I have all that except the inline filter. I found the tank cap "sock" filter is great but too slow to fill up at the fuel stations - the attendants don't get it and don't slow the flow so the fuel has time to flow through, hence it overflows. So I gave up on that at fuel stations and just use it when fuel comes out of a barrel or something. This is in South America... and I did get some crap clogging the carb inlet filter a few times - surprisingly in the two more developed countries only - Chile and Brazil. Easy and quick to clean out though and the carb has remained clean.

The best mod I did was a very long breather hose from the cap. When bike stops because fuel is too low i can grab it and blow into it, tie a knot and keep going - all without leaving the comfort of the seat. It is long enough to go down to the higher metal speedo cable holder that attaches at the fender. Tuck the end in there and pull it out when you need to pressurise tank.

My petcocks are the metal ones with a metal handle/tap. No issues with either of them and I turn them on and off each day (riding most days) for the last 8 months. Sounds like the taps between us are all over the place. Glad I got the good ones!

Where you guys shipping to?

Shipping to Cape Town. Taking the first bike to the ship yard tomorrow and the other one next week.

I had the same issue with the big Safari tank. Repositioning the carb inlet pipe on the DR650 solved the problem. Like bigdon said earlier in this thread. See here for my writeup in post #9.

http://www.horizonsunlimited.com/hub...ari-tank-47452

Here's another reference. Carby mod to suit 33 litre Aqualine tank - DR - ThumperTalk

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I fixed it by shortening the pipe entering the carby, making the curve smaller. Rode 20,000km in 94 days and it didnt happen once. I guess there was an air block previously.

hi bigdon, you mention here to turn the inlet at the carby approx 90 degrees , can you please advise how to do this ?

Thanks

rodney

I used an big adjustable wrench.
Put it along the inlet pipe and carefully turn to 90 degrees.
The inlet is push fit. It needs to turn in the carb body, not bend.
Mine turned pretty easily, some have had more trouble.
Good luck.

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Cheers
Grif

'11 KTM 450 EXC
'09 Suzuki DR650
'00 Discovery Series 2 V8
'95 Defender 90 300 Tdi Overlander
http://gipperstravels.blogspot.ca

Here’s how I fixed mine. Removed carb, let inlet pipe/carb connection steep in Liquid Wrench overnite.

Used my vise with some rubber strips to protect the inlet pipe metal.

Position inlet pipe in the vise and tighten vise. I had mine between the two clamps on the left side of the vise.

IMPORTANT – you want the pipe connection point to the carb as flush & tight as possible in the vise. This is to prevent kinking the pipe. If you have even 1mm or 2mm space you risk kinking the pipe.

So with the pipe connection as flush & tight in the vise as possible, you move the full carb. It took a LOT of force to move it and yes it is a little nerve-wracking. Finally, it gave way just slightly -- you can feel it give.

I removed from vise, examined, and repeated the procedure about four times until I had it where I wanted it (9 o'clock, which has worked fine). It gets a little easier once the first movement is made.

One time I was a little careless and didn’t have the pipe fully flush in the vise. Result – a slight kink. No big deal but lesson learned.

Some guys have tried to do this with vise grips or some kind of wrench, with bad results.

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That's probably the best way to move the metal fuel inlet pipe.

Of course, I did it differently!

I took Carb off bike, carefully held it in a vise using rubber padding. If you clamp too tight ... you will crack your Carb in two!

I then used a big Channel lock pliers. Grabbed inlet tube evenly and with quite a bit of pressure, simply rotated it to 9 'o'clock position, all in one move. Done. Done it on two DR650 Carbs, no problems ... and now I can use ALL of my reserve on my IMS tank. From 10 mile reserve to 30 miles!

Some fit a fuel pump to the Safari in order to suck all the fuel out ... and many use two petcocks, right and left.

Hi guys. We just fitted a 20L acerbis. We used the petcock that came with the tank.

We blocked of the second little vacuum pipe. The bike started but would jot go around the block. Tonight he wont even start.

Also the petrol only flows out on reserve but doesnt fill the little filter thingie ( sorry im a girl and learning all the terminogy)

Can my tank be too empty. I only have a petcock on the left. Other side is empty

Also must the small vacuum hose that was in the original petcock be opened or sealed off.

I commute every day and cant use my bike at the mo

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We all have problems with terminology. What is a wrench in one part of the work is something different in another part of the world.. even where they are supposed to be speaking the same language.

So the basic questions...
The inlet of fuel to the carburettor .. does it point up, or horizontal? Standard it points up, and that means the fuel has to flow up from your tank to get to the carburettor .. liquids don't normally flow up hill. So the inlet has to be rotated so it is horizontal .. see the other posts above as to how that is done.

If you remove the rubber fuel feed line where it gets to teh carburettor fuel should come out (when the tap is turned on). If it does not then you have a problem before this point. Open the fuel cap on top of the fuel tank and see if that fixes it. If not then try removing the fuel line from the fuel tap and see if the fuel now come out of the tap. If not .. look closely at the tap... If you cannot see any thing wrong .. then I'd remove the tap and check fuel will come out of the tank. If fuel comes out the tank then it points to the fuel tap ...

See how your going from looking for fuel at one point .. and moving that point back and back untill you get fuel and isolate one item that is obstructing the fuel? That is the way all fault finding works. There are further considerations .. but on a simple system to a complex system .. this is what is done. It takes time, but you just work through it.

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Oh .. the vacuum line .. you seal that off. Unless the fuel tap requires it.

As Warin says, figure out if the fuel is flowing out of the tank and to the carb first. Sometimes the small inline fuel filters do not look like they have much fuel in them, don't worry about that, see if the fuel is getting to the carb


Can you post a photo of the bike from the side, at the height of the petcock or just below - looking at the side of the carb and showing the fuel hose going from the petcock to the tank?

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Cheers
Grif

'11 KTM 450 EXC
'09 Suzuki DR650
'00 Discovery Series 2 V8
'95 Defender 90 300 Tdi Overlander
http://gipperstravels.blogspot.ca

Thank you Warin... we turned it horizontal. Well try your advice!

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Ok will do

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Ok.it seem it only flows on reserve...so maybe to empty for on? Ok we closed vacuum line with nut. Stayed on for 5'seconds.

Hope this is pics you wanted

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