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drz400 oil leak
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Author:  barntodv [ Wed Jan 01, 2014 11:38 am ]
Post subject:  drz400 oil leak

Hi guys , I am not a mechanical person as below probably points out...
my DRZ400S developed an oil leak from a pipe going into the cylinder head just above the exhaust.when i removed it i could not see a gasket.
when i look in my Haynes manual, this pipe is not mentioned.infact the only picture shown is in removing cam section, and the pipe connection blanked off.
i found a copy of the drz microfish on line and it is also not mentioened.only a top end gasket set...
I suppose my question is..should there be a gasket...if so does anyone know if it comes with a the only thing i can find which is a gasket set for the top end.
or should i just put some gasket seal on it..
comments gratefully received..

Author:  old boy [ Wed Jan 01, 2014 12:12 pm ]
Post subject:  Re: drz400 oil leak
Is it anything to do with the decompression plug ?

Author:  Hugh Cleary [ Wed Jan 01, 2014 12:58 pm ]
Post subject:  Re: drz400 oil leak

Happy New Year,

It would help if we knew where you are and could then direct you to a reliable dealership.

For Suzuki in the North West I know that the following companies are very knowledgeable about their products and perhaps more importantly are honest too;

Crooks Suzuki - Barrow in Furness -
Road & Racing - Hyde - Tameside -
Single Tracker - Crewe -

I have dealt with these people, family run enthusiastic independent companies, for many years and I have always found them to be helpful.

You could take a photo of your offending item and post on this website so that we can identify it. :idea:

Hope this helps.


Author:  barntodv [ Wed Jan 01, 2014 1:15 pm ]
Post subject:  Re: drz400 oil leak

File comment: oil leak
oilleak1.jpg [ 505.67 KiB | Viewed 15168 times ]
oil leak

i live in kent,
i have the same parts picture old boy and there is nothing pointing to the connection just above the exhaust..

Author:  barntodv [ Wed Jan 01, 2014 1:45 pm ]
Post subject:  Re: drz400 oil leak

File comment: better picture
oilleak2.jpg [ 534.87 KiB | Viewed 15153 times ]

Author:  Joel [ Wed Jan 01, 2014 1:49 pm ]
Post subject:  Re: drz400 oil leak

Could this be an American emissions thingy ? They have them on crf's destined for California... Not sure what they do though ? Bleeds off some of the exhaust for some reason or maybe just a breather for the rockers ( head etc)

Author:  Hugh Cleary [ Wed Jan 01, 2014 2:11 pm ]
Post subject:  Re: drz400 oil leak

Scratching my head here trying to remember, but if I do then, I think that the pipe is part of the engine crankcase breather system and is not under any major air or oil pressure.

There was, I think, a rubberised type collar seal, something a kin to a large fork leg slider seal, which simply slid over the outlet stub and around the pipe, again if this is correct I think that you can simply mark (permanent marker pen) where the pipe fits into the seal; remove and clean the pipe and its seal, apply a small bead of of Hylomar blue gasket cement inside the lip of the seal or onto the top of the spigot, refit the seal, sparingly apply another small bead of Hylomar blue gasket cement around the pipe just below your mark and then slowly push the pipe back in to place. You might want to follow the other end of the pipe which goes to an oil collector box just below the air box; make sure that it is clear along its length and drain the collector if necessary.

I have a feeling that this was part of the 'clean air' action for US legislation whereby engine breather systems had to have a closed loop system so that the engine burnt its own fumes. Check with one of my dealers listed, they might be able to supply you with a new collar seal.



Author:  Richard Simpson [ Wed Jan 01, 2014 3:20 pm ]
Post subject:  Re: drz400 oil leak

You might find a Clymer manual more informative: it covers all versions including USA, Swiss etc and their various emissions control systems.

Author:  Hugh Cleary [ Fri Jan 03, 2014 4:30 pm ]
Post subject:  Re: drz400 oil leak


Just interested, did you find any correct information or fix the leak and if so how?


Author:  barntodv [ Sun Jan 05, 2014 10:10 am ]
Post subject:  Re: drz400 oil leak

Hi Hugh. I tried all suggested cannot find of the local guys is popping up to take a look.

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