Rajan Wilcox
The Suzuki DR650 is a dual-sport motorcycle that was introduced in 1990. It has a 13-litre fuel tank, but owners have been known to replace it with larger tanks, such as the 5.3-gallon Acerbis tank, to increase the bike's range. When upgrading the fuel tank, it is important to consider the size of the fuel line and filters. The stock carb and petcock have a size of 5/16, but some owners have reported using 1/4 fuel lines without any issues. It is recommended to use the correct size fuel line to ensure a snug fit and avoid any potential issues with fuel delivery.
| Characteristics | Values |
|---|---|
| Engine | 644 cc, 4-stroke, single cylinder, SOHC, 4-valve, air/oil cooled dual-sport motorcycle with a counterbalanced engine that develops 36 horsepower |
| Fuel Tank Capacity | 13 L |
| Fuel Hose Size | 1/4" or 5/16" |
| Fuel Line Size | 8mm (5/16") |
| Petcock Size | 8mm (5/16") |
| Aftermarket Petcock Size | 1/4" |
| Fuel Tank Options | Acerbis 5.3 gal tank, Clarke 3.7 gal tank, IMS 4.9 gal tank, Acerbis 6.6 gal tank, Aqualine 8 gal tank |
| Fuel Type | Unleaded gasoline, methanol, ethanol (E10, E15, E85) |
| PSI Rating | 35 to 50 |
| Temperature Range | -40°C to +125°C (-40°F to +257°F) |
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What You'll Learn
The Suzuki DR650 has a 13L fuel tank
The Suzuki DR650 is a dual-sport motorcycle with a 13L fuel tank. Introduced in 1990 as a replacement for the DR600 model, the DR650 has a 644 cc, 4-stroke, single-cylinder, SOHC, 4-valve, air/oil-cooled engine with a counterbalance that develops 36 horsepower. The stock fuel tank is heavy and made of steel, but there are a variety of replacement options available, including lighter-weight alternatives.
The Acerbis 5.3-gallon tank is a popular choice for the Suzuki DR650, offering both functionality and aesthetics. It incorporates modern lines and high-quality construction, and it comes with all the necessary mounting hardware, including a gas cap and petcock. Installation of this tank, however, requires relocating the front turn signals to prevent contact with the tank at full lock. To address this, turn signal relocation brackets can be used to move the signals up and forward, clearing the larger tank.
There are also larger capacity options available for the Suzuki DR650, such as the 6.6-gallon Acerbis tank, which can be fitted to 1996 and newer DR650SE models with minor adjustments and brackets. This tank provides a significant increase in fuel capacity while maintaining a sleek design. Additionally, the IMS 4.9-gallon fuel tank is another viable option, offering increased range and available in a range of colours, including natural, white, black, and blue.
When considering fuel lines for the Suzuki DR650, there are two main options: the OEM 1/4th ID (1/2" OD) fuel line, and the 5/16th ID hose. The former fits snugly on the carb barb and petcock barb, requiring no clamps, while the latter is easier to mount but requires clamps or ties, especially when using certain filters. It's important to note that the stock carb and petcock have a 5/16" size, so fuel lines and filters should match this size to ensure compatibility.
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The 5/16 fuel line is the correct size
The Suzuki DR650 is a longstanding model in Suzuki's lineup, introduced in 1990 as a replacement for the DR600. The DR is a 644 cc, 4-stroke, single-cylinder, SOHC, 4-valve, air/oil-cooled dual-sport motorcycle with a counterbalanced engine that develops 36 horsepower. It has a 13-liter fuel tank.
There are two options for fuel lines on the DR650. The first option is to use a 1/4" fuel line, which is the OEM size and fits the stock fuel line spring very snugly on the carb and petcock barbs. No clamps are required on 1/4" filters, and this size is less likely to get any air bubbles in your fuel line. However, using a 1/4" line will result in reduced fuel flow.
The second option is to use a 5/16" fuel line, which is the correct size for the DR650. This size is easier to mount on the OEM carb and petcock barbs, but it is a bit loose and will require clamps or ties, especially if you use 1/4" inline filters. It works better with 5/16" "Pancake" filters. While this size may be too big for the OEM fuel line spring guard, this guard is not necessary.
If you have purchased 5/16" filters, you should also use a 5/16" fuel line. The stock carb and petcock on the DR650 are both 5/16, as is the Acerbis petcock. While it is possible to use a 1/4" line with these fittings, it is not easy and can be difficult to remove when you need to take off the tank.
There are several fuel tank options available for the DR650, including the stock 13-liter tank, a 3.7-gallon tank from Clarke, a 4.9-gallon tank from IMS, and a 5.3-gallon tank from Acerbis. The Acerbis tank incorporates modern lines and high-quality construction and includes a gas cap, petcock, and all mounting hardware. Installation of this tank requires relocation of the front turn signals.
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1/4 fuel lines can also be used
The Suzuki DR650 is a long-standing model in Suzuki's lineup, introduced in 1990 as a replacement for the DR600 model. The DR is a 644 cc, 4-stroke, single-cylinder, SOHC, 4-valve, air/oil-cooled dual-sport motorcycle with a counterbalanced engine that develops 36 horsepower. It has a 13-liter fuel tank.
