Fuel tank hose routing

team7 · June 16th, 2018, 11:09 AM

Hi, ive been lurking on here for a while. I recently pulled my carb to fix a stuck float. I have everything back together and realized fuel is pouring out the bottom of the tank. I was hoping someone could tell me where the nipple routes to. Probably hard to see as its up and to the right. I am thinking I either have a loose hose somewhere or I have a hose misrouted. I have been trying to look through the service manual but not finding what I need. Thank you!

Keithb7 · June 17th, 2018, 06:59 AM

I just put my tank back on yesterday. Over on the RH bottom side of your tank, that there is the fuel gauge sending unit. There is no line hooked up to that. Not on my tank any way.

Is it possible the fuel is leaking from some other hose or fitting on your bike?

team7 · June 17th, 2018, 07:24 AM

Thanks for the confirm Keith. I found one other video where there was a shot of that and it wasn't connected. I messed with the petcock pri and on. When I went to fill again nothing came out. I think it was a fluke but that makes me feel better it's not connected to anything.

Bike still won't start though. It sat for a few years and one of the floats were stuck which caused the fuel to mix with gas. I replaced the floats, changed oil, changed spark plugs and no luck. Bike iddled a bit and then I tried to pull the choke lever back and it died never to start again. Plugs were wet so I know it's getting fuel.

When pulling the carbs the instructions had you adjust the mixture screws before I knew what I was doing. Tighten them all the way down and two and a half turns back out was the setting. Could this be the issue?

Keithb7 · June 17th, 2018, 08:03 AM

I am fairly new to the Ninja but have experience with other gas toys. If the bike did start and run and now won't there are a couple tricks I would try.

3 basic things. Fuel, compression & spark. A good foundation to start for troubleshooting.

Double check the spark plugs. Pull one and lay it on the head. Crank bike over. You should be able to see spark. Check both plugs.

If plugs are good, I would consider compression test next. Do you have access to a compression tester? Best to know what is going inside your engine. This will tell us a ton of things.

Fuel: You say you know you are getting fuel. There are a couple ways I like to check fuel supply. Pull carbs. Remove bowls. Clean in there? Gas residue in the bowls? Pull and clean jets. Check that float needles are opening and closing properly. I simply put the bowl gas input fitting up to my lips and blow in. LOL. With the bowls off you can open and close the flat needle. Are the opening and closing properly? You'll hear the air supply move and feel resistance when you blow in. Ensure carb internal parts are assembled properly. With Clean jets back in place you can blow compresses air through all the jets and other tiny orifices. Check choke linkage. Appear to be moving properly? Fuel line removed from carb. Put fuel line into a jerry can. Open fuel petcock to "Prime" position. Drain some fuel into gas can. Lots coming out? Good flow? Clean, fresh gasoline used in the tank? Re-install carbs and all related parts.

Turn fuel tank petcock to "Prime" position to re-fill carb bowls. Turn petcock to normal run position. Choke on, fully charged good battery? Crank engine over. Still won't run? This is where I get creative with an alternate fuel supply.

I have done this on single carb engines, not twin carbs so no guarantees here. I get a propane torch. Safety glasses. Don't ignite it. Just set it up so the propane gas can come out. A small amount. Get the bike outside. Remove bike air filter. Have a friend crank the engine over while you open up torch gas valve a little and put torch nozzle in the intake box. As close to a carb intake as possible. Just a little propane while the engine is cranking over. Don't over do it. Be very careful and limit the amount of propane used. The engine will likely fire up and run on the propane gas supply. While it is running, shut off the propane. Does the bike stall? Then absolutely you have a gasoline delivery problem.

This only a brief test to confirm engine will run on alternative fuel supply. If it does and won't run when propane is removed, it's time to look at the fuel system again in it's entirety.

