Question about Suzuki DR-Z 400 S Motorcycles

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More on ... 2006 Suzuki DRZ400S oil leak from bottom of air cleaner.


I bought the bike with 2,400 miles on it. I am assuming that the previous owner was not able to do any significant damge to the rings during that period of time but, I do not know for sure.

I have not ridden the bike that hard so, I do not believe that I have damaged the rings. The bike now has about 6,300 miles on it.

I took it into a Suzuki dealer and they basically just checked the oil level, which was fine, and they wiped out the air cleaner.

I did not notice any leakage for about a week but, then it started again. I guess that it took that long to build-up in the air cleaner before it started to leak out again.

Come to find out, this bike came from California so, it has extra emmision **** on it. I wonder if that has complicated this situation?

Is there a value on the breather hose that may be defective?



for part lists.

Do you think that the extra emmisions **** is complicating this problem? If yes, can the extras emmisions **** be removed? How do I do that?

Do you have any other suggestions as to how I can prevent oil from enterring the air cleaner case from the breather hose?

Thank you,
Tom Kraus

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Add a pcv valve by disconnecting the hose form the breather box and installing a universal crank case vent pcv valve p.c.v positive crankcase ventilation
this should solve your problem, you can purchase this valve at any parts store like advance auto parts o reilly or auto zone

Posted on Jan 22, 2009

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SOURCE: More on ... 2006 Suzuki DRZ400S oil leak from bottom of air cleaner.


Thank all of you very much for taking the time to help me resolve this problem.

As it turns out, after two trips to the Suzuki dealer and $200+ later, it was determined that the previous owner had removed the Oil Return Tank and tied-up the hoses.

Apparently, he thought this was unnecessary emissions equipment but, the Emissions Control section of the Service Manual does not even mention the Oil Return Tank.

I have not noticed any oil dripping out of the Air Cleaner over a two week period, after a new Oil Return Tank was installed.

When buying a used bike, ALWAYS ask the owner several times what parts have been removed and/or added?

Thank you,
Tom Kraus

Posted on Mar 16, 2009

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My suzuki 2005 s83 boulevard oil looks like chocolate milk.Bike has only 8000 miles.Rode and checked oil the other day was fine.I only rode 1 mile, not that hard.Checked oil today...looks bad

Sounds like water / oil emulsification. Is your bike water cooled or air cooled? If it's water cooled then you may have a gasket leak. If it's air cooled then you may not be riding the bike enough to get a good temp up inside the engine which would drive off the condensation inside the crank case / sump thereby leading to the emulsification. You say you rode an easy mile - certainly that's not enough to get the temp up enough to drive off the water. Was the bike running ok? Was it accelerating and braking ok? If so then try a cautious longer run and keep an eye on your levels. If in doubt consult a bike shop.

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Does it smoke at all? It's possible that you have either added to much oil, or you have worn pistol rings and the oil is slipping past the pistons and being forced into your breather.

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My harley has a small leak coming from the air filter, the mechanic at the harley dealership told me it was the air filter. So i bought a new filter put it on and checked the oil level, with the bike...

Regrettably, a small oil leak from the air cleaner assembly is "normal". This is because the EPA requires all crankcase emissions to be routed to the intake system so that it can be burned in the engine. The result is that oil mist in the crankcase vented condenses in the air cleaner and eventually drips out.

The crankcase vent for your Sporty is in the heads. If you noticed, there are two large bolts that are hollow holding the air filter backing plate on. The crankcase vents into the air cleaner assembly through these two bolts. There is an "unbrella valve" in the rocker box center section that allows the air to flow one way but not the other. There are baffles in this area to keep the oil mist to a minimum but still there is some in the air coming out of the engine.

There are a few kits available on the aftermarket for re-routing this crankcase vent. You can direct the exit anywhere you wish using one of these kits. Most people just route the hose down and exit it under the bike just in front of the rear wheel.

When adding oil to your bike, only add the oil when the engine is hot. On your dipstick, you have two marks. The upper mark represents "FULL HOT" while the lower mark represents 'FULL COLD", Do not overfill. Check the level with the bike on the side stand.

