Intermittent gas leak - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 56 Old 06-10-2010, 04:56 PM Thread Starter
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Intermittent gas leak

I haven't been able to ride much in the last year and just getting back into the saddle again. With my '06 DL1000 after it sits for couple weeks, about 1 out of 10 times on cold start I have gas leaking from somewhere down between the cylinders. After riding minimal time or switching off and restarting it stops. My shadetree degree tells me it must be an o-ring or connection drying out and then resealing. After owning too many m/c's I realize what happens to one model bike most likely happens to other people too. I tried to do a search, but my computer skills are actually worse than my mechanical ability. Have any of you riders experienced this?
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post #2 of 56 Old 06-10-2010, 05:13 PM
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It's frequently the hose going between the throttle bodies.

Scott Craig - Nashville, TN
Red '06 Suzuki DL650 - Red '07 Honda VFR800 - My Bike Page
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post #3 of 56 Old 06-10-2010, 05:17 PM
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It's happened on other bikes too. It's usually the short fuel hose shown in blue
between the injector fuel rails or the O rings on the rails or the injectors and the cylinders. Sometimes, tightening or replacing the red clamps is all that is needed. See post #11 here for the proper type of clamp.


Pat- 2007 DL650A was ridden to all 48 contiguous states. I didn't quite make it to 17,000 miles on the 2012 DL650A.
Nicknames I use to lessen typing, Vee = 2002-2012 DL1000s. Vee2=2014-2016 DL1000s. Wee = 2004-2011 DL650s. Glee = 2012-2016 DL650s
See https://www.stromtrooper.com/general-...nicknames.html

Please vote in the poll on what Strom(s) you have at https://www.stromtrooper.com/informat...-you-have.html

Last edited by greywolf; 05-17-2015 at 06:43 PM.
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post #4 of 56 Old 06-10-2010, 06:12 PM Thread Starter
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I'm old guy, so probably repeating myself. But the two quick responses once again demonstrate why this site and the FZ1OA are the two best sites going. Go to some of the sites where riders are in their early twenties and ask any question other installing led lights or stretching the swingarm and wait for an answer. Thanks again.
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post #5 of 56 Old 06-10-2010, 11:41 PM
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Just made the same repair myself. Nice job on the graphics Greywolf. The cheezy crimp on factory hose clamps on the hose Greywolf described was the culprit. Almost as worthless as the rest of the hose clamps on the bike but much more dangerous. You've got to remove the fuel tank and air box to get to the rascal. I used a cut off wheel on my dremel tool to CAREFULLY cut away the original clamps and installed some good screw down types from NAPA to solve the problem. Not that bad of a project but it just pisses me that it had to be done in the first place. All clamps on this bike are total junk.

07 DL1000. Bone stock. 8000 miles
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post #6 of 56 Old 06-11-2010, 12:10 AM
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Graphics are from Suzuki colored by John Weldon at VSRI.

Pat- 2007 DL650A was ridden to all 48 contiguous states. I didn't quite make it to 17,000 miles on the 2012 DL650A.
Nicknames I use to lessen typing, Vee = 2002-2012 DL1000s. Vee2=2014-2016 DL1000s. Wee = 2004-2011 DL650s. Glee = 2012-2016 DL650s
See https://www.stromtrooper.com/general-...nicknames.html

Please vote in the poll on what Strom(s) you have at https://www.stromtrooper.com/informat...-you-have.html
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post #7 of 56 Old 07-17-2010, 09:20 AM
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Quote:
Originally Posted by k-oss View Post
Just made the same repair myself. Nice job on the graphics Greywolf. The cheezy crimp on factory hose clamps on the hose Greywolf described was the culprit. Almost as worthless as the rest of the hose clamps on the bike but much more dangerous. You've got to remove the fuel tank and air box to get to the rascal. I used a cut off wheel on my dremel tool to CAREFULLY cut away the original clamps and installed some good screw down types from NAPA to solve the problem. Not that bad of a project but it just pisses me that it had to be done in the first place. All clamps on this bike are total junk.
I'm really glad to find this extremely helpful thread--love the colored diagram!

I have this exact issue right now. I ride the bike regularly, got it out of the garage last week and after idling for a minute, I went to get on and noticed gas dripping. Upon further inspection, it appears to be around the front clamp of that short fuel hose between the intakes (color blue in the diagram).

So my question to those that have done this repair---HOW DO YOU GET THE AIR BOX OFF? The DL650 frame is so wide that it blocks the access to the area above the carbs dramatically. It appears that I can use a long, skinny, phillips to loosen the large clamp on the front intake. The rear intake is easy to get to. After that, it appears there are lots of things attached to the airbox---perhaps enough slack to pull the air box aside to do the fuel hose repair?
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post #8 of 56 Old 07-17-2010, 09:56 AM
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It appears you have a handle on the operation. Loosen the clamps and disconnect all the hoses and wiring that are attached to the air box. It needs to come off entirely to access the area. The first time I did it, I got a fault indicated because I failed to connect one of the sensors. Try starting the bike as soon as you get the tank back on to check for a fault. If there is one, you won't have to take as much stuff off to get back in there.

Pat- 2007 DL650A was ridden to all 48 contiguous states. I didn't quite make it to 17,000 miles on the 2012 DL650A.
Nicknames I use to lessen typing, Vee = 2002-2012 DL1000s. Vee2=2014-2016 DL1000s. Wee = 2004-2011 DL650s. Glee = 2012-2016 DL650s
See https://www.stromtrooper.com/general-...nicknames.html

Please vote in the poll on what Strom(s) you have at https://www.stromtrooper.com/informat...-you-have.html
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post #9 of 56 Old 10-26-2010, 04:28 PM
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gas leak

I had the same problem. Started the bike and gas flowed out from the area up under the gas tank. I never could see exactly where the leak was from but I decided to do the procedure described by Greywolf. My knuckles are raw, I'm scratching my head as to why the engineers made it so difficult to remove the air-box, but, I started it up and the problem was fixed.

The suzuki shop didn't have the fuel injector line clamps but my auto parts store did.

Thanks for sharing all of the knowledge.
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post #10 of 56 Old 10-26-2010, 04:54 PM
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Fuel leak

Wow, awesome site. I was just checking in and have fixed the exact same issue this weekend.

1) The original clamp on mine was just a little loose so I used some flat face wire cutters and just tightened the crimp a little. Hose clamps would be OK too I guess but this fitting is under a high fuel pressure and the oem clamp applies a constant spring tension....no matter how cheesy you feel it is. So I kept it on mine.

2) The easy way to remove the air box is to remove the clamp for the rear TB but NOT the front. On the front, squeese the rubber horn coming into the box and give it a little spit or WD 40 for lube and push it down through its hole leaving it attached to the front TB. Then upon reassembly, do the opposite being sure the groove in the rubber horn is correct in the air box and seals correctly.

Warning, there is a bunch of EFI crap under the box, remember how it goes back. Install the TB clamps exactly as they come off, if on wrong, they could interfer with throttle linkage.

And lastly, it took me an hour to figure out how the push pins work. Also, blue painters tape around the plastic pieces keeps you from scuffing up your pretty parts shoving the gas tank back in while using your other 4 hands to make the pieces spread apart enough.


When done, I went out back and hit myself in the head with a 2x4...it was much more fun than this repair which took me 3 hours. (1 hour for the friggin push pin)
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Last edited by Scott E. Bonds; 10-26-2010 at 05:00 PM.
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