Suzuki DF2.5 fuel tank cap problem

Gixer

Gixer

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I was just draining the fuel from my 2022 Suzuki DF2.5 and when looking into the tank I could see small black particles.
On closer inspection i noticed the source was the fuel cap. It looks like there is/was a foam ring but it’s disintegrated! Apparently it’s some kind of baffle.
I’m really surprised, what could have caused this? Have you seen this before?
I would assume Suzuki would use a fuel safe material.

IMG_2025-10-31-180806.jpegIMG_2025-10-31-180729.jpeg
 
That’s not too clever. Hopefully you have a fuel filter in line to the carb. That plastic/rubber would probably be fairly terminal once it got into the cylinder!

I’ll check my cap next time I’m at the boat - thanks for the heads up!
 
Looks alarming. Have you had the engine from new or could someone else have fitted a replacement bit thats not compatible with fuel.
 
Minerva said:
That’s not too clever. Hopefully you have a fuel filter in line to the carb. That plastic/rubber would probably be fairly terminal once it got into the cylinder!

I’ll check my cap next time I’m at the boat - thanks for the heads up!
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Think the filter on these is integral with the tap and is inside the tank.
 
I have noticed the same on a 2-year old (replacement) filler cap, albeit to a far lesser extent. I could not see any evidence that the particles had passed the inline fuel filter (fuel in the carb bowl was clean); I am not too impressed with the design though. Not sure on what caused it but the material is some sort of sponge/foam.
 
Thanks for the responses guys, really disappointed. I’m usually a Suzuki fan having had many of their bikes.

Fuel is just the normal pump standard unleaded. I’ll remove the tank, clean it and the fuel system thoroughly. Good to hear it’s not an integral part, I’ll do the same as you Snowbird.

Thanks again

Dave
 
Just had a look at my wee Suzuki 2.5. The foam sponge donut looks ok on mine - so it might not be modern fuel related.

I’ll be keeping a wary eye on it from here on in mind you!
 
Minerva said:
Just had a look at my wee Suzuki 2.5. The foam sponge donut looks ok on mine - so it might not be modern fuel related.

I’ll be keeping a wary eye on it from here on in mind you!
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It is some time since I dealt with that engine, probably one of the original 2.5's 🥴 However, just a thought, is the foam acting as an air filter as the fuel tank breather is in the cap?:unsure:
 
Alex_Blackwood said:
It is some time since I dealt with that engine, probably one of the original 2.5's 🥴 However, just a thought, is the foam acting as an air filter as the fuel tank breather is in the cap?:unsure:
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The foam acts as a baffle to stop fuel splashing through the breather in the cap apparently.
I’ve messaged Suzuki, interested to hear what they say.
 
Really crap response from Suzuki.

'I’ve liaised with our Technical Department at Head Office, who confirmed, this is not something we have seen before in the UK. There is also nothing similar recorded in the factory system to suggest a known concern of this nature. The foam ring would normally be fuel-resistant, so it seems it has been affected by something external that has caused it to break down over time.
Regrettably, we’re unable to confirm the exact cause, it may have been influenced by prolonged contact with non-standard fuels, additives, or environmental conditions.'

100% sure that none of the three suggested reasons have caused this.

I'm just going to clean the tank and move on, life's too short...
 
Alex_Blackwood said:
Good question :unsure: :ROFLMAO: :ROFLMAO:
I don't think you could have got anything else from Suzuki. They won't admit the foam is anything other than fit for purpose. What ever that is!:unsure:
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I had the same sort of response from Suzuki when the paint started peeling just out of warranty, no sign of etching primer under top coat. They said they had never received complaints before so must have been abused. Will never buy another Suzuki.
 
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