There are two options for fuel lines on the DR650:
- OEM 1/4" ID (1/2" OD): This option fits the stock fuel line spring and is very snug on the carb and petcock barbs. No clamps are required (but are still recommended) on 1/4" KN straight/90-degree filters from Procycle, and it is less likely to get any air bubbles in your fuel line.
- 5/16" ID hose: This option is a lot easier to mount on OEM carb/petcock barbs, but it is a bit loose, so it will require clamps/ties, especially if you use the 1/4" KN straight/90-degree inline filters. It works better with the 5/16" "Pancake" filters.
While the 5/16" option is the correct size for the DR650, many people have used the 1/4" fuel lines on their DR650s without any issues. The 1/4" option is more snug and less likely to get air bubbles, but it is harder to get on and off. The 5/16" option is easier to mount but requires clamps and is more likely to get air bubbles.
The 1/4" fuel line is a good option for small engines, such as lawnmowers, snowblowers, and power washers. It is also suitable for transferring petroleum-based products, fuel lines, vapor emission lines, vacuum smog control, and crankcase ventilation. It has been used for over 30 years on top race machines and can withstand temperatures from -65F to 223F without deterioration. It is also kink and abrasion-resistant and will not harden or crack even under extreme use.
Therefore, while the 5/16" fuel line is the correct size for the Suzuki DR650, the 1/4" fuel line can also be used without any issues. The decision between the two comes down to personal preference and the specific needs of the rider.
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The Acerbis 5.3 gal tank is an option
One of the key benefits of choosing the Acerbis 5.3 gal tank is its increased capacity, which can extend the range of your Suzuki DR650. This is especially useful if you plan to cover long distances or want to reduce the frequency of refuelling stops. The tank's top-quality design and materials also make it a popular choice for DR650 projects.
However, it's important to note that installing the Acerbis 5.3 gal tank requires some modifications to your Suzuki DR650. Specifically, the relocation of the front turn signals is necessary to prevent the stock signals from contacting the tank at full lock. ProCycle offers Turn Signal Relocation Brackets that move the front turn signals up and forward, ensuring they clear the larger tank.
Additionally, when considering the Acerbis 5.3 gal tank, it's worth thinking about the fuel line size that will work best for your setup. There are two main options for fuel lines on the DR650:
- OEM 1/4th ID (1/2" OD): This size fits snugly on the carb barb and petcock barb, and no clamps are required when using 1/4" KN straight/90-degree filters from Procycle. It also reduces the likelihood of air bubbles in your fuel line.
- 5/16th ID hose: This size is easier to mount on OEM carb/petcock barbs, but it is a bit loose and will require clamps or ties, especially when using 1/4" inline filters. It works better with 5/16" "Pancake" filters and is too big for the OEM fuel line spring guard.
The Acerbis 5.3 gal tank is a great option for those seeking increased fuel capacity and a modern, sleek look for their Suzuki DR650. With its high-quality construction and the availability of necessary accessories, it can be a functional and aesthetically pleasing upgrade for your motorcycle.
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The stock petcock uses a vacuum assist
The stock petcock is a small shut-off valve that controls the flow of liquid or gas. It is a vacuum-assisted petcock, which means it uses an engine vacuum to pull back a small piston, allowing fuel to flow when the engine is running. When the engine is shut off, the vacuum is removed, and the fuel is cut off. This prevents fuel from overflowing and damaging the engine.
The stock petcock on the Suzuki DR650 has a 5/16" fuel line. This is the standard size for all fuel fittings and lines on this model. The vac lines are smaller. It is possible to use a 1/4" line, but it will be a tighter fit and more difficult to install and remove.
There are two options for fuel lines on the DR650:
- OEM 1/4" ID (1/2" OD): This fits the stock fuel line spring very snugly on the carb and petcock barbs. No clamps are required, but they are still recommended, especially when using inline filters. This option helps prevent air bubbles in the fuel line.
- 5/16" ID hose: This is easier to mount on the OEM carb/petcock barbs, but it is looser and requires clamps or ties. It works better with "pancake" filters.
It is important to note that while some people choose to eliminate the vacuum petcock, it serves an important function. The vacuum petcock prevents fuel from leaking when the bike is turned off, reducing the risk of engine damage.
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Frequently asked questions
The stock fuel tank for the Suzuki DR650 is 13L, but there are several upgrade options available, including a 3.7-gallon tank from Clarke, a 4.9-gallon tank from IMS, and a 5.3-gallon tank from Acerbis. There is also a 6.6-gallon Acerbis tank available for pre-1996 DR650 models, and an 8-gallon Aqualine Safari tank.
The Suzuki DR650 has two options for fuel lines: 1) OEM 1/4th ID (1/2" OD) or 2) 5/16th ID hose. The 1/4" option is snugger and doesn't require clamps, while the 5/16" option is easier to mount but requires clamps or ties.
The fuel capacity of the Suzuki DR650 has varied over the years. The original model had a 21-liter fuel tank, which was reduced to 17 liters in 1992, and then further reduced to 13 liters in 1996 for the DR650SE model.
When installing an Acerbis fuel tank on the Suzuki DR650, you will need to relocate the front turn signals to clear the bigger tank. Additionally, you may need to enlarge the mounting holes on the ignition coil bracket to prevent it from touching the front bracket. It is also recommended to use zinc-plated clamps to ensure the fuel line stays connected.
