California Gas cap

TRBO ZRX · 07-06-2004, 04:25 PM

I'm not sure if the other 49 state models have this. I removed the emissions garb last week and didn't notice any problems until I went on a long ride this past Sunday with Rick61. At sustained high rpm in 5th gear the engine seemed to starve for fuel. I did vent the red nipple on the bottom of the tank into another line that went to the underside of the transmission just infront of the slave cylinder. It was hanging lower than the engine so I cut @ 4" off of it. That solved that problem. I became curious as to why it wouldn't vent through the fuel cap, so I took it apart. I removed the spring loaded vent valve and put it back together. I put a vacuum hose on the vent nipple on the cap and I was able to draw air in & out through the cap. I am going to plug both the red & blue nipples on the bottom of the tank so I can top off the tank. I was unable to fill it to the top because fuel would drain out through nipples on the bottom of the tank on to the ground.

TRBO ZRX · 07-06-2004, 04:28 PM

Back together minus the spring loaded valve.

DARE-NS-ZRX · 07-06-2004, 04:58 PM

CA = Crap!

red · 07-06-2004, 05:49 PM

So what's the deal with this, explain it to me. When I took my emmisions crap off, I joined the red and blue to one hose and routed it behind the tranny, just in front of the swingarm. I first noticed that the Rex doesn't whine or squeal anymore from the gas cap like it used to after long rides. Then I noticed that when I fuel close to the top, after riding I can see fuel vapor coming from the re-routed hose and black residue (small amount) at the front of the swingarm. What exactly does removing the spring loaded vent valve do to fix this? Is there a possibility of fuel spilling out onto the tank since now the focus is to that area? What are you going to use to plug the red and blue? Thx. Hope these don't sound like dumb questions....

dano · 07-06-2004, 05:59 PM

I removed "most" of all the emissions equip. when I did my Ivan's Jet Kit.

But.....I left the red/blue lines under the tank alone. I did examine them closely, and decided that there wasn't enough weight, fuss/muss involved to create any add'l. benefit by removing or capping them off.

I'm still thinking about the charcoal cannister under the rear part of the seat though.....

TRBO ZRX · 07-06-2004, 06:22 PM

Quote:

Originally posted by red
So what's the deal with this, explain it to me. When I took my emmisions crap off, I joined the red and blue to one hose and routed it behind the tranny, just in front of the swingarm. I first noticed that the Rex doesn't whine or squeal anymore from the gas cap like it used to after long rides. Then I noticed that when I fuel close to the top, after riding I can see fuel vapor coming from the re-routed hose and black residue (small amount) at the front of the swingarm. What exactly does removing the spring loaded vent valve do to fix this? Is there a possibility of fuel spilling out onto the tank since now the focus is to that area? What are you going to use to plug the red and blue? Thx. Hope these don't sound like dumb questions....

The valve inside of the cap only allows the tank to vent when a given pressure or vacuum is reached. The emissions equipment does the "cleaning" of vapor from the tank through the carbon canister. What I didn't like was the fact that I was not able to fill my tank up, I had to leave the level @ 1/2 to 3/4 below the restrictor that is just inside of the tank (only on CA models). The cap has a vent that, when closed, mates up to a drain that leads to the ground (the large nipple to the right of the red & blue ones). If I can gain 30 to 40 miles from a tank, it would have been worth it. Thought it may have been worth sharing! I hope it helps. Steve

TRBO ZRX · 07-06-2004, 06:26 PM

Quote:

Originally posted by dano
I removed "most" of all the emissions equip. when I did my Ivan's Jet Kit.

But.....I left the red/blue lines under the tank alone. I did examine them closely, and decided that there wasn't enough weight, fuss/muss involved to create any add'l. benefit by removing or capping them off.

I'm still thinking about the charcoal cannister under the rear part of the seat though.....

If you remove only the canister under the seat, you might as well remove all of it. Just removing the canister would cause a vacuum leak, and if you plug it off, you will have the same type of difficulties that I did. Steve

klr_rider · 07-06-2004, 06:34 PM

So when you put the cap back together did you just leave out the spring and that little dot (whatever it is) or did you leave out all the pieces you have circled in the first picture...

dano · 07-06-2004, 06:40 PM

I can understand the need for getting more miles out of a tank of gas on the ZRX.

