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Old April 12th, 2016, 10:27 AM   #1
Mrcas14
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Fuel Cell Swap

Hey guys, I have an 08 red-tank karate kid 250. I purchased the 09 Special Edition green w/black bottom tank, and the corresponding rear cowlings (438,000 times better than red). My red tank has 3 inlets/outlet hoses on the front left of the tank for the evap can, separator pump, and the airbox. The green tank lines up properly, the fuel gauge and petcock went right in, I'm having supply problems.

The dilemma is that the green tank has one spout... Did I purchase a fake tank? Is it maybe off a 650? I don't understand how it's possible because on the parts diagram, 08-12 have the same 3 hoses going to the same places.

I'm severely confused and upset. My now "complete" 2-year project just turned into a nightmare. It's going to be a really cool build if I ever get this to work, I promise I'll throw up some pics on the forum!! Please correct me if I'm wrong, I'm a rook with the pavement stuff, I usually just put premix in my two smoker dirt bikes and braaaaappppp away into the distance.

Thanks guys,
Luca
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Old April 12th, 2016, 10:59 AM   #2
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I believe the newgen tanks have a petcock on the side, and in the back they either have one over flow, or an over flow, a vent, and something to do with California epa stuff. The tank should flow gas through the petcock and vent ari through the gas cap. The new gens should also have a prime fitting on the petcock.

Try turning the petock to prime and opening the gas cap to see if fuel flows. (If not its almost certainly a bad petcock).
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Old April 12th, 2016, 11:08 AM   #3
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Not sure but I think the red tank is a California tank
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Old April 12th, 2016, 11:54 AM   #4
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Welcome Luca!

You got yourself a 49 state tank and your existing red tank is the "enhanced emissions" California version.

Just delete the extra emissions stuff and you should be good to go.

http://faq.ninja250.org/wiki/File:Routing.gif

EDIT: This will be helpfull too. https://www.google.com/webhp?sourcei...w.ninjette.org
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Old April 12th, 2016, 12:03 PM   #5
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Didn't mean to mark Chris' post unhelpful. @Alex can you change that to helpful or change it so that I can change my decision myself?
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Old April 12th, 2016, 12:04 PM   #6
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Old April 12th, 2016, 12:27 PM   #7
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Old April 12th, 2016, 01:31 PM   #8
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Old April 12th, 2016, 01:50 PM   #9
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So basically I need to pull the whole system, and plug the airbox/valve head? Since I'm going from 3 vents to 1 vent, which hose remains connected to the single vent on the new tank?
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Old April 12th, 2016, 01:51 PM   #10
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Pretty much...
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Old April 12th, 2016, 01:57 PM   #11
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Quote:
Originally Posted by Mrcas14 View Post
So basically I need to pull the whole system, and plug the airbox/valve head? Since I'm going from 3 vents to 1 vent, which hose remains connected to the single vent on the new tank?
The one that goes nowhere and is simply an overflow/vent.
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Old April 14th, 2016, 11:12 AM   #12
Mrcas14
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Kleen system is off. I'm left with the empty vent hose going to the bottom of the bike, and the Y hose going to the carbs. Which one stays connected?
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Old April 14th, 2016, 02:19 PM   #13
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Quote:
Originally Posted by Mrcas14 View Post
Kleen system is off. I'm left with the empty vent hose going to the bottom of the bike, and the Y hose going to the carbs. Which one stays connected?
The empty vent hose goes to the gas tank.

The Y hose on the carb needs to either:
A be replaced with a single piece of hose, or
B be capped off.

Else wise you will have a vacuum leak and your bike will run terribly.
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