guidance for dr200 petcock/carb
 

1997 dr200 (troublefree for 10 years)
started leaking gas through airbox
I've read up on petcock being bad and possible sticking of needle valve

Current status: carb is off and on the bench
I have the service manual and I am somewhat mechanically inclined.
I've seen the cyclopedia and I am not sure I need it?
The service manual says to take apart carb, but my ?? to you guys and gals is do I need to completely take every part off to clean it?

Gas tank off/petcock removed

I want to get a manual petcock but I've seen so many different post of this works and that works...what really is a good one to go with that the fuel line will work and it will bolt up.

Welcome!

I don't have any direct experience with a bike like yours, but I'm happy to contribute. Is the gas getting into the airbox when parked or when running?

Welcome to these forums. :) I'm not too familiar with your Suzuki, DR200SE; however I will try to help. ;)

If fuel is leaking into your airbox, perhaps the needle valve in your carb's float bowl is damaged. ;) You don't need to disassemble your entire carb to examine the needle valve. Remove the float bowl, and examine the needle valve attached to the top of the float bowl assembly. ;)

I believe your Suzuki employs a vacuum fuel petcock, and many owners substitute a manual fuel petcock. If the vacuum petcock fails, I believe it might cause your carburetor to leak fuel. Therefore, a manual petcock might solve your problem. However, I can't recommend a manual fuel petcock that will fit your Suzuki DR200SE; I think you might be able to find a suitable unit by searching the threads at ThumperTalk. ;)

Spud :)

Agreed with the above.

I'd look into a new petcock from Suzuki.

You probably need a needle valve for your fuel float. They wear out with time. It will cost only a few bucks.

You can cheat with the petcock. Splice a new petcock for a lawnmower or such in between the original tank petcock and the fuel filter. Leave the old one on and use the second one to shut the fuel off.

CHECK YOUR OIL IT IS VERY POSSIBLE/LIKELY GAS GOT INTO THE CRANKCASE AND WILL RUIN THE MOTOR IF YOU RUN IT. I'd change the oil just to be safe...

Also check the DR-200 thread at advrider. There are several options for a manual petcock.

Replace the petcock, An ebay search will bring up many results with manual petcocks of yamahas an such. The original ones are just plain bad.