DAMN Riders - No rules, Just ride!

I recently swapped the OEM tank on my 2009 DRZ to the 3.9 gallon Clarke tank. Everything fit perfectly -- no issues other than needing to get a slightly longer length of fuel line.

But after the installation, I have noticed that the choke is partially blocked by the side of the tank, preventing me from pulling it more than about halfway out. I haven't had any issue starting the bike since, but I can imagine on some cold morning in the future, it could present an issue.

Has anyone else who has gone with the Clarke 3.9 gallon tank seen this issue on their DRZ as well?

Given that the choke lever itself is something of a disk attached to a shaft, I was thinking that grinding down the upper side of the disk could allow the choke to be pulled out farther.

Sorry I don't have a photo -- I'll try to post one up later this afternoon.

Rearden - Mine does the same thing - but I believe I can pull mine at to full choke...we will have to check it out up at Mt Rid this weekend.

Mine does that too. For cold starts I just have to hold the choke out for a few seconds while it warms up. I have heard, and seen, some guys trim the top half of the choke knob off for clearance.

Ovo, Wingfixer, I definitely think that trimming the disk down will improve the situation some... Thanks - I was starting to think I had gotten a variant on the tank that didn't line up properly with the '09 chassis.

If there's anyone out there who actually has shaved down the disk and this has worked (or if ), I would love to hear about it.


The promised photos...Here's the choke pushed in:


And here's the farthest I can get it out (that's a weird sentence... )

somebody here has a plastic welding unit

I vote you carve the tank out and reweld!

Couldn't you just rotate the carb a little?

Mine's the same...never had a problem. I have read a lot of dudes taking the plastic part off, drilling a small hole through the metal pin, and running a ring (like a keychain ring) through the drilled hole in order to get a grip on it. Again though, haven't had problems with mine and it's exactly the same.

Kyler wrote:somebody here has a plastic welding unit

I vote you carve the tank out and reweld!

Man, that sounds like a golden hammer -- everything looks like a nail! Given the good news from Ovo and biffer that they see the same thing and there's no foul effect, I think I'm going to let it ride... But thanks for the offer.

If nothing else, I want to SEE that plastic welding unit work!

biffer99 wrote:Mine's the same...never had a problem. I have read a lot of dudes taking the plastic part off, drilling a small hole through the metal pin, and running a ring (like a keychain ring) through the drilled hole in order to get a grip on it. Again though, haven't had problems with mine and it's exactly the same.

Thanks, biffer... that puts my mind at ease a little. I'll probably ride it out as-is until some cold morning when I can't get it started and I'll "assign" blame to my half-pulled choke...

Heat the problem area of the tank with a heat gun, then use your thumb to make a little more clearance. Not much will be needed, and be careful not to overheat the plastic. Heat just enough to make it a little pliable, hold the pressure, and as the plastic cools it will maintain the shape.