Ran '03 DR-Z400E out of gas, now leaks fuel.

[TheFleshRocket]

Yesterday, I ran my DRZ out of gas on the way to the gas station.  No big deal, the wife brought me a gas can and made fun of me while I poured it in.  I went to the gas station and topped of the tank--to less than an inch below the top.  (Not gonna run it out of gas again, I thought!)

 

At work, I noticed a few drops of gas but assumed it was because I'd overfilled.  Near the end of the day, a couple of the guys said it smelled like gas around my bike and, sure enough, it was still leaking gas from one of the hoses in front of the swingarm.  Drip... drip... drip... drip.  Steady and moderately quickly.  I rode it home and it was still leaking gas after I parked it.  

 

Shutting off the petcock stops the leak after a bit--maybe 5-10 minutes.  Running the bike with the petcock off until it dies stops the leaking immediately.  I've taken the bike on a handful of short trips and every time I stop, it drips.  I've tried tapping the carb a few times gently with a plastic screwdriver handle, with no apparent benefit.

 

I checked the oil and it is not high, nor does it smell like gas.

 

The bike only gets run a thousand miles or so a year (mostly around my yard with my kids, sometimes to work which is only 7 miles away).  It gets a steady diet of premium, albeit with 10% ethanol (as there is no non-ethanol gas available), but it does get Seafoam added with every tankful as well.  It's never had any problems starting or running (aside from being a little cold-blooded if I don't leave the choke on for a few minutes, but even that is mild).  When it's parked for several months over the winter, I don't run the gas out of the carb, but again, it's got Seafoam in it and in my personal experience, it keeps E10 gas good for at least a year.  

 

I assume that the float valve is no longer seating properly, causing the bowl to overfill, and leak.  (I'm assuming--not sure of any other way it could be leaking fuel like this.)  I figure the carb internals OUGHT to be in good shape, though.  Is there any way to resolve this short of pulling and cleaning/adjusting the carb so that the float (assuming that's what the problem is) is working properly?  Is there anything else that could be causing the persistent, steady leak?

[bumtarder]

Yes,float needle and seat are bad and need replacing to stop the leak.You basically answered your own question.

[Dmouse]

 Run the carb dry, lean it against a wall on the right side, disconnect the fuel line at the carb, then spray carb cleaner in the opening. You may have a spec of dirt or something on the needle, pulling the carb is a bear, it's worth a try 

[bumtarder]

Pulling a fcr39 is only a 20 min. deal.It wouldn't be a bad idea to also get a rebuild kit as that carb is getting pretty old and should be gone through and freshened up.

[Dmouse]

Pulling a fcr39 is only a 20 min. deal.It wouldn't be a bad idea to also get a rebuild kit as that carb is getting pretty old and should be gone through and freshened up.

 It takes me 20minutes to remove seat, tank and plastic side panels! I bought my 03 E 8years ago, it had sat for a couple years and was dripping gas like the OPs', I did the carb-cleaner trick that I mentioned and it worked fine. I have only pulled my carb once, 5years ago to re-jet, compared to previous bikes I've owned, it was difficult, one thing I didn't do was loosen the sub-frame, is that something you do? 

[bumtarder]

It takes me 20minutes to remove seat, tank and plastic side panels! I bought my 03 E 8years ago, it had sat for a couple years and was dripping gas like the OPs', I did the carb-cleaner trick that I mentioned and it worked fine. I have only pulled my carb once, 5years ago to re-jet, compared to previous bikes I've owned, it was difficult, one thing I didn't do was loosen the sub-frame, is that something you do?

No,I don't touch the subframe.You remove,disconnect and set aside the r/r,disconnect the intake boot from the carb inlet and with a pair of large pliers handles pull the boot off and fold it back behind the frame.Loosen the breather box.This will make removing and installing the fcr a snap.

Years ago Eddie did fcr39 conversions at his shop in 30 min. while the guys waited,that included removal and install and set up.

[Dmouse]

No,I don't touch the subframe.You remove,disconnect and set aside the r/r,disconnect the intake boot from the carb inlet and with a pair of large pliers handles pull the boot off and fold it back behind the frame.Loosen the breather box.This will make removing and installing the fcr a snap.

Years ago Eddie did fcr39 conversions at his shop in 30 min. while the guys waited,that included removal and install and set up.

 Pull the boot off with a pair of large pliers handles? I'm not following you, you mean like waterpump pliers? If so, the handles? Use them like chopsticks? And when you say 'breather box', you mean the airbox, not the plastic oil breather box, right?

[bumtarder]

I use a large padded pliers handles and yes,like chopsticks or a shift fork to cradle the airboot back while l lever the other end of the tool against the frame.I was referring to the crankcase oil recovery tank,the black box not the air filter housing.

[TheFleshRocket]

I ran the bike with the petcock off until it stalled, then leaned it up against the garage (on its right side), removed the hose that goes into the carb, and shot a couple of bursts of carb cleaner into it.  After reconnecting the hose, turning the fuel back on, and starting the bike, instead of drip.... drip.... drip... it was now dripdripdrip.  So, I took it over to the local hole-in-the-wall bike shop and left it with them.  Carb internals are pretty much black magic as far as I'm concerned--I understand the principles of how carbs work, but every time I've taken one apart, I've either made no improvement or made it worse.  

 

Thanks for the input, everyone, and hopefully someone else can benefit from the knowledge presented here.