New tank and Removing Cali Emissions

jenbrack · September 21st, 2010, 10:25 AM

Hello guys! This is my first post

I just bought a 1990 EX250 that has cali emissions on it. The tank was severly damaged so I got a new one not thinking and it only has one outlet on it instead of three. So my queastion is, where or what hoses do I need and dont need as I have removed the box and cylinder already. Any advice would be awesome! I really want to get riding it instead of looking at it sitting in my garage! LOL

kkim · September 21st, 2010, 11:08 AM

does this help?
http://www.ninjette.org/forums/showthread.php?t=55567

Snake · September 21st, 2010, 11:23 AM

This thread may help you as well as it shows what needs to be removed and what to plug.

http://www.ninjette.org/forums/showthread.php?t=22296

jenbrack · September 21st, 2010, 11:33 AM

Does there happen to be a diagram like the one with the black box and cylinder but without it so I know how a regular fuel system looks? I just know with the new tank I dont have a place for the 2 extra hoses on it. so how do I bypass the black box and cylinder?

Snake · September 21st, 2010, 11:35 AM

^^^ follow the directions in the thread I posted. It tells you which line to plug.

jenbrack · September 21st, 2010, 11:45 AM

I think I get it now, Thanks for the help!

kkim · September 21st, 2010, 11:48 AM

Quote:

Originally Posted by jenbrack

I think I get it now, Thanks for the help!

let us know how it turns out.

ride on

Snake · September 21st, 2010, 11:53 AM

No prob Jen, anytime.

jenbrack · September 21st, 2010, 02:27 PM

Ready for my new issue?

So I took the carbs off and rebuilt them, the problem is the guy who owned it before me didnt have all the hoses connected and there is a place for a hose between the two carbs that I have no Idea what it goes to. So, I included a pic

IMG_20100921_125146.jpg

IMG_20100921_125055.jpg

IMG_20100921_125138.jpg

kkim · September 21st, 2010, 03:55 PM

connects to nothing... that's a vent hose.

jenbrack · September 24th, 2010, 04:41 PM

Ok, got the carbs on, floats are great, needle and seats are great, but now I cant get it to idle. Mind you I took off the emissions crap. I plugged the hole on the side of the airbox. When I give it gas it dies. Like its getting too much air. Are these bike notorious for bad parts like carbs or anything? I did ride it down the street last night and was able to get it to 3rd gear, but if I tried to open it up it would pop and try to die. Any suggestions would be fantasic! Thanks!
Oh ya, and the choke has to be completely on.

kkim · September 24th, 2010, 04:43 PM

are you sure you didn't pinch or tear the diaphragms when you reassembled the slides?

jenbrack · September 24th, 2010, 04:46 PM

yes i was extremly careful.

jenbrack · September 24th, 2010, 04:51 PM

there was a clip missing off one of the slides that i replaced but that shouldnt make it not run?

kkim · September 24th, 2010, 04:52 PM

Jen,

some background, please? was the bike running well before you started work on it or did you get it not running?

anything else you can tell us about the history of the bike will certainly help.

kkim · September 24th, 2010, 04:53 PM

Quote:

Originally Posted by jenbrack

there was a clip missing off one of the slides that i replaced but that shouldnt make it not run?

what did it look like? did you replace with a stock piece?

jenbrack · September 24th, 2010, 04:55 PM

yes, I got one from the local dealer

jenbrack · September 24th, 2010, 04:58 PM

i lied, he said he found an "E" clip lying in it. So he put it in the top one? slide? he was vague

jenbrack · September 24th, 2010, 05:07 PM

I wish I could post a video so you guys could see and hear what I'm talking about.

kkim · September 24th, 2010, 05:21 PM

stock needles don't have E clips. has your bike been rejetted with an aftermarket jet kit?

like I said... some bike history would do well in cutting down the number of questions we need to ask to help you.

jenbrack · September 24th, 2010, 06:01 PM

bahaha! so I took it to the gas station to put more fuel in it, and not realizing that my fairings were not on the gas spewed out the screw hole on the tank. could this have been part of it?

