Regan Brown
The Suzuki DR-Z400 is a popular motorbike, but like all vehicles, it requires regular maintenance. One common task is removing the fuel tank, which can be done by following these steps: first, turn the fuel valve off or to 'RES' or 'ON' if there is no off option; disconnect the vacuum line; and then remove the tank. It is important to store the tank upright to avoid leaks. This process is relatively straightforward and can be completed in around 30 minutes.
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What You'll Learn
Turn the fuel valve off before removing the tank
It is important to turn the fuel valve off before removing the tank on your DRZ400. This is because the fuel valve is vacuum-operated, and the 'ON' and 'RES' settings are closed until a vacuum is created. Therefore, when the engine is not running, these settings will prevent fuel flow.
To turn off the fuel valve, you should select either the 'ON' or 'RES' setting. The 'PRI' setting should be avoided as it is a vacuum diaphragm petcock, which will result in a continuous fuel flow and potential flooding of the engine.
If you are concerned about fuel leakage, you can drain the gas into a jerry can using your fuel line. This is a quick process that should take no more than five minutes. Additionally, you can consider swapping the petcock, as it is known to fail open, leading to potential flooding of the engine.
Once the fuel valve is turned off, you can proceed to remove the fuel tank. Remember to disconnect the vacuum line and store the tank right-side up to avoid any accidental fuel leaks that could damage the paint on your tank.
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Pick either ON or RES if there is no OFF option
If you are looking to remove the fuel tank on your DRZ400, the first step is to turn the fuel valve off. However, some DRZ400 models do not have an OFF option, and the available settings are ON, PRI, and RES. In this case, you can select either ON or RES, as both options are closed until a vacuum is created.
It is important to note that the petcock, which controls the fuel flow, is known to fail open, causing the engine to flood with gas. Therefore, depending on your intended actions, you may want to consider swapping the petcock. If you notice gas leaking from the tank when it is in the ON position, this could indicate an issue.
To ensure a proper fuel supply, it is recommended to use the PRI setting when the bike is out of gas, as it allows fuel to flow freely to the carburetor. This is particularly useful if the bike has been stationary for a while. Once the bike is started, you can switch it back to ON.
When riding, if you notice the engine starting to sag, you can switch to RES to access the remaining fuel at the bottom of the tank. This will help you reach a gas station or your destination safely. Remember to switch back to ON after refueling.
By following these steps and paying attention to the fuel settings, you can safely remove the fuel tank on your DRZ400, even if there is no OFF option available.
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Disconnect the vacuum line
Disconnecting the vacuum line on a DRZ400 is a necessary step when removing the fuel tank. The vacuum line is connected to the petcock, which controls the flow of fuel.
To disconnect the vacuum line, first locate the petcock. It is usually found just in front of the carb and has two bolts, with the bottom bolt being the vacuum nipple. Once you have located the petcock, follow the hose from the petcock to the vacuum line. This hose needs to be disconnected.
It is important to note that the petcock is vacuum-operated, and the vacuum line plays a crucial role in its function. When the engine pulls in air, it also pulls from the petcock diaphragm, actuating it. If the vacuum line is disconnected, it can cause a vacuum leak, affecting the fuel/air mixture and engine performance. Therefore, it is essential to ensure that the vacuum line is properly connected for the DRZ400 to operate correctly.
Additionally, the petcock should have a position called "Prime," which opens the petcock without running the engine, allowing for fuel filling. If the vacuum line is left unhooked, it can lead to issues with the engine running and idling.
By following these steps and being mindful of the vacuum line's function, you can safely disconnect the vacuum line when removing the fuel tank on a DRZ400.
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Store the tank right side up to avoid leaks
When removing a fuel tank from a DRZ400, it is important to store the tank right side up to avoid leaks. Storing the tank in this manner will ensure that gasoline does not leak out and cause damage to the surrounding area.
To avoid leaks and potential damage, it is crucial to follow the correct procedures when removing and storing the fuel tank. Firstly, turn the fuel valve off before removing the tank. If your fuel valve does not have an "OFF" option, you can turn it to either “ON” or “RES”, as these positions are considered closed until vacuum. Disconnect the vacuum line as well.
Once you have removed the fuel tank, place it on a flat surface with the gas cap facing upwards. This will prevent gasoline from leaking out through the gas cap. Leaking gasoline can not only damage the paint on your tank but also pose a safety hazard.
By storing the tank right side up, you can avoid leaks and maintain the condition of your DRZ400's fuel tank. This simple precaution will help you avoid any amateur mistakes that could lead to aesthetic issues or more serious problems. Whether you are performing maintenance or repairs, always remember to store your fuel tank properly to prevent leaks and ensure the safety of your surroundings.
Following these instructions will help you safely and effectively remove and store your DRZ400's fuel tank, preventing leaks and maintaining the integrity of your motorcycle.
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Consider swapping the petcock to prevent engine flooding
If you own a DRZ400, you may have experienced or be concerned about your bike's engine flooding. This can happen when the petcock is not turned off, or due to a faulty petcock that fails open. The petcock on the DRZ400 is vacuum-operated, and the 'OFF' position is indicated by either the "ON" or "RES" setting. However, some users have reported that their petcocks have failed in the open position, resulting in a flooded engine.
To prevent engine flooding, you may want to consider swapping out the petcock for an upgraded version. This is because the stock petcock on the DRZ400 is known to fail open, which can lead to a flooded engine and potential damage. By swapping the petcock, you can avoid this issue and ensure a more reliable fuel system.
There are a few options available for upgrading the petcock on your DRZ400. One option is to install a vacuum petcock, which can help to prevent flooding. This type of petcock is designed to automatically shut off the fuel flow when the engine is not running, even if you forget to turn it off manually. This can provide peace of mind and help to avoid the hassle and expense of engine flooding.
Another option is to install an aftermarket petcock, such as the raptor petcock. However, some users have reported issues with this particular upgrade, including fuel flow problems and compatibility issues with the stock steel tank. It is important to carefully research and consider the compatibility and potential drawbacks of any aftermarket upgrades before installing them on your bike.
Additionally, some users have suggested that instead of upgrading the petcock, you can simply ensure that the seal is fresh every few years to maintain the reliability of the stock vacuum petcock. This can help to prevent leaks and flooding, while still utilising the original equipment designed for the bike.
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Frequently asked questions
Your manual might instruct you to turn the fuel valve off before removing the tank, but if your fuel valve has no OFF position, set it to either "ON" or "RES" as these are considered closed until vacuum. You will also need to disconnect the vacuum line.
After removing the fuel tank, store it right side up to prevent gas from leaking out and damaging the paint on your tank.
The petcock is known to fail open and flood the engine with gas, so consider swapping it out.
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