Similar Threads
Thread	Thread Starter	Forum	Replies	Last Post
Fuel Vent Hose Routing	NinjaDog	1986 - 2007 Ninja 250R Tech Talk	1	January 27th, 2019 07:07 PM
Carb Hose Routing	jschatte	1986 - 2007 Ninja 250R Tech Talk	6	July 8th, 2014 08:30 AM
Cali bike / 49 state replacement tank / hose routing help	djliquid	1986 - 2007 Ninja 250R Tech Talk	7	December 14th, 2011 09:33 AM
Routing for fuel overflow hose	haze5736	1986 - 2007 Ninja 250R Tech Talk	3	July 7th, 2011 07:09 PM
Routing for 'side hose' on fuel tank	kobachi	2008 - 2012 Ninja 250R Tech Talk	11	December 12th, 2010 05:00 PM

June 17th, 2018, 06:59 AM	#2
Keithb7 2008 & 2010 250cc Name: Keith Location: Western Canada Join Date: Jun 2018 Motorcycle(s): 2008 and 2010 Ninja 250 Posts: 10	I just put my tank back on yesterday. Over on the RH bottom side of your tank, that there is the fuel gauge sending unit. There is no line hooked up to that. Not on my tank any way. Is it possible the fuel is leaking from some other hose or fitting on your bike?

June 17th, 2018, 07:24 AM	#3
team7 ninjette.org newbie Name: Jesse Location: Fishers, IN Join Date: Jun 2018 Motorcycle(s): 2009 Kawasaki Ninja 250R Posts: 2	Thanks for the confirm Keith. I found one other video where there was a shot of that and it wasn't connected. I messed with the petcock pri and on. When I went to fill again nothing came out. I think it was a fluke but that makes me feel better it's not connected to anything. Bike still won't start though. It sat for a few years and one of the floats were stuck which caused the fuel to mix with gas. I replaced the floats, changed oil, changed spark plugs and no luck. Bike iddled a bit and then I tried to pull the choke lever back and it died never to start again. Plugs were wet so I know it's getting fuel. When pulling the carbs the instructions had you adjust the mixture screws before I knew what I was doing. Tighten them all the way down and two and a half turns back out was the setting. Could this be the issue?

June 17th, 2018, 08:03 AM	#4
Keithb7 2008 & 2010 250cc Name: Keith Location: Western Canada Join Date: Jun 2018 Motorcycle(s): 2008 and 2010 Ninja 250 Posts: 10	I am fairly new to the Ninja but have experience with other gas toys. If the bike did start and run and now won't there are a couple tricks I would try. 3 basic things. Fuel, compression & spark. A good foundation to start for troubleshooting. Double check the spark plugs. Pull one and lay it on the head. Crank bike over. You should be able to see spark. Check both plugs. If plugs are good, I would consider compression test next. Do you have access to a compression tester? Best to know what is going inside your engine. This will tell us a ton of things. Fuel: You say you know you are getting fuel. There are a couple ways I like to check fuel supply. Pull carbs. Remove bowls. Clean in there? Gas residue in the bowls? Pull and clean jets. Check that float needles are opening and closing properly. I simply put the bowl gas input fitting up to my lips and blow in. LOL. With the bowls off you can open and close the flat needle. Are the opening and closing properly? You'll hear the air supply move and feel resistance when you blow in. Ensure carb internal parts are assembled properly. With Clean jets back in place you can blow compresses air through all the jets and other tiny orifices. Check choke linkage. Appear to be moving properly? Fuel line removed from carb. Put fuel line into a jerry can. Open fuel petcock to "Prime" position. Drain some fuel into gas can. Lots coming out? Good flow? Clean, fresh gasoline used in the tank? Re-install carbs and all related parts. Turn fuel tank petcock to "Prime" position to re-fill carb bowls. Turn petcock to normal run position. Choke on, fully charged good battery? Crank engine over. Still won't run? This is where I get creative with an alternate fuel supply. I have done this on single carb engines, not twin carbs so no guarantees here. I get a propane torch. Safety glasses. Don't ignite it. Just set it up so the propane gas can come out. A small amount. Get the bike outside. Remove bike air filter. Have a friend crank the engine over while you open up torch gas valve a little and put torch nozzle in the intake box. As close to a carb intake as possible. Just a little propane while the engine is cranking over. Don't over do it. Be very careful and limit the amount of propane used. The engine will likely fire up and run on the propane gas supply. While it is running, shut off the propane. Does the bike stall? Then absolutely you have a gasoline delivery problem. This only a brief test to confirm engine will run on alternative fuel supply. If it does and won't run when propane is removed, it's time to look at the fuel system again in it's entirety.