I bought the bike a few weeks ago, the guy I got it from didnt know much about it, but for $600 I wasn't going to complain. I got it home, took all the fairings and tank off due to cracks to repair. I hauled it to my dads house to have the carbs rebuilt which I got kits from the dealer for. Cleaned out the airbox which had sand in it, removed the cali emissions stuff, put the new tank on and replaced everything but the fairings.

kkim · September 24th, 2010, 08:11 PM

did you ride it home? if so, how was the bike running? if not... egads.

jenbrack · September 24th, 2010, 09:01 PM

Test drove it about 5 miles and it was fine, lol and then I trucked it home

Please tell me that the screw holes on the tanks that attach the fairing are drilled all the way through. If not then I have more issues than I thought lol

kkim · September 24th, 2010, 09:10 PM

no. it's a common problem when owners use the wrong length screws when they reinstall the fairings. you will need to patch the holes if they are leaking fuel. try not ride the bike until you fix it. spilling gas is a REAL danger around a hot engine.

I would suggest taking it to a welder in your area that has done tank repair before.

jenbrack · September 24th, 2010, 09:14 PM

Nice, I bought the tank from a guy on ebay. I Boo him! I will take it to the local guy and have it fixed. I'm starting to think that I need to give up on this bike and get one that is needing less repair. lol

kkim · September 24th, 2010, 09:20 PM

to be clear... the gas is leaking from puncture holes in the sides of the tank... is that correct?

jenbrack · September 24th, 2010, 09:44 PM

yes, the upper fairing screw holes

kkim · September 24th, 2010, 11:19 PM

Quote:

Originally Posted by jenbrack

yes, the upper fairing screw holes

then, yes... they need to be repaired.

can you not get your money back from the seller? did he explain that the tank had holes?

jenbrack · September 25th, 2010, 11:20 AM

Quote:

Originally Posted by kkim

then, yes... they need to be repaired.

can you not get your money back from the seller? did he explain that the tank had holes?

I just sent the seller an email. So fingers crossed. Also I was told it sounds like i have a vacuum leak? I plugged the hole on the side of the airbox and i cant find anything else that would maybe be letting too much air into the carb.

jenbrack · September 25th, 2010, 11:28 AM

Do you think maybe a head gasket or valve adjustment? Or bad valves? Im at a complete loss. lol I guess i could take it to the dealer, but Im sure it would cost me more than to just get a new one.

kkim · September 25th, 2010, 11:38 AM

did you let the bike warm up at least a few minutes before riding it? These bikes take a lot of time to warm up properly.

vacuum leaks (which makes the bike run lean) can occur anywhere before the air/fuel mixture enters the engine cylinder.

make sure all clamps for the carbs are tight and that the hoses are connected correctly and have no holes or tears.

if the bike will only run with the choke, it sounds like the carbs need to be cleaned again. The pilot jets sound like they are clogged.

kkim · September 25th, 2010, 11:39 AM

Quote:

Originally Posted by jenbrack

Do you think maybe a head gasket or valve adjustment? Or bad valves? Im at a complete loss. lol I guess i could take it to the dealer, but Im sure it would cost me more than to just get a new one.

the fact that you rode the bike prior to purchase and was running good (correct?) says that it's something you did since purchasing it.

jenbrack · September 25th, 2010, 11:43 AM

Quote:

Originally Posted by kkim

the fact that you rode the bike prior to purchase and was running good (correct?) says that it's something you did since purchasing it.

Correct, that's what leads me to believe a vacuum leak.

kkim · September 25th, 2010, 11:57 AM

Quote:

Originally Posted by jenbrack

Correct, that's what leads me to believe a vacuum leak.

yes, what I was trying to say is it's something that's been worked on and not to go looking for more problems beyond what you've been working on for now.

jenbrack · September 25th, 2010, 12:25 PM

Quote:

Originally Posted by kkim

yes, what I was trying to say is it's something that's been worked on and not to go looking for more problems beyond what you've been working on for now.

Agreed!