And if you can do that by modding the fuel cap / filler neck, that's great!

My ZRX runs great with all that I've done to it.... so far. I think I'll just leave the charcoal can alone and not mess wth it.

TRBO ZRX · 07-06-2004, 10:57 PM

Quote:

Originally posted by klr_rider
So when you put the cap back together did you just leave out the spring and that little dot (whatever it is) or did you leave out all the pieces you have circled in the first picture...

Yup

red · 07-07-2004, 04:58 AM

so what are you gonna use to cap the red and blue lines from beneath the tank..('scuse me a moment

)...just curious.

Rick61a · 07-07-2004, 01:17 PM

Quote:

Originally posted by red
so what are you gonna use to cap the red and blue lines from beneath the tank..('scuse me a moment )...just curious.

M6 bolts work quite well....

TRBO ZRX · 07-07-2004, 01:52 PM

Quote:

Originally posted by red
so what are you gonna use to cap the red and blue lines from beneath the tank..('scuse me a moment )...just curious.

Short piece of the original hose & a small piece of round bar @ 6mm in diameter.

red · 07-07-2004, 01:57 PM

Are 6 mm bolts what most people use to plug and what material are the bolts made of. Do you use some sort of sealant or washer or something so that the fuel doesn't make it's way past the threads of the bolts? I can just see that happening.........thx

TRBO ZRX · 07-07-2004, 06:35 PM

Quote:

Originally posted by red
Are 6 mm bolts what most people use to plug and what material are the bolts made of. Do you use some sort of sealant or washer or something so that the fuel doesn't make it's way past the threads of the bolts? I can just see that happening.........thx

You can use the unthreaded part of a bolt that is long enough. Just remove the threads with a hacksaw. There isn't much room under the tank for something to hang down too far. Reuse the wire spring clamps (that are at every vacuum hose connection) where you insert the section of unthreaded bolt, that should keep it sealed.

TRBO ZRX · 07-11-2004, 02:06 AM

I found out today that the blue nipple on the bottom of the tank DOES need to be vented to the ground behind the transmission. Should have listened to Rick!

It leads to the gas cap. I had it plugged off & still had the same problem. I ran some .030 wire through the hole just inside the filler neck and it felt plugged, so I removed the BLUE one first and the wire went through! When I first removed the smog stuff, I noticed that the blue nipple had a check valve and prevented the tank from freely venting. I thought it was inside of the tank. It's not, it was the check valve that I removed from the gas cap at a later date.

So, plug the RED nipple, vent the BLUE one and remove the check valve from the gas cap. I tested it with a vacuum pump & it works great! Sheeewh Trial & error....

Quote:

Originally posted by red
So what's the deal with this, explain it to me. When I took my emmisions crap off, I joined the red and blue to one hose and routed it behind the tranny, just in front of the swingarm. I first noticed that the Rex doesn't whine or squeal anymore from the gas cap like it used to after long rides. Then I noticed that when I fuel close to the top, after riding I can see fuel vapor coming from the re-routed hose and black residue (small amount) at the front of the swingarm. What exactly does removing the spring loaded vent valve do to fix this? Is there a possibility of fuel spilling out onto the tank since now the focus is to that area? What are you going to use to plug the red and blue? Thx. Hope these don't sound like dumb questions....

red · 07-12-2004, 04:00 AM

Rick states to plug the RED with M6 bolt. Is that how you did it or was it done another way. If another way, procedure please...

TRBO ZRX · 07-12-2004, 01:09 PM

Quote:

Originally posted by red
Rick states to plug the RED with M6 bolt. Is that how you did it or was it done another way. If another way, procedure please...

I used the part of a bolt that was unthreaded. And yes, plug the RED. The BLUE leads to the gas cap vent. Remove the check valve & spring. I filled the tank just about to the rim and not even a drop went on the ground. I had over 60 miles on that tank before the gauge started to move. I haven’t filled it yet from near empty, so I'm not sure yet what it takes to top it off from that point. I'm very happy with the results.

red · 07-12-2004, 02:41 PM

This may sound like a dumb question, but what is the unthreaded part of a bolt and how is it installed to plug the RED. Also, did you use any type of sealer, gasket, washer, etc. along with the unthreaded part of the bolt to keep any fuel from leaking (or IS there fuel that can leak from the RED if not plugged...)

