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Old April 26th, 2020, 07:32 PM   #1
Emu
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Name: Emu
Location: Oklahoma
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Motorcycle(s): 2011 Ninja 250r

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Update on new "oem" gas cap on 2011 250R

So a short recap for anyone who didn't read the short thread someone posted about "rain in the tank/bike runs poorly."

Guys problem, and mine, was an issue with the rubber seal on the gas cap drying out and cracking. This causes a loss of pressure in the tank, I literally could not get over 15 mph at all.

I ended up ordering a new gas cap from vipih ( https://vipih.com/products/lockgas-k...e124a024&_ss=r ) oem style for $25.

I installed on the bike and it ran great, highway speeds easily, starts up every time, no sluggish or unresponsive throttle. The issue now is fuel economy. for a short while I logged how much fuel I put in the tank, the mileage on the trip meter, and where the needle was on the fuel level. I would always fill all the way up

sep 12, 2019: 4.3 gallons filled, 231 miles on trip @ 2.19/gallon=$9.50
sep 27, 2019: 4.3 gallons filled, 229 miles on trip @ 2.23/gallon=$9.67

My most recent was nearly half that, I was so annoyed I didn't even bother to fully record it. I was at about a half tank with I believe 60 miles on the trip with I filled up. I rode out to help my friend work on his GSXF750 carbs, same thing, half tank at barely 70 miles on the trip meter.

The next project, probably tuesday this week is to take apart both caps, still have the old one, and see if I can take the seal off the new cap to put it on the old one.

The two are designed a little differently and I think the issue is the vent holes built into the old cap from 2011. I'll edit to add detailed pics when I have a chance.

Edit 1: I completely dismantled both gas caps (still kept the old one) and laid everything out in the pics below.

I took the new seal off and put it on the old assembly, it didn't fit. I modified the section that goes around the left retention bolt with a dremel to fit

While I was at it I decided to try out mixing parts. I used the new locking tab that slides in and out when you turn the key on the old assembly, that was so rough I would not recommend it.
The 4 small springs holding the seal up are the exact same so I traded them out.
the new cap had a spring in the dead center pushing against the 2 stack of washers, I put this on the old assembly to see if this effects gas mileage/venting.
Lastly on mods, I lost the stock phillips head screw that goes down onto the tank so I had to use the new one, it is actually longer than stock length and I bottomed out the hole before I even hit the tab it secures.

The last thing for me to do is to hit all the grease points that need it with 100% silicone grease, she's real dry and doesn't like being handled right now.

I completely bit the bullet for the sake of the forum and ordered the new OEM cap from bikebandit, part number CAP-TANK,FUEL 51049-5009 https://www.bikebandit.com/oem-parts...685&sch=706581

This was $134.95, When this comes in I'll put it on the bike and see how different it is from what these obviously knockoffs are.
Attached Images
File Type: jpg IMG_20200503_171936[1].jpg (112.0 KB, 1 views)
File Type: jpg IMG_20200503_171947[1].jpg (135.1 KB, 1 views)
File Type: jpg IMG_20200503_172246[2].jpg (102.0 KB, 4 views)
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File Type: jpg IMG_20200503_173358[1].jpg (131.4 KB, 2 views)
File Type: jpg IMG_20200503_175659[1].jpg (138.0 KB, 1 views)

Last futzed with by Emu; May 3rd, 2020 at 05:01 PM. Reason: uploading pics, adding info, testing new mods.
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Old May 1st, 2020, 06:45 AM   #2
rstnick
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Name: Rob
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Motorcycle(s): 2011 250R, 2000 ZRX1100C4, 1978 KZ650C2

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Keeping an eye on this as we also have a 2011.
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Old September 4th, 2021, 01:58 PM   #3
Emu
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Update on the journey, I am still having fuel economy issues. I sent off my carbs to ducatiman for service, still bad fuel economy. Had speratic power loss here and there, brought the bike into my local shop to have valve adjustment done, fixed power loss but still fuel issues. The only annoying thing about getting a factory gas cap by itself is having a completely different key from the other two, if you order the kit that comes with ignition switch, fuel cap, and pillion seat lock you get two brand new matching keys though. My fuel cap came with two new keys. Not sure if anyone has ever tried to rekey any of this before, as in changing the discs in the actual locking mechanism.
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Old September 4th, 2021, 03:54 PM   #4
DannoXYZ
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Did refurbished carbs fix your gas-mileage issues?

You can remove lock-cylinder from old cap and install on new one to keep same keys.

Can also re-key new lock to match old one. I hear that Toyota wafers are similar enough to use. Perhaps with minor filing here and there.
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Old September 5th, 2021, 02:39 PM   #5
Emu
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I ma still having gas mileage issues, at this point I don't really know why. I haven't been riding the bike at all because both side of my front forks went out and need to rebuild them.

I know I don't have any fuel leaks anywhere but when I start the bike I smell a strong gas scent, dunno if that's just because of startup. I might start at the tank and work my way down, probably gonna replace all of the fuel lines and junk.

I don't know where I put my original gas cap, I have moved twice (weird circumstances) and it might be in a box somewhere. If I manage to find it I will try and see if the gasket won't interfere with the key turning the way the knock off's did. When I get around to it I will post again.
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