September 21st, 2010, 10:25 AM	#1
jenbrack ninjette.org member Name: Jen Location: UT Join Date: Sep 2010 Motorcycle(s): 1990 EX250 Posts: 21	New tank and Removing Cali Emissions Hello guys! This is my first post I just bought a 1990 EX250 that has cali emissions on it. The tank was severly damaged so I got a new one not thinking and it only has one outlet on it instead of three. So my queastion is, where or what hoses do I need and dont need as I have removed the box and cylinder already. Any advice would be awesome! I really want to get riding it instead of looking at it sitting in my garage! LOL

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September 21st, 2010, 11:08 AM	#2
kkim Join Date: Nov 2008 Posts: Too much.	does this help? http://www.ninjette.org/forums/showthread.php?t=55567

September 21st, 2010, 11:23 AM	#3
Snake ninjette.org certified postwhore Name: Rick Location: Alexandria, Louisiana Join Date: Jan 2009 Motorcycle(s): 05 Blue Ninja 250 Posts: Too much. MOTY - 2017, MOTM - Jan '19, Oct '16, May '14	This thread may help you as well as it shows what needs to be removed and what to plug. http://www.ninjette.org/forums/showthread.php?t=22296

September 21st, 2010, 11:33 AM	#4
jenbrack ninjette.org member Name: Jen Location: UT Join Date: Sep 2010 Motorcycle(s): 1990 EX250 Posts: 21	Does there happen to be a diagram like the one with the black box and cylinder but without it so I know how a regular fuel system looks? I just know with the new tank I dont have a place for the 2 extra hoses on it. so how do I bypass the black box and cylinder?

September 21st, 2010, 11:35 AM	#5
Snake ninjette.org certified postwhore Name: Rick Location: Alexandria, Louisiana Join Date: Jan 2009 Motorcycle(s): 05 Blue Ninja 250 Posts: Too much. MOTY - 2017, MOTM - Jan '19, Oct '16, May '14	^^^ follow the directions in the thread I posted. It tells you which line to plug.

September 21st, 2010, 11:45 AM	#6
jenbrack ninjette.org member Name: Jen Location: UT Join Date: Sep 2010 Motorcycle(s): 1990 EX250 Posts: 21	I think I get it now, Thanks for the help!

September 21st, 2010, 11:53 AM	#8
Snake ninjette.org certified postwhore Name: Rick Location: Alexandria, Louisiana Join Date: Jan 2009 Motorcycle(s): 05 Blue Ninja 250 Posts: Too much. MOTY - 2017, MOTM - Jan '19, Oct '16, May '14	No prob Jen, anytime.

September 21st, 2010, 02:27 PM	#9
jenbrack ninjette.org member Name: Jen Location: UT Join Date: Sep 2010 Motorcycle(s): 1990 EX250 Posts: 21	Ready for my new issue? So I took the carbs off and rebuilt them, the problem is the guy who owned it before me didnt have all the hoses connected and there is a place for a hose between the two carbs that I have no Idea what it goes to. So, I included a pic IMG_20100921_125146.jpg IMG_20100921_125055.jpg IMG_20100921_125138.jpg

September 21st, 2010, 03:55 PM	#10
kkim Join Date: Nov 2008 Posts: Too much.	connects to nothing... that's a vent hose.

September 24th, 2010, 04:41 PM	#11
jenbrack ninjette.org member Name: Jen Location: UT Join Date: Sep 2010 Motorcycle(s): 1990 EX250 Posts: 21	Ok, got the carbs on, floats are great, needle and seats are great, but now I cant get it to idle. Mind you I took off the emissions crap. I plugged the hole on the side of the airbox. When I give it gas it dies. Like its getting too much air. Are these bike notorious for bad parts like carbs or anything? I did ride it down the street last night and was able to get it to 3rd gear, but if I tried to open it up it would pop and try to die. Any suggestions would be fantasic! Thanks! Oh ya, and the choke has to be completely on.

September 24th, 2010, 04:43 PM	#12
kkim Join Date: Nov 2008 Posts: Too much.	are you sure you didn't pinch or tear the diaphragms when you reassembled the slides?

September 24th, 2010, 04:46 PM	#13
jenbrack ninjette.org member Name: Jen Location: UT Join Date: Sep 2010 Motorcycle(s): 1990 EX250 Posts: 21	yes i was extremly careful.

September 24th, 2010, 04:51 PM	#14
jenbrack ninjette.org member Name: Jen Location: UT Join Date: Sep 2010 Motorcycle(s): 1990 EX250 Posts: 21	there was a clip missing off one of the slides that i replaced but that shouldnt make it not run?

September 24th, 2010, 04:52 PM	#15
kkim Join Date: Nov 2008 Posts: Too much.	Jen, some background, please? was the bike running well before you started work on it or did you get it not running? anything else you can tell us about the history of the bike will certainly help.

