Carburetor Fuel Overflow Tube Replacement

[Jim Moore]

Folks,

There is a clear plastic tube that comes out from between my carbs. I think it's pictured here.

http://faq.ninja250.org/wiki/File:Inside_carb_9.jpg

Mine got mis-routed past the chain and the chain cut it almost in half. I'm going to replace it. Can I get to it by simply taking the tank off? Where is it supposed to go? What size is it?

Also, my vent lines and fuel lines look pretty beat up (it's new-to-me '98) so I'm going to replace them too. The vent lines look like 1/4" i.d. fuel lines. Right? The fuel line from teh petcock to the carb looks a little bigger. Two questions. What size is it, and is it pre-formed?

I really appreciate all the info you guys have been giving me. I'm actually not a bad machanic. Someday soon I'll be able to answer questions instead of just asking them.

Thanks,

[Jim Moore]

Well, here's what I learned yesterday. First, you cannot get to the clear plastic line by simply taking the tank off. It comes out of the back of the carbs and is completely covered by the airbox. I ended up cutting the bad part away. I'm gonna splice some fuel line onto it and route it beneath the exhaust.

As for the vent lines, the line on the far left is the fuel tank vent line. The one on the right is the gas cap vent line.

The line from the petcock to the carb is 5/16" i.d. It was probably preformed, but it was pretty easy to bend a piece of fuel line to fit.

[dubojr1]

Good deal. I'm glad you figured it all out.

BTW...welcome aboard. It's good to see some other Jacksonville folks in here.

[Jim Moore]

Originally Posted by dubojr1

BTW...welcome aboard. It's good to see some other Jacksonville folks in here.

Thanks. I've been looking for a Ninja 250 locally for awhile.

[CynicalC]

It's ok to replace preformed with regular old tubing as long as there's no kinks and you secure it properly. On the right side of the bike on the bottom of the frame, there's a 1" hoop with some vent hoses through it (tank and coolant res.) I routed my carb overflow there. Best to splice in a new piece to the existing. The line comes from between the carbs and would be hell to replace on the bike.

[Jim Moore]

Originally Posted by CynicalC

On the right side of the bike on the bottom of the frame, there's a 1" hoop with some vent hoses through it (tank and coolant res.) I routed my carb overflow there.

Yep. That's exactly what I did. Thanks.

[Jim Moore]

Originally Posted by Jim Moore

As for the vent lines, the line on the far left is the fuel tank vent line. The one on the right is the gas cap vent line.

I think i was wrong on this. After a test-ride, the left line was leaking a tiny amount of fuel. I did some checking and found the site below:

http://faq.ninja250.org/wiki/Hose_ro...ine_fuel_tanks

Turns out I have a "California tank with no emissions equipment." So, the right tube is the gas cap vent. The center tube is the fuel tank vent. The left tube has to do with the emissions equipment and can be capped off, which I did. It's working great now.