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Old January 28th, 2016, 10:37 AM   #1
Bowtie2Bimmer
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Tank Swap Help

Hello everyone. I am trying to assist a friend bring his 2005 EX250 back to life. Without giving a long winded story, 2 years ago my buddy was working on his bike and had to remove his tank. He walked away from it and while he was gone, someone stole his gas tank. Ridiculous, right?

Well it has taken him 2 years to get the motivation to work on his bike again. He sourced a used tank from Ebay. However upon receipt, we realized that the two tanks are slightly different. The original one had 3 vent tubes at the bottom. This seemed to run to the Evap Canister. However on the new tank he received, it only has one vent tube.

Is this going to be an issue? How can I route the line so that he can use the new tank? I live in florida so I don't need the evap canister, I am not above removing it if need be.

Any advice would be extremely helpful
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Old January 28th, 2016, 10:47 AM   #2
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The evap canister should be a California thing.

I would just remove it.
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Old January 28th, 2016, 11:01 AM   #3
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That what I was leaning toward. What do I need to do to delete it? And where would the one line from the back of the tank go?
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Old January 28th, 2016, 02:11 PM   #4
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The one line on the non-CA bikes just runs down behind the engine and dumps out on the ground.

I'm not sure exactly what is involved in removing the evap canister.
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Old January 28th, 2016, 02:26 PM   #5
Bowtie2Bimmer
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Awesome, that is a huge help. So I can scrap the Canister assembly and remove all of those lines. One line I will run from the tank to the ground.

What about the hose on the carbs for CA emissions? Should I just connect them together? Cap them off? How do the carb lines look for a non CA model?

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Old January 28th, 2016, 06:58 PM   #6
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...... What about the hose on the carbs for CA emissions? Should I just connect them together? Cap them off? How do the carb lines look for a non CA model?
Welcome, Tony and friend !!!

Yes, remove or cap that T.
That hose carries vacuum to the coasting enricher (left side of carburetor).

Take a look at these articles:
http://faq.ninja250.org/wiki/Intake

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Old January 28th, 2016, 08:03 PM   #7
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Welcome, Tony and friend !!!

Yes, remove or cap that T.
That hose carries vacuum to the coasting enricher (left side of carburetor).

Take a look at these articles:
http://faq.ninja250.org/wiki/Intake

So I should just be able to remove the T and run a straight connector between those two lines?
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Old January 28th, 2016, 09:27 PM   #8
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So I should just be able to remove the T and run a straight connector between those two lines?
Yes; or run a new whole hose.
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Old January 29th, 2016, 08:43 AM   #9
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Fantastic. Sounds easy enough.

Last question, is there a difference in gas caps between the two tanks. the new tank didn't come with cap so we are going to use the old cap. However i read that sometimes there may be an issue with vapor lock?
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Old January 29th, 2016, 08:50 AM   #10
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Quote:
Originally Posted by Bowtie2Bimmer View Post
Fantastic. Sounds easy enough.

Last question, is there a difference in gas caps between the two tanks. the new tank didn't come with cap so we are going to use the old cap. However i read that sometimes there may be an issue with vapor lock?
The gas caps should be the same, however all gas tank lids have been known for the two seals to go bad and cause vapor lock, I haven't removed my seals yet, but I plan on doing it soon after I go over my jeep. I might take some pictures to help you out, I once saw a DIY on it before, but cant manage to find it.
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Old January 29th, 2016, 11:05 AM   #11
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gas caps are the same.

49-state tank is a welcome change IMO. Easier to get rid of the EVAP stuff
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