n da zone
Expert Class
Posts: 215
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posted December 15, 2002 07:49 PM
Trying to neuter a Calif ZX12R
I was halfway into Fish_Antlers suggested mods that boost HP on a stock 12R, and discovered I have a 'California' bike. Bought it as an Oregon bike, but it must have snuck across the border one night when the border patrol was asleep. I am in Florida so I don't need this clean air/fuel recovery shit on here. All this stuff must weigh 10 lbs!
Anyway, today I removed the cat material, and drilled the stock exhaust can. I was looking at how to remove the KLEEN gear, when I found some suspicious hoses that ended up going into a fuel separator thingy under the seat, and a fuel vapor canister under the taillight.
Service manual has good illustrations on the stuff, so it looks pretty easy to remove. If anyone has done this before, ping me if you can add more info or cautions to my work.
Two questions :
#1. Where the fuel separator feeds fumes back into
throttle body #4, I will just pull the hose and
plug the nipple.
Doing this step, as well as removing the KLEEN air
system, isolates the entire fuel recycling
system so it can be just cut out like Lola
cut my heart out. ..... RIGHT ??
#2. The fuel tank. The 49-state fuel tank has
a left-side (blue dot) drain line coming out
of it, way down low on the tank, near the
back of & under the drivers seat. Nothing on the
right side. The blue-dot line may be an 'overflow'
of some kind?
Calif model tank has two drains under the seat.
The regular bluedot goes into the soon-to-be-cut
separator, and on the right a red-dot line that
receives excess/overflow gas from the soon-to-be-
cut out separator and puts it back into the tank.
===> I plan on plugging the red line where
it exits the tank.
===> I plan to make the blue line just drain
to the street.
Well, if any of you guys have removed this fuel emission stuff before, and have any advice, lemme know.
What's some good ways to permanently plug a line that has fluid/fuel in it?
Tanks.
Mark
alan0252@aol.com
  
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swft
Needs a life
Full throttle!
Posts: One MEEEEEELLION
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posted December 15, 2002 08:01 PM
#1 right!
#2 right!
That'll work!
Never had to touch a CA bike.
Both of those are overflow drains, (called seperator tubes) so I beleive you can just join them together and let it drain to the street, or a catch bottle.
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ZHooligan
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posted December 15, 2002 08:55 PM
If I recall corectly Ted G. did one of these.
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n da zone
Expert Class
Posts: 215
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posted December 16, 2002 05:56 AM
 Edited By: n da zone on 17 Dec 2002 17:24
OK. Thanks. I'll ping TedG and see if he can chime in. It looks pretty straightforward.
http://community.webshots.com/image4/2/80/4/57728004AzYMCK_ph.jpg
;D
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F-15
Novice Class
Posts: 37
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posted December 17, 2002 12:17 PM
Edited By: F-15 on 17 Dec 2002 12:36
I have a Cali bike. I did the samething. As far as the blue line. I left it where it laid.I though it might spit gas but it has never been a problem.
Dave
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n da zone
Expert Class
Posts: 215
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posted December 17, 2002 05:21 PM
Thanks. I also found a previous discussion on this topic (more than one actually), but the most informative was at :
http://www.bikeland.org/board/viewthread.php?FID=1&TID=5035
on Bikeland. So, it looks like it is easily removed, and will not affect the operation of the bike.
I need to learn to use the search engine here FIRST! It is great!! I just typed in 'emission' and got several good threads.
But 'preciate the response.
--Mark--
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beansbaxter
Needs a life
Posts: 5911
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posted December 19, 2002 01:08 AM
F-15...if that avatar is a pic of you, please change it.
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F-15
Novice Class
Posts: 37
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posted December 19, 2002 07:00 AM
Ha Ha Ha Your funny guy bean.Ya that's me and I also found one of you!
PS No hard feeling right pal?
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TedG
Moderator
Posts: 8222
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posted December 19, 2002 10:56 AM
Sorry I have been super busy and only have a chance to glance at the boards and throw in a snyde remark occasionally.. Did you figure out what you need to do?? If not let me know and I will help. I will monitor this thread. I saw your e-mail last night but was in the process of selling my old TV and didn't have time to answer.
