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Old March 24th, 2012, 11:27 AM   #121
gstx
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Hey guys, so I was getting ready to do this mod but I noticed something different that the old owner probably did to the bike. First there isn't any small tube that runs from the 'vacuum controlled valve' to the 3 way T connector, only the 2 big tubes to the cylinder head and airbox.

Secondly, the 3 way T connector listed in the pictures.. one goes to the carb, one goes to the fuel petcock, and one goes into the fuel tank. I have no idea what that means, but since my setup is currently different from the instructions I don't want to really mess anything up. Will appreciate any advice, thanks!
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Old March 24th, 2012, 01:31 PM   #122
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hmm will have to look into this.
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Old July 6th, 2012, 05:09 PM   #123
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i had previously removed the kleen air system on the bike. Plugg'ed a couple of the hoses as you can see from the BB's used at the ends of the 2 hoses in the photo.

Installed a smog plate, and now bike doesn't want to run with the tank hooked up. Bike runs when it's hooked up to a gas container at the shop tho.

pic1.jpg

I'm wondering if one of the hoses is suppose to be connected still?

The the nipple at the top of airbox is capped off with the supplied piece.

pic2.jpg
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Old July 6th, 2012, 05:23 PM   #124
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Sounds to me like you removed the hose that runs from the vacuum source (on the carbs) to the fuel tank valve.

There is a built-in shut-off valve on the fuel tank that requires a negative pressure to open and allow fuel to flow. This negative pressure comes from the carbs. You'll need to reconnect the small hose that ran from the carbs to the fuel tank in order to get everything working.

Cheers,
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Old July 6th, 2012, 06:29 PM   #125
htdub
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I totally am lost on the hose routing

pic3.jpg pic4.jpg
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Old July 6th, 2012, 07:10 PM   #126
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Can't remember which of the carb hoses went to the petcock
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Old July 6th, 2012, 07:22 PM   #127
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I don't even have my bike any more, so I can't really confirm which it is...

I've circled the valve on the petcock that needs to be connected, and the two that I was able to narrow it down to on the carbs. If the hoses go to anywhere else on the carbs, then it's not that one. The hose in question used to run to a T connector, then off to the petcock and the Kleen Air system. If you removed the Kleen Air system and the petcock is disconnect, then you must have a hose coming off the carbs that goes nowhere.

See the attached pictures... Where do the two hoses circled in red go to?

Cheers,
Owen
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Old July 6th, 2012, 07:27 PM   #128
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I had the hose from the front middle of the carbs goto the circled petcock photo

The other 2 circled hoses, those just goto the Othe side of the carbs
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Old July 6th, 2012, 07:41 PM   #129
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Ahh... sorry. I remember now. That is indeed correct the way you have it. You can attach the two ports indicated with the arrow directly to one another. That's the way I did it and it worked like a charm.

Are they well connected? Do you have a leak anywhere?

Make sure the hose is pushed fully onto the petcock and the carb.

If it's not that, then I really don't know. You might need to adjust your idle.

I had serious issues when I performed this modification (I went over them in detail several posts back) but installing a K&N pod filter an re-jetting solved the issue. With the stock airbox though, I had idle problems and times when I would completely lose power and the bike would stall.

Cheers,
Owen
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Old July 6th, 2012, 10:23 PM   #130
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I had that hose running to petcock

I think it's suppose to be a overflow and just run a open hose from it
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Old July 7th, 2012, 01:48 PM   #131
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Nope... you definitely have it right. The overflow tube is much farther up the tank and comes directly out the side.

From what I remember, you can bypass the whole petcock negative pressure valve by just setting that switch on the petcock to "prime". You might want to try that and just rule out any possibility of leaks in that hose. If the bike runs fine with that valve in the prime position, but doesn't run with it in the "on" position, then you can be sure your problem is likely a leak in the vacuum system.

Another thing to try is to adjust your idle. You may need to increase it a little to get the bike to run in a stable manner. You can also try your choke to see if richening up the mixture helps.

Cheers,
Owen
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Old July 7th, 2012, 01:57 PM   #132
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Tried prime and didn't want run that well at all. Going to check all the connections again.
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Old July 7th, 2012, 02:14 PM   #133
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Now that I look a little closer, I'm pretty sure you have a California bike with the significantly more elaborate Kleen Air system.

The pictures of your removed system don't look like mine at all.

Look closely at the first post in this thread, and notice that the normal Kleen Air system only has three hoses coming off it. One goes to the cylinder head, one goes to the carb, and one goes to the airbox.

At the bottom of that post, there are pictures of the California model with several more hoses and another box tucked away.

Based on the pictures you've posted I'm guessing that's what you've got, which requires a whole different procedure for removal.

Cheers,
Owen
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Old September 10th, 2012, 07:20 PM   #134
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Just wanted to give credit to the OP. This is my first post on this forum so as a quick intro, live in the DFW area and decided to pick up riding about 3 months ago as a new hobby, but more to save on $$ on fuel costs and went and purchased a new 2012 Ninja 250r and shorty took the MSF course and the rest is history.