September 24th, 2010, 04:55 PM	#17
jenbrack ninjette.org member Name: Jen Location: UT Join Date: Sep 2010 Motorcycle(s): 1990 EX250 Posts: 21	yes, I got one from the local dealer

September 24th, 2010, 04:58 PM	#18
jenbrack ninjette.org member Name: Jen Location: UT Join Date: Sep 2010 Motorcycle(s): 1990 EX250 Posts: 21	i lied, he said he found an "E" clip lying in it. So he put it in the top one? slide? he was vague

September 24th, 2010, 05:07 PM	#19
jenbrack ninjette.org member Name: Jen Location: UT Join Date: Sep 2010 Motorcycle(s): 1990 EX250 Posts: 21	I wish I could post a video so you guys could see and hear what I'm talking about.

September 24th, 2010, 05:21 PM	#20
kkim Join Date: Nov 2008 Posts: Too much.	stock needles don't have E clips. has your bike been rejetted with an aftermarket jet kit? like I said... some bike history would do well in cutting down the number of questions we need to ask to help you.

September 24th, 2010, 06:01 PM	#21
jenbrack ninjette.org member Name: Jen Location: UT Join Date: Sep 2010 Motorcycle(s): 1990 EX250 Posts: 21	bahaha! so I took it to the gas station to put more fuel in it, and not realizing that my fairings were not on the gas spewed out the screw hole on the tank. could this have been part of it? I bought the bike a few weeks ago, the guy I got it from didnt know much about it, but for $600 I wasn't going to complain. I got it home, took all the fairings and tank off due to cracks to repair. I hauled it to my dads house to have the carbs rebuilt which I got kits from the dealer for. Cleaned out the airbox which had sand in it, removed the cali emissions stuff, put the new tank on and replaced everything but the fairings.

September 24th, 2010, 08:11 PM	#22
kkim Join Date: Nov 2008 Posts: Too much.	did you ride it home? if so, how was the bike running? if not... egads.

September 24th, 2010, 09:01 PM	#23
jenbrack ninjette.org member Name: Jen Location: UT Join Date: Sep 2010 Motorcycle(s): 1990 EX250 Posts: 21	Test drove it about 5 miles and it was fine, lol and then I trucked it home Please tell me that the screw holes on the tanks that attach the fairing are drilled all the way through. If not then I have more issues than I thought lol

September 24th, 2010, 09:10 PM	#24
kkim Join Date: Nov 2008 Posts: Too much.	no. it's a common problem when owners use the wrong length screws when they reinstall the fairings. you will need to patch the holes if they are leaking fuel. try not ride the bike until you fix it. spilling gas is a REAL danger around a hot engine. I would suggest taking it to a welder in your area that has done tank repair before.

September 24th, 2010, 09:14 PM	#25
jenbrack ninjette.org member Name: Jen Location: UT Join Date: Sep 2010 Motorcycle(s): 1990 EX250 Posts: 21	Nice, I bought the tank from a guy on ebay. I Boo him! I will take it to the local guy and have it fixed. I'm starting to think that I need to give up on this bike and get one that is needing less repair. lol

September 24th, 2010, 09:20 PM	#26
kkim Join Date: Nov 2008 Posts: Too much.	to be clear... the gas is leaking from puncture holes in the sides of the tank... is that correct?

September 24th, 2010, 09:44 PM	#27
jenbrack ninjette.org member Name: Jen Location: UT Join Date: Sep 2010 Motorcycle(s): 1990 EX250 Posts: 21	yes, the upper fairing screw holes

September 25th, 2010, 11:28 AM	#30
jenbrack ninjette.org member Name: Jen Location: UT Join Date: Sep 2010 Motorcycle(s): 1990 EX250 Posts: 21	Do you think maybe a head gasket or valve adjustment? Or bad valves? Im at a complete loss. lol I guess i could take it to the dealer, but Im sure it would cost me more than to just get a new one.

September 25th, 2010, 11:38 AM	#31
kkim Join Date: Nov 2008 Posts: Too much.	did you let the bike warm up at least a few minutes before riding it? These bikes take a lot of time to warm up properly. vacuum leaks (which makes the bike run lean) can occur anywhere before the air/fuel mixture enters the engine cylinder. make sure all clamps for the carbs are tight and that the hoses are connected correctly and have no holes or tears. if the bike will only run with the choke, it sounds like the carbs need to be cleaned again. The pilot jets sound like they are clogged.