____________
Ted
2000 Green ZX12 sold
The fast color!!
Green 2005 ZX10R
2009 Concours Black ABS
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n da zone
Expert Class
Posts: 215
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posted December 19, 2002 11:35 AM
Thanks Ted. I think it's a go at this point.
Based on everyones concensus here, and the previous threads, I will do two things.
1). Connect the blue and red fuel lines with a 'T', and drain to the ground. These are just passive 'overflow/reflow' lines that are specific to a Calif bike.
2). Plug the vacuum line inlet on throttle body #4 where the little separator thing plugged in.
Note: I am guessing that plugging, rather than leaving
it open, is right, right? I am thinking it is a vacuum
that operates the separator, and if left unplugged it
could affect the vacuum level in tb#4. How did you
handle that line?
--Mark--
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TedG
Moderator
Posts: 8222
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posted December 19, 2002 02:38 PM
You are right you must plug it. I believe I used a vacuum plug I bought from Pep boys. I also bought that little bottle that goes in place of the seperator along with the rubber baby buggy bumpers. I don't believe they are necessary but it made it look right. Mostly what you want to do is make it look exactly like the 49 state model which is illustrated in the parts catalog and the service manual. The only difference in the end should be the extra vent in the tank, which you can Y off or just plug the r/h vent(which I did).
____________
Ted
2000 Green ZX12 sold
The fast color!!
Green 2005 ZX10R
2009 Concours Black ABS
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havabusa12r
Expert Class
Posts: 425
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posted December 19, 2002 08:05 PM
ditto TED!
I did my 00 and copied my 02 as per Ted's advice. I used the little drain
bottle thingy and I plugged the other line from the tank. I did NOT tee
them together.
It took me a while to even realize that I had a cali model. I just assumed that mine was the 49er. The dealer says it is easier to get the calis west
of the Missippi? oh well
____________
(68 Yam 175 2-stroke)
(99 Copper Busa) (99 Duc 900 SS full fairing) (00 MV Agusta F4S) (02 Aprilia RSV Mille) (02 ZX 12r CTB) (03 KTM 950 Adv)
(04 Yam R1) (05 LE Busa) (07 ZX 14)
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ZHooligan
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posted December 19, 2002 08:45 PM
At this moment I would like to make it clear for the record that I in no way participated in the illegal removal of any emissions systems. And I am certain that those participating in this discussion are merely speculating about how this work could be accomplished. 
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n da zone
Expert Class
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posted December 20, 2002 05:38 AM
Don't worry. This particular 12 has been modified for 'OFF ROAD' use only.
The nonEPA exhaust, nonDOT blinkers and headlights, the nonSCAQMD fuel-evaporative system and the bad attitude of the driver make this bike ILLEGAL and UNSAFE on any road. 
Fookin lawyers have ruined us all. 
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mach111
Novice Class
Posts: 81
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posted December 21, 2002 10:49 PM
nda zone.i dont know if your refering to the fuel seperator under the tail section?if you are DO NOT remove it,all the 00 california models have one,and all the 01 zx12's have one.if you take it off the gas tank will have no where to ventilate fumes.cant say if it will explode,but taking it off does nada for performance.i'm refering to the fuel seperator on pg.2-111 in manual.just take the kleen air off. on my 01, i also took the seperator off once,just to see,and it didnt help squat.it did however make the gas cap hard to open and it hissed when i did.just my .02 if you were thinking of plugging it.
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n da zone
Expert Class
Posts: 215
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posted December 22, 2002 08:19 AM
ooops! Too late! Thanks for the input, but it is all out of there now. I will keep an eye on the tank overpressure you mentioned, though.
I ended up plugging the 'return' (red) side with a vacuum plug (per TedG), since there is now nothing to return.
I ran the overflow down to the street, right along with the little fuel pump overflow thingy that already hangs down. I wasw thinking that the 'overflow' is probably going to equalize the tank pressure, since it will allow air to flow in to the tank as gas is used up.
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havabusa12r
Expert Class
Posts: 425
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posted December 22, 2002 03:18 PM
mach-
I've done both of my 12's, with no problem.