TRBO ZRX · 07-12-2004, 04:11 PM

Quote:

Originally posted by red
This may sound like a dumb question, but what is the unthreaded part of a bolt and how is it installed to plug the RED. Also, did you use any type of sealer, gasket, washer, etc. along with the unthreaded part of the bolt to keep any fuel from leaking (or IS there fuel that can leak from the RED if not plugged...)

Fuel will come out of the red nipple when the tank is near full. I didn't use any sealer, just make sure you have a tight fitting plug. I didn't use the rubber caps that you can buy at the parts store because they rot and crack & the next thing you know is you have fuel leaking. The hose that was there is made to tolerate the fuel. I hope this helps.

Here is a picture of a bolt with a good donor!

red · 07-12-2004, 05:52 PM

TRBO ZRX · 07-14-2004, 01:48 PM

The tank hit the reserve and I went 10 miles to the gas station. It took 4.25 gallons from reserve + 10 miles to top off. Before the mod, I would go 35 miles on reserve and the tank would only take 3.8 gallons to top it off. Mission accomplished! I am averaging 42 mpg overall.

kawa1st · 10-29-2005, 03:56 AM

Hi, I removed all the ca-crap

and need now to know what exactly I have to remove out of the gas cap- what spring is that and what valve? do you have better pics to describe it?

And what happens if I close the nipples between the carbs 1 and 2 and carbs 3 and 4? Do they need vent?

07-06-2004, 04:25 PM	#1
TRBO ZRX Turbo Slim Fast Join Date: Apr 2004 Location: "Steve" Big Bear, California. You knew me as "Roundhouseman"	California Gas cap I'm not sure if the other 49 state models have this. I removed the emissions garb last week and didn't notice any problems until I went on a long ride this past Sunday with Rick61. At sustained high rpm in 5th gear the engine seemed to starve for fuel. I did vent the red nipple on the bottom of the tank into another line that went to the underside of the transmission just infront of the slave cylinder. It was hanging lower than the engine so I cut @ 4" off of it. That solved that problem. I became curious as to why it wouldn't vent through the fuel cap, so I took it apart. I removed the spring loaded vent valve and put it back together. I put a vacuum hose on the vent nipple on the cap and I was able to draw air in & out through the cap. I am going to plug both the red & blue nipples on the bottom of the tank so I can top off the tank. I was unable to fill it to the top because fuel would drain out through nipples on the bottom of the tank on to the ground. Attached Images __________________ Member #5692 Member of the Shannon "YTRAP" Bitzer fan club The man on top of the Mountain didn't walk there. He rode a Kawasaki!

07-06-2004, 04:28 PM	#2
TRBO ZRX Turbo Slim Fast Join Date: Apr 2004 Location: "Steve" Big Bear, California. You knew me as "Roundhouseman"	Back together minus the spring loaded valve. Attached Images __________________ Member #5692 Member of the Shannon "YTRAP" Bitzer fan club The man on top of the Mountain didn't walk there. He rode a Kawasaki!

07-06-2004, 05:49 PM	#4
red BadAss Hooligan Join Date: Nov 2002 Location: SoCal	roundhouseman So what's the deal with this, explain it to me. When I took my emmisions crap off, I joined the red and blue to one hose and routed it behind the tranny, just in front of the swingarm. I first noticed that the Rex doesn't whine or squeal anymore from the gas cap like it used to after long rides. Then I noticed that when I fuel close to the top, after riding I can see fuel vapor coming from the re-routed hose and black residue (small amount) at the front of the swingarm. What exactly does removing the spring loaded vent valve do to fix this? Is there a possibility of fuel spilling out onto the tank since now the focus is to that area? What are you going to use to plug the red and blue? Thx. Hope these don't sound like dumb questions.... __________________ Oh, I'm sorry, did I break your concentration!! 2002 red ZRX 1200R 2007 red ZX10

07-06-2004, 05:59 PM	#5
dano Supreme Benevolent Grand Wankeroo Join Date: May 2003 Location: S. OR.....and likin it.	I removed "most" of all the emissions equip. when I did my Ivan's Jet Kit. But.....I left the red/blue lines under the tank alone. I did examine them closely, and decided that there wasn't enough weight, fuss/muss involved to create any add'l. benefit by removing or capping them off. I'm still thinking about the charcoal cannister under the rear part of the seat though..... __________________ Speed kills..........but only the dumb and the inexperienced! ZRXOA Exalted Supreme Benevolent Grand Master Member #4875 (Same as a Pope) or (God as it gets)

07-06-2004, 06:34 PM	#8
klr_rider BadAss Hooligan Join Date: Dec 2003 Location: Santee, CA	roundhouseman So when you put the cap back together did you just leave out the spring and that little dot (whatever it is) or did you leave out all the pieces you have circled in the first picture...

