your tank, but this can be challenging, especially with plastic tanks. Remember to seal the inside of your tank before painting to prevent paint bubbling. Alternatively, consider coating your tank with a spray-on bed liner for a unique look and protection.
Fuel Management
Proper fuel management is crucial for maintaining your fuel tank and overall motorcycle health. Always shut off the fuel when you're not riding to avoid issues with the stock float needle and fuel backfeeding into the crankcase vent. Additionally, consider using a one-way vent cap to prevent fuel from sloshing out while still allowing air into the tank.
By following these maintenance tips and instructions, you can keep your Suzuki DR650's fuel tank in optimal condition, ensuring a smooth and enjoyable riding experience.
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Fuel tank customisation
The Suzuki DR650 has a variety of fuel tank customisation options available. The stock fuel tank has a capacity of 13L, but there are several upgrade options that offer larger capacities and improved functionality.
One popular option is the Acerbis fuel tank, available in 5.3 and 6.6-gallon capacities. The 5.3-gallon tank provides increased fuel capacity and modern, sleek aesthetics. The 6.6-gallon tank is suitable for pre-1996 DR650 models and can be fitted to 1996 and newer DR650SEs with minor adjustments and fabrication.
Another option is the IMS 4.9-gallon fuel tank, which offers increased range and is available in natural, white, black, and blue colours. The natural colour option is recommended for easily monitoring fuel levels.
For those seeking an even larger capacity, the Aqualine 8-gallon (30-liter) Safari tank is an option for post-1996 DR650SE models.
In addition to capacity upgrades, there are several other customisation options available for the DR650 fuel tank. Custom tank grip pads can be added to improve grip and cover scuffs, and there are various replacement gas caps available for different tank models.
For those seeking a unique aesthetic, customisation can be achieved by attaching items such as tank bags, pockets, studs, lights, graphics, or even hand-stitched leather to a tank cover. Duct tape can also be used to create a pattern or design on the tank.
It is important to note that painting plastic polyethylene tanks can be challenging due to fuel vapours passing through the plastic and the flexibility of the material. However, it is possible to successfully paint or coat a tank with the proper preparation and techniques.
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Fuel tank replacement
The Suzuki DR650 is a popular motorcycle, and there are a variety of fuel tank options available for it. The stock tank is made of heavy steel, but there are several replacement options that are lighter and have a larger capacity.
When replacing the fuel tank on a Suzuki DR650, there are a few steps you need to follow. Firstly, you will need to disconnect the fuel hose and vacuum line from the stock fuel tank petcock. You can then remove the stock fuel tank and discard the black plastic cover in front of it. It is important to plug the vacuum hose fitting that comes out of the carburetor to prevent a vacuum leak. You must then disconnect and remove the ignition coil.
If you are replacing the stock tank with an Acerbis tank, you will need to use the vacuum plug that comes with the new tank. You may also need to drill out the hole slightly to fit the stock petcock into the new tank. It is also recommended to tilt the coil cooler forward.
There are a few different fuel tank options available for the Suzuki DR650. The Clarke 3.7-gallon tank is a lightweight option that can increase your range by about 20 miles. The IMS 4.9-gallon tank is another popular choice, available in natural, white, black, and blue. The natural colour is recommended if you want to easily see the fuel level.
If you have an older DR650, the 6.6-gallon Acerbis tank is a good option. It can be fitted to 1996 and newer DR650SEs with a set of brackets and some minor adjustments. The adapter brackets can be fabricated with a grinder, drill, and welder.
When choosing a fuel tank, it is important to consider the material. Most fuel tanks available for the DR650s are made of plastic polyethylene. Plastic tanks are lightweight and waterproof, but they may not be road legal. They can also be more difficult to paint, as fuel vapors can cause paint to bubble or peel.
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