Did you try it as per TedG?
Performance gains:
1. it's just the thought of getting rid of it.
2. you can stash more crap in the tail-a better tire repair kit, etc.
____________
(68 Yam 175 2-stroke)
(99 Copper Busa) (99 Duc 900 SS full fairing) (00 MV Agusta F4S) (02 Aprilia RSV Mille) (02 ZX 12r CTB) (03 KTM 950 Adv)
(04 Yam R1) (05 LE Busa) (07 ZX 14)
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mach111
Novice Class
Posts: 81
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posted December 23, 2002 12:56 AM
so just plug the red side on the tank?what about the hose going to the tb's?and the other color dotted hose on the tank?
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mach111
Novice Class
Posts: 81
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posted December 23, 2002 01:08 AM
i think i found my problem here.when i did it i removed BOTH hoses at the tank and vacuum plugged them both. this caused a very bad pressure buildup in the tank below 1/2 a tank of gas.
so,should i have just capped the red one,and let the blue hang to the street?i also should plug the t.b one too?????????????????????
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n da zone
Expert Class
Posts: 215
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posted December 23, 2002 06:19 AM
Mach111, you are correct . Let the 'blue' one breathe to the outside to keep the pressure equalized. And, make sure all newly exposed throttle body nipples are plugged. This is what I plugged:
1). A small vacuum line went from the Kleen cartridge to a 'T' vacuum connector on throttle body # 2 & # 3. That line needs to be plugged. I pulled the vacuum hose off the 'T', and slipped a vacuum plug over the now-exposed 'T' nipple.
2). Throttle body #4 has the vacuum line that runs to the evaporator thing. Pull it, and cap with a vacuum plug (any auto parts store, Pep Boys, etc has these ... abt 3/16" will work).
Note : TB #1 has a vacum nipple like the other three, but it is plugged already by the factory.
3). Gas tank, right side (red). Use another vacuum plug over that nipple. It was a 'gas return' line from the evaporator/separator thing, which of course is no more. That side is actually 1/4", but all I had was 3/16" plugs, and it finally went on with some grunting.
4). gas tank, left side (blue). Leave this side open and drain it to the ground. That is now the tank will now breathe when gas is used up.
A little pic of these changes is below.
http://community.webshots.com/image4/2/80/4/57728004AzYMCK_ph.jpg
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beansbaxter
Needs a life
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posted December 23, 2002 01:51 PM
In regards to the California-spec models of motorcycles, do the restrictions result in less power then the normal models? Does it hurt their resell value?
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n da zone
Expert Class
Posts: 215
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posted December 24, 2002 07:26 AM
Edited By: n da zone on 24 Dec 2002 07:38
My research & my dealer told me that (surprisingly) the Calif thing makes no performance difference one way or another, on or off. There is no timing changes or sensor plugs to cut off.
I did it primarily to get more room in the tail, as I will be tackling a Dussault undertail soon, secondly because I was removing the KLEEN system which feeds the vacuum to the (Calif) fuel separator under the seat. With the KLEEN off, it wouldn't function anyway, so i got rid of 3 lbs of stuff, and got a little more room under the seat.
But again, it doesn't hurt anything to leave it on, if the KLEEN system is still in place.
As far a 'resale' goes, ...IMHO it would be a problem only if I lived in or near Calif and was planning to sell it there. That's a big market and shouldn't be overlooked by west coasters, but I live in Florida, and unless I am planning to sell it (hah!) ... and sell it in Calif (not likely either!) ... then there is no problem.
btw, you guys on the left coast may want to keep the take-offs in case it has to be re-smogged for sale in the poppy state.
However, with all the timing, mapping and exhaust changes on any of our bikes, I doubt the evaporator/separator thing being MIA will make any more difference it getting the emissions up-to-date.
again imho. 
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beansbaxter
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posted December 24, 2002 09:15 AM
Which state is the poppy? We're all apples here.
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n da zone
Expert Class
Posts: 215
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posted December 24, 2002 03:55 PM
quote:
btw, you guys on the left coast may want to keep the take-offs in case it has to be re-smogged for sale in the poppy state.
where they grow em and smoke em --- Cal-high- fornia
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