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gas leak, gas in oil, won't run-tried everything

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I have a 2000 DR-Z 400 and I decided to have the gas tank boiled out and coated to get rid of some surface rust. the problem is when I re-attached everything (including the vacuume line to the petcock) and tried to crank it, it smoked like crazy. started leaking gas, fowling the spark plug and after having the carb rebuilt by a pro (who also put some kind of spring in the housing of the petcock he said to open the diafram?)I still can't diagnose what happened. it still won't run. I am draining the oil now to find that it has more gas in it than oil and I found your web site when I over filled it with 2 quarts and took the plug out and no oil came out. I found the posting about the oil being in the frame. Boy this is nothing like my old XR250 or 79 RM 125.

any advice to a new DRZ owner???

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I have a 2000 DR-Z 400 and I decided to have the gas tank boiled out and coated to get rid of some surface rust. the problem is when I re-attached everything (including the vacuume line to the petcock) and tried to crank it, it smoked like crazy. started leaking gas, fowling the spark plug and after having the carb rebuilt by a pro (who also put some kind of spring in the housing of the petcock he said to open the diafram?)I still can't diagnose what happened. it still won't run. I am draining the oil now to find that it has more gas in it than oil and I found your web site when I over filled it with 2 quarts and took the plug out and no oil came out. I found the posting about the oil being in the frame. Boy this is nothing like my old XR250 or 79 RM 125.

any advice to a new DRZ owner???

where is it leaking gas from?

he added a spring to the petcock or replaced a damaged part?

Does the fuel flow from the petcock with the engine off and the petcock in the ON position?

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I am draining the oil now to find that it has more gas in it than oil and I found your web site when I over filled it with 2 quarts and took the plug out and no oil came out.

I don't understand this part. No oil came out when you removed the drain plug from the engine? There are two plugs, one on the frame and one on the motor.

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1'st

The spring inside the petcock probably isn't the best idea. Vacumn from the carb operates the diaphram allowing fuel to flow when in the on position. He has now jury rigged it to be the same as the prime position. Since there is no overflow on the carb this is not really good.

2nd. The oil plug was it the engine or the frame? Did you get no oil out of either?

3rd where did the fuel leak from. There is a recent thread about open fuel lines dumping fuel into the cylinder and air box not out the vent.

Good luck.

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you have an s model from the petcock repair.put the lever in the pri position(lever straight down and check to see if fuel comes out the end(on and res need a vacuum to work).wheres the fuel leaking from?if you oil had that much gas in it the only reason i can think of is you or someone else pored gas in the oil filler hole on the top of the frame :bonk: but i'm sure you didn't do that right :thumbsup: .i would find the leak and fix it put the right amount of oil in it and a new plug and try again.the oil didn't come out of the bottom drain on the frame is because it needs to trickle down from the frame.if it started up the oil would go to the bottom right away.if you cracked the frame drain lots of oil would of come out.

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Sounds like the petcock is operating on gravity flow rather than vacuum. This allows fuel to overflow the carb and drain into the crankcase. You need to undo the spring job your not-so-knowledgeable "professional" mechanic did.

As far as no oil in the crankcase is concerned, if you put two quarts of oil in the proper hole then you are removing the wrong plug to check the oil. What's the dipstick say?

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OK, Heres the deal... apparently the gravity flow allowed gas to flow into the crank case. This I figured out. The oil not coming out when I took out the plug was solved last night when I read the DRZ-info page :thumbsup: . I didn't know about the oil in the frame. This bike was a recent purchase and I obviously haven't done my homework on it yet.

Thanks for your help!!!

I learned everything I needed to push me in the right direction.

Today I found the other drain plug, got oil corrected, changed my plug and fired her off. Problem solved.

My puzzle lies in what caused the petcock to go into gravity mode?

How do I get it back to normal or prevent it from re-occurring?

Today I could not spot any gas coming out of the overflow or smell it on the dip stick.

Thanks again for all of your help,

Hulsenator

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My puzzle lies in what caused the petcock to go into gravity mode?

How do I get it back to normal or prevent it from re-occurring?

Today I could not spot any gas coming out of the overflow or smell it on the dip stick.

Thanks again for all of your help,

Hulsenator

The S petcock is vacuum operated. No fuel should flow with the petcock in the ON position and the motor off. You should be able to leave it in this position and remove the fuel line. Take the fuel line off and see if fuel flows.

My S petcock was faulty from day 1 and even though I was able to take it apart and fix it myself, I never trusted it after that. I replaced it with a manual petcock from the E and then plugged the vacuum port on the carb. Now I just have to remember to turn the fuel off. :thumbsup:

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OK, Heres the deal... apparently the gravity flow allowed gas to flow into the crank case. This I figured out. The oil not coming out when I took out the plug was solved last night when I read the DRZ-info page :thumbsup: . I didn't know about the oil in the frame. This bike was a recent purchase and I obviously haven't done my homework on it yet.

Thanks for your help!!!

I learned everything I needed to push me in the right direction.

Today I found the other drain plug, got oil corrected, changed my plug and fired her off. Problem solved.

My puzzle lies in what caused the petcock to go into gravity mode?

How do I get it back to normal or prevent it from re-occurring?

Today I could not spot any gas coming out of the overflow or smell it on the dip stick.

Thanks again for all of your help,

Hulsenator

take the petcock apart. you'll see a spring loaded diaphram. it sounds like your mechanic intentionally put the spring on the wrong side to keep petcock in full flow mode. that spring should be holding diaphram closed. when the motor turns over,the vacuum from it is meant to pull that diaphram open.

or, buy a manual petcock, plug the vacuum port on the carb. & turn it to the off position when not in use. i personally hate the vacuum petcock.

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Also, if that petcock diaghram is leaking or not sealing properly, then gas might be draining or being pulled through the vacuum line right into the intake tract and right into the engine.

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2 questions?

Which side of the diaphram should the spring be?

(he took a old spring and cut it and stuck it in the diaphram)

Should there be a gasket between the petcock & the frame?

(gas is leaking around the petcock where they sanded the paint off when putting the peckoct back on the paint.)

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2 questions?

Which side of the diaphram should the spring be?

(he took a old spring and cut it and stuck it in the diaphram)

Should there be a gasket between the petcock & the frame?

(gas is leaking around the petcock where they sanded the paint off when putting the peckoct back on the paint.)

The petcock never touches the frame :thumbsup: so I'm guessing here, you mean petcock and tank? If so the answer is yes, it has an o-ring.

First of all.. Your killing your self trying to save a 6 year old faulty fuel valve, which not once but twice allowed raw fuel to enter the motor... Throw that that valve away. Pick up a new one, Pingle makes a great fitting great quality valve. If you really want the vac operated OEM one,, then look at the TT OEM parts store http://oem.thumpertalk.com/SearchResult.aspx?KeyWords=44300-29F20 or one of the other on line OEM parts retailers

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The risk of not replacing it is fairly great, oil loses it's ability to provide lubrication when mixed with gas. If it happens and you are riding there is a chance you will take out your engine.

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