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Old 11-01-2017, 06:51 PM
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Default Suzuku DS80 carb fuel leak

     

All,

Just picked up a second hand 1998 Suzuki DS80 for my son. It was a mess and so I "restored" it to the best of my ability. I'm currently working on the carb and just finished installing a rebuild kit. My problem is that fuel leaks from the carb from a hole at the 6 o'clock position inside the air intake ring (see photo).

I've set the fuel bowl float at 21.4mm and replaced both the seat and the needle for the float and it still starts leaking out the hole and through the airbox within about 10 seconds, I'm assuming as soon as the bowl fills up. I've also verified that the float itself floats in a cup of fuel - no leak.

Could it be something else within the carb? Is that hole where the shot of fuel is supposed to come from when the throttle is turned?
Thanks in advance for the help!
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Old 11-01-2017, 11:25 PM
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Sounds like the needle valve is not sealing. I had to use an old needle in my wife's XR100 because the one in the off-brand carb kit wouldn't seal.
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Old 11-02-2017, 06:38 AM
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Thanks for the response. Frustrating thing is I've tried two separate seats and needles and both seem to leak. I was hoping it was coming from somewhere else. The hole where the arrow is pointing- is that where the jet of fuel is supposed to come from?

Last edited by Augoose; 11-02-2017 at 07:08 AM.
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Old 11-06-2017, 09:20 AM
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I don't believe that is where the fuel is pulled into the carb from the bowl, an easy test- remove the bowl, remove the float and needle, and spray some carb cleaner up through the passage.
I should have a better answer for you as I've been through the carb on my DS80 ad finitum, but is it possible you forgot to replace a jet or another part when you had the carb apart?
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Old 11-10-2017, 07:05 PM
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Thanks all for the help. As an update, I figured it out. This DS80 used to have the oil injection system but now it uses premix. As a result, I capped ALL the leads to/from the carb except the the line in from the fuel tank of course thinking they would just cause a vac leak. Turns out the line on the same side as the idle speed screw needs to be returned to the bottom of the fuel bowl while the line on the opposite side of the carb needs to be wide open. As soon as that lead was opened instead of capped the fuel stopped flowing.
The bike runs perfectly now with no fuel leak.
Weird.
Thanks for the help!
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