Replace the Fuel Tap Diaphragm and Gaskets on a Suzuki DR650 SE

Introduction

Vacuum-operated fuel taps can often cause issues like fuel supply interruptions or leaks. That's why it's important to check and clean them regularly. This guide walks you through a full gasket and diaphragm replacement on a Suzuki DR650SE SP46B. Always use original replacement parts—aftermarket ones have caused issues in the past.

What you need

Step 1 Fuel Tap Diaphragm and Gaskets

Replace the Fuel Tap Diaphragm and Gaskets on a Suzuki DR650 SE, Fuel Tap Diaphragm and Gaskets: step 1, image 1 of 1

Loosen the two screws—either with a large Phillips screwdriver or a 10 mm open-end or ring spanner.
Important: The tank should be no more than 1/4 full to prevent fuel from leaking. Once it's drained enough, you can stand it upright.

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Step 2

Replace the Fuel Tap Diaphragm and Gaskets on a Suzuki DR650 SE: step 2, image 3 of 3

Using a PH2 Phillips screwdriver, remove the five screws from the diaphragm cover and carefully lift it off. Caution: The diaphragm spring is under tension and may pop out when opening the cover.
Diaphragm
Diaphragm spring
Diaphragm cover
Inspect the seal kit and clean the parts if necessary.
Now remove the diaphragm together with the backing plate.

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Step 3

Replace the Fuel Tap Diaphragm and Gaskets on a Suzuki DR650 SE: step 3, image 3 of 3

Using a PH2 Phillips screwdriver, remove the two screws and take out the actuator.
Remove the sealing plate and the O-ring.
Actuator
Spring washer
Cover plate
Now remove the base gasket.

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Step 4

Remove the diaphragm. At this point, all components should now be fully disassembled.

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Step 5

Diaphragm
Diaphragm intermediate plate
Diaphragm cover
Diaphragm spring
Base gasket
Body
Sealing plate

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Step 6

Replace the Fuel Tap Diaphragm and Gaskets on a Suzuki DR650 SE: step 6, image 3 of 3

Countersunk screws
Actuator
Spring washer
O-ring
Cover plate
Pan head screws
Here's a diagram that shows how the fuel tap works.

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Step 7

Lightly grease all three gaskets. Use the metal spudger to remove the old seals. You can press the new ones in by hand.
Insert the sealing plate
Place the O-ring into the body

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Step 8

Replace the Fuel Tap Diaphragm and Gaskets on a Suzuki DR650 SE: step 8, image 3 of 3

Insert the spring washer and the cover plate into the actuator, then install it into the main body. ⚠️ Make sure the spring washer doesn't get pinched during assembly. You’ll notice this if the fuel tap gets stuck when turning from "On" to "Res"—this indicates the washer is misaligned and needs to be repositioned.

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Step 9

Replace the Fuel Tap Diaphragm and Gaskets on a Suzuki DR650 SE: step 9, image 3 of 3

Install the new diaphragm into the intermediate plate

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Step 10

Replace the Fuel Tap Diaphragm and Gaskets on a Suzuki DR650 SE: step 10, image 3 of 3

Insert the diaphragm back into the body.
Position the spring in the center of the diaphragm plate.
When reassembling, make sure the spring sits precisely in the inner ring of the diaphragm cover—if misaligned, the valve mechanism on the opposite side may jam.

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Step 11

Replace the Fuel Tap Diaphragm and Gaskets on a Suzuki DR650 SE: step 11, image 3 of 3

Use a PH2 Phillips screwdriver to reattach the five screws on the diaphragm cover.
Fuel outlet
Vacuum port
Function test: Apply a slight vacuum to the vacuum port. The valve should open. You can test this by blowing into the fuel outlet. When the vacuum is released, the valve must close immediately.
Finally, install the base gasket.