My first mod was to change the exhaust as to stand out more and be heard... Didn't really do it for a performance increase. Like most, the exhaust began popping and backfiring and did start get on the annoying side. I decided to take the plunge and give this mod a shot, take in mind that my mechanical skills is very novice, but the instructions seemed pretty straight forward. Only thing that took me for surprise was that I didn't think I was going to have to remove the gas tank. Probably a good thing though or I may have decided not to attempt it, but after having taking everything apart, decided to keep modding.

The result ended with the popping/backfiring was greatly reduced, but not completely eliminated. I only tested it out for a short ride, but I'll see how well it worked on my ride to work tomorrow morning.

Thanks, kkim, for the write up!
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Old December 13th, 2012, 04:51 PM   #135
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Kleen air

Has anyone had any problems after removing the system and i mean mechanical such as to much pressure or blowing gaskets?
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Old December 13th, 2012, 05:07 PM   #136
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Originally Posted by Superninja View Post
Has anyone had any problems after removing the system and i mean mechanical such as to much pressure or blowing gaskets?
no
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Old December 15th, 2012, 09:51 AM   #137
htdub
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My bike runs only as a track bike and it runs very well.
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Old January 13th, 2013, 08:42 AM   #138
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Question kleen air system???

Bought my bike in Texas, 2012. Does it have the Kleen air system a well?
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Old January 13th, 2013, 11:23 AM   #139
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yup... they all have it as far as I know.

California bikes have a more elaborate version with a few more connections and another module involved, but I think all other versions are the same type as what you see in this thread.

Cheers,
Owen
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Old January 13th, 2013, 11:49 AM   #140
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Just a note but some bikes sold in other states are actually CA models. It's not uncommon for the factory to setup a few to many bikes as CA models then ship them off to other states in need more bikes.
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Old February 22nd, 2013, 12:52 PM   #141
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so do I need to cap the crankcase "chimney" too?
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Old April 20th, 2013, 11:29 AM   #142
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Brining up an old thread.

Why is the airbox hose attachment blocked off?

Thanks,
Doug
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Old April 20th, 2013, 11:51 AM   #143
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Brining up an old thread.

Why is the airbox hose attachment blocked off?

Thanks,
Doug
It attaches to the clean air side of the airbox.

snorkel intake -> air filter -> clean air -> carbs


If you don't block it off, you run the risk of dirt getting into your carbs, because it by passed the air filter.
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Old April 20th, 2013, 11:53 AM   #144
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aha... didn't realize it was on the other side of the air filter.

Thanks,
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Old April 1st, 2014, 01:16 PM   #145
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Smile Reinstalling CA emissions

Trawling up an old thread here. I recently bought a 1998 250 with 1100 miles that a title search showed had never been anywhere but TX (where I live), yet it had a CA tank but no CA emission equipment. Possible that the tank was a replacement but can't be sure. Plus the L side panel had the CA emissions hose diagram that suggests it was a CA spec bike.

I originally capped off the red line as suggested by many others on the forum, but didn't like the idea of that becoming a source of leakage. So I got on eBay and found a complete set of emissions for $33, went to the local auto parts store and constructed a 'T' line between the carbs and plugged it all up per the routing diagram. The Haynes manual suggests testing it by putting 20 mL fuel in the top of the separator and seeing if it makes it to the blue return. Everything seems to be working so far, so I have not done it.

Has anyone done something similar? If so were there any problems? Or am I the only idiot who actually re-installed emission control equipment in pursuit of 'keeping it original'?

Thanks! And thanks to all for this great forum which helped me figure this out in the first place!
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Old August 23rd, 2014, 07:34 PM   #146
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Can anybody help me with the ca emissions version? I tried following OP as best as I could but as pointed out the CA model has some extra connections. I'm currently left with a hose out of carb to a T connection, one end capped, the other end to petcock. Air box and chimney are capped. My issue is with the gas tank connections. There are 3 connections on the gas tank. Only the overflow is connected. The other 2 are capped. Is one of the other connections supposed to go somewhere?
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Old August 24th, 2014, 04:28 AM   #147
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Hi all,

In regards to removing the kleen system. If you've done it, does it stop the bike from backfiring loudly when turning on? My bike does that from time to time and it sounds like a gunshot. I'd rather not wake up the whole street at 4:30am with it too...
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Old August 24th, 2014, 04:14 PM   #148
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This answered my question. Middle vent needs to stay open.

Quote:
Originally Posted by Linkin View Post
Hi all,

In regards to removing the kleen system. If you've done it, does it stop the bike from backfiring loudly when turning on? My bike does that from time to time and it sounds like a gunshot. I'd rather not wake up the whole street at 4:30am with it too...
Not sure that it does, but the backfire at startup is notorious with our bikes
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Old March 15th, 2019, 12:15 PM   #149
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Hate bringing up a VERY VERY old thread, but I always think it's best to had as much info in one thread as possible, as opposed to a hundred I pulled the clean air system, and after reading all the pages here I'm still slightly confused is it best to VENT this, or CAP it. Thanks!
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Old March 15th, 2019, 02:39 PM   #150
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I capped mine, didn;t want an opening into my engine.
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Old March 15th, 2019, 06:10 PM   #151
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Mine I put a little breather on.
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Old March 15th, 2019, 06:55 PM   #152
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This is what I went with...
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Old March 15th, 2019, 07:37 PM   #153
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Quote:
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This is what I went with...
Yeah like that but mine points straight up.
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