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Removing the Carb on my XT250 #120583 04/12/14 11:57 AM
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BobMcC 81 Offline OP
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Ok I need to get the carb off my 2008 XT250. I have read the factory service manual and I think removed all the bolts required.

Do I really have to remove the battery, the whole electrical box and the air box (where the air filter goes) ?

The manual references sliding it all back. Does it really slide back enough to get the carb out?

Thanks for any step by step.


Last edited by BobMcC 81; 04/12/14 01:20 PM.

Bob
245 on a 250
Re: Removing the Carb on my XT250 [Re: BobMcC 81] #120584 04/12/14 02:54 PM
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Reggie Offline
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Hi Bob,

on my 2005 Japan spec, 250 I found it easier to loosen off the manifold that connects it to the engine, leaving the battery etc in place and with a bit of juggling it comes free.

When you pull the carb backwards, there's just enough room, with the front manifold loose, to allow the carb to come clear.

Regards


Reggie

Team Cabra, Brazilian XT225, Team Ukulele, Japan import XT225, a 250 to be named and loads of 2 stroke Kawasaki AR's!
Re: Removing the Carb on my XT250 [Re: Reggie] #120615 04/14/14 11:58 AM
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BobMcC 81 Offline OP
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Reggie,

Thanks for the input. Maybe it's a difference in bikes or my lack of tools but I couldn't manuever around enough to get the mnaifold allen bolts loose. But I did figure it out. I'm going to outline it here for others that may be search the forums for a similar answer. I do appreciate your suggestion.

1. Remove seat, side panels, gas tank, etc.
2. Remove the choke from the bracket and let it dangle
3. Remove the 3 hoses from the carb
4. Unplug the carb warmer circuit, cut the tiewrap, and let it dangle
5. Loosen the clamps at both ends of the carb ALOT
6. remove the airbox/battery box bolt that faces the rear of the bike
7. Removes the 5 +/- screws holding the left side of airbox holding that cover to the main airbox.
8. Do not remove the side airbox cover but remove the two hoses that plug into it on the front side of the bike.
9. Remove the battery hold down scrap, completely off the bike
10. Remove the 2 remaining screws in the battery box and pull the battery box away and towards the rear of the bike slightly
11. The airbox directly under the seat should now be free to slide backwards about an inch.
12. Hold the carb and slide the airbox back until it disengages with the carb. It will only muscle back about an an inch but that's enough
13. Now you should see an air gap between the carb and the airbox. Not much but that is enough to muscle the carb out of the intake manifold and bring it up to work on.
14. The manual said to remove the throttle cables and the choke enricher. It would have been more convenient but I chose to leave those attached.


Bob
245 on a 250

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