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That is a lot of oil - is it blowing smoke? Is there any indication of where the oil is going?
The GSX engine is bulletproof - normally - and doesn't use much oil at all. I have serviced 35,000 mile bikes after 7500 miles and the oil has been spot on.
Looking on the net, it seems the 1400 is a bit vulnerable to oil-cooler damage. With an air/oil cooled bike this could be an indication of where the problem lies. The engine won't leak oil while stationary - well, maybe a drop... but when it is warm and under revs any hole in the oil cooler could be a direct exit point for oil. Look for stains on the exhaust headers - if you are driving and there is a leak, that'll be the first place the oil will go.
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Want to change the oil on my 2006 suzuki drz400s- there is not dipstick on the filler cap and I do not want to over fill it. any advice?

provided the bike doesnt leak oil... all you have to do is measure the amount of oil that comes out when you drain it then replace that amount

Jun 16, 2009 | 2007 Suzuki DR-Z 400 SM

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Oil overspill coming out of air cleaner/filter

Relax...... Harley's all vent oil thru the air cleaner, actually, S & S does to, except they put a overflow valve so it drips on the road rather than the engine. Various little things can cause the oil flow to increase, and yes, over filling, over heating, and sometime, just running balls out for awhile.

Its normal, and shouldnt cause any problems more serious than oil mist on yer engine ( and sometimes passenger)

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I just baught an 06 m50 with 8500 miles on it. I am used to bikes with chains, chokes, carbs etc and dont really know what to do with this one. How would you recommend I take care of it.

Great Bike. Suzuki recommends Oil/air change every 6000Klms.(+-3700 miles)
Suggest you blow out air cleaner every 1000 miles.
No adjustment required on drive (Diff), I change the diff oil every 10,000 klm (6000 miles)
As for the rest, it requires no tuning etc, but will required tapped adjustment At +- 12000klm. I would check yours now (8500 miles). There are manuals available on the net.
Obviously check brakes /tires/ oil levels etc
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More on ... 2006 Suzuki DRZ400S oil leak from bottom of air cleaner.

Check the compression. Pressure getting past the rings can cause the problem. Does the bike burn any oil when you ride? If it does the rings are suspect....... Okay, you have oil > is it the right oil? The prior owner may have put something stupid like 5w30 oil in the crankcase. Do an oil change and put in the heaviest oil Suzuki says is proper. If extra emission stuff is on the engine the dealer should be able to identify the items and you or they could remove or bypass them. Are they contributing to the problem... who knows. Kind of a shot in the dark on that part of the equation.

Jan 20, 2009 | 2004 Suzuki DR-Z 400 S

1 Answer

2006 Suzuki DRZ400S oil leak from bottom of air cleaner.

Often times there is a engine breather tube that has to do with emissions that runs from the engine to the air filter breather box. This tube can in some cases blow oil through it when the engine is run hard. Make sure you're not over filling the engine with oil when you change it because this will cause the oil to "blow off" the excess and the air box is where it often goes.
There is also another possibility, are you using too much oil in your air filter after you clean it? This too is a common cause for oil in the air box, if that's the case I would not worry about it.
The last case scenario is one you don't want, that would be washed out rings which cause blow by and that in turn causes the engine to blow oil out of the breather tube which I'm confident it venting into the air box.
Please let me know if these resolve your question and if not give me more details and I will be happy to assist you further.

Dec 08, 2008 | 2006 Suzuki DR-Z 400 SM

1 Answer

Gas Mileage for 2005 Suzuki DRZ400S

40-50 depending on how you drive it and where you go. Hard riding off road less mileage. Street riding taking it easy better. Check out for some good tips on the DRZ. Also under the DRZ section is great info and more than you ever wanted to know about your bike. I'v had mine for 2 years now and love it. If your going to go off road at all get diffrent tires. The stock death wings are dangerious off road. Good choice in bikes.

Nov 10, 2008 | 2004 Suzuki DR-Z 400 S

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