07-06-2004, 04:58 PM	#3
DARE-NS-ZRX BadAss Hooligan Join Date: May 2003 Location: Arizona	CA = Crap!

07-06-2004, 06:40 PM	#9
dano Supreme Benevolent Grand Wankeroo Join Date: May 2003 Location: S. OR.....and likin it.	I can understand the need for getting more miles out of a tank of gas on the ZRX. And if you can do that by modding the fuel cap / filler neck, that's great! My ZRX runs great with all that I've done to it.... so far. I think I'll just leave the charcoal can alone and not mess wth it. __________________ Speed kills..........but only the dumb and the inexperienced! ZRXOA Exalted Supreme Benevolent Grand Master Member #4875 (Same as a Pope) or (God as it gets)

07-07-2004, 04:58 AM	#11
red BadAss Hooligan Join Date: Nov 2002 Location: SoCal	roundhouseman so what are you gonna use to cap the red and blue lines from beneath the tank..('scuse me a moment )...just curious. __________________ Oh, I'm sorry, did I break your concentration!! 2002 red ZRX 1200R 2007 red ZX10

07-07-2004, 01:57 PM	#14
red BadAss Hooligan Join Date: Nov 2002 Location: SoCal	Hey Rick Are 6 mm bolts what most people use to plug and what material are the bolts made of. Do you use some sort of sealant or washer or something so that the fuel doesn't make it's way past the threads of the bolts? I can just see that happening.........thx __________________ Oh, I'm sorry, did I break your concentration!! 2002 red ZRX 1200R 2007 red ZX10

07-12-2004, 04:00 AM	#17
red BadAss Hooligan Join Date: Nov 2002 Location: SoCal	roundhouseman Rick states to plug the RED with M6 bolt. Is that how you did it or was it done another way. If another way, procedure please... __________________ Oh, I'm sorry, did I break your concentration!! 2002 red ZRX 1200R 2007 red ZX10

07-12-2004, 02:41 PM	#19
red BadAss Hooligan Join Date: Nov 2002 Location: SoCal	This may sound like a dumb question, but what is the unthreaded part of a bolt and how is it installed to plug the RED. Also, did you use any type of sealer, gasket, washer, etc. along with the unthreaded part of the bolt to keep any fuel from leaking (or IS there fuel that can leak from the RED if not plugged...) __________________ Oh, I'm sorry, did I break your concentration!! 2002 red ZRX 1200R 2007 red ZX10

07-12-2004, 05:52 PM	#21
red BadAss Hooligan Join Date: Nov 2002 Location: SoCal	Helped alot....THX __________________ Oh, I'm sorry, did I break your concentration!! 2002 red ZRX 1200R 2007 red ZX10

07-14-2004, 01:48 PM	#22
TRBO ZRX Turbo Slim Fast Join Date: Apr 2004 Location: "Steve" Big Bear, California. You knew me as "Roundhouseman"	UPDATE The tank hit the reserve and I went 10 miles to the gas station. It took 4.25 gallons from reserve + 10 miles to top off. Before the mod, I would go 35 miles on reserve and the tank would only take 3.8 gallons to top it off. Mission accomplished! I am averaging 42 mpg overall. __________________ Member #5692 Member of the Shannon "YTRAP" Bitzer fan club The man on top of the Mountain didn't walk there. He rode a Kawasaki!

10-29-2005, 03:56 AM	#23
kawa1st Licensed to post Join Date: Apr 2005 Location: Alamogordo, NM	Hi, I removed all the ca-crap and need now to know what exactly I have to remove out of the gas cap- what spring is that and what valve? do you have better pics to describe it? And what happens if I close the nipples between the carbs 1 and 2 and carbs 3 and 4? Do they need vent? __________________ ZRX 1200 R, GPZ 900 R, 2 x SR 500, Monster 900, 907i.e.

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