Cali bike / 49 state replacement tank / hose routing help

[djliquid]

Hi. My wife has a 2003 EX250 and the previous owner had it hit in San Francisco while parked.

Anyways, the tank was pretty beat so I bought a pretty good condition replacement on eBay. I took the old tank off - removed the petcock, fill cap assembly - mounted it back onto the bike and realized it only has 1 hose vs 3. To confirm I have all the CA emissions stuff on the bike and these 2 extra hoses with nowhere to go :]

It ran for like a minute and then sputtered and died. I tried bending the blue striped (to blue dot hose) and that didn't help... and i tried the same for the middle one (obviously with no luck). It also seemed to leak gas toward to top of the gas cap seal (~ 10 o'clock)

I am looking for some insight on how to get the bike to function - I assume it's a vacuum or emissions thing. Ideally if I can cap it off that would be ideal, while retaining the emissions stuff on the bike.


Thanks for the insight.


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

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

http://kawasakiworld.com/zx-12r/2041...n-control.html

[Alex]

/moved to pre-gen tech area

[Jiggles]

Those hoses are for the Kleen Air System, a useless piece of junk. There is a DIY on removing it but it is for the newgens. You can still follow the DIY, things will just be in different places.

http://www.ninjette.org/forums/showthread.php?t=9948

You're going to need a few caps to plug some hoses and the holes on the bike. Good luck

[djliquid]

thanks, guys.

I'll give that a look. If anyone stumbles into a thread for a 2003 (or any pre-2007) it'd be greatly appreciated.

peace-
e

[Skippii]

Originally Posted by Jiggles

Those hoses are for the Kleen Air System, a useless piece of junk.

Whoa....Isn't the KAS the air-into-exhaust injection system that comes on new bikes to optimize catalytic conversion of unburnt hydrocarbons as the expense of NOx gases? The thing that makes them all pop on decelleration?

That's a totally different thing with a totally different purpose than the evaporative fuel system, which stops gasoline from evaporating out of your tank.

[djliquid]

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

i re-read this page.

On the 49 state tank there's the one hose outlet (drain).
49 state models have only one hose coming from the rear of the fuel tank. This is a drain hose for fluid that gets in the depression between the filler neck and the top of the tank, from being in the rain or overfilling the tank. Air vents into these tanks

On the Cali tank there's 3 (L-R), with the middle apparently the drain.

• The right tube allows air into the fuel tank through the gas cap as the gas level drops. This tube must remain open.
• The middle tube is the drain and should keep the stock routing under the bike in the hose cluster (right-hand side of the frame, as discussed above).
• The left tube circulates fumes to the emissions system and should be capped off.

I vented the red tube - running it to the left side by the coolant reservoir.
I capped off the third tube (blue stripe) by bending it back and ziptieing (like with landscape irrigation).

I started it up and it ran fine for at least a few minutes, which is way more than before, and showed no sign of stalling. The red tube did drip some gas, but this was likely because I had stupidly hooked it up to drain before reading anything.

So far so good - will report after more thorough test.

[Jinx250]

Yank the round R2D2 looking thing and the rectangular lunchbox and all the assorted hoses. Then swith out the vacuum line on your carbs from a 2 piece hoe with a T in the middle to a one piece with no T.

And the system is call the CA evaporative emissions control or some BS like that. The Kleen Air System is totally different and does not exist on the 250.

[CynicalC]

I had the exact same scenario with my bike. Rip all the emissions stuff off and replace that little hose on the carbs (the one with a T in it) with a piece of solid hose. The nipple on the tank is just a drain. Send it right down to the ground.