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Old July 22nd, 2019, 07:20 PM   #1
Ninja Rob
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04 Ninja 250 Carb rebuild kit

It's been a while since I've been here. I'm looking for a 04 Ninja 250 Carburator Rebuild kit. Can anyone point me in the right direction?
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Old July 22nd, 2019, 07:47 PM   #2
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Old July 22nd, 2019, 08:29 PM   #3
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I'll be interested in what Ducatiman says, since I have no confidence in carb rebuild kits. The ones I'm familiar with use offbrand parts that are not correct, and cause more problems than they fix.
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Old July 23rd, 2019, 05:41 AM   #4
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^ agreed

These days...."replace everything" (all jets, needles included) is becoming the accepted norm. Brainwashing the lazy with a convenient, easy "solution" to carb "cleaning".
The Far East copy kits containing brass jets and needles are notorious for both wrong parts and improperly sized jets and/or float valves. The companies maximizing their applications (profits) , with near generic fitment. They are NOT using genuine Keihin components unless specifying.

I'm a proponent of properly *cleaning your proper factory jets*. Unless the heads are mauled, there is no reason to replace them. If you DO replace them, use Keihin in correct size.

Otherwise, carb refurb parts needs are minimal....bowl oring (gasket), pilot screw orings, float valves, fuel and vent rail orings (if splitting). What IS needed is employing of correct, efficient methods to clear circuits, followed by careful setup and wet testing prior to replacing the carbs back on the bike.

As these bikes are getting old, splitting and replacing rail rings is advisable.
They do flatten, harden, corrode and leak, as we read about frequently here.

I keep the required, reliable, proven stuff in stock always, OP is welcome to PM.
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Old July 23rd, 2019, 11:15 AM   #5
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I am going to clean them. However, there are some parts that need replacing like the gaskets, some of the bolts are rounded from the previous owner but I managed to remove them, the parts that push the floats up, and some other parts I don't know the names for. I will put pictures up of the stuff that needs replacing later when I get home.
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Old July 23rd, 2019, 05:06 PM   #6
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Pics added. Note that I did NOT make any of the damage on the parts, the previous owner maybe didn't have the right patience and tools and you can see how rounded some of the parts are. Especially that gold colored one in the 1st and 2nd pic. I gently removed it with a smaller screw driver ( not the one in the pic) and screwed back in but not all the way so I can easily take it out when I clean/replace the part. Gaskets look worn out too. The floats do not rise to the same height. 3rd pic, I think it's called a drain bolt but that thing is really rusted so I'm going to have some trouble removing it and will probably just replace them. I am also going to replace the 8 bolts that hold each carb closed so those I'll get at home Depot. I got the size from that Ninja250 org website. The other needles and parts are in good condition and just need a good cleaning but some of the parts do need to be replaced. I took the carbs apart and put all back together but these were the damage concerns that I have. Any feedback?
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Last futzed with by Ninja Rob; July 23rd, 2019 at 05:13 PM. Reason: Stupid auto correct on phone
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Old July 23rd, 2019, 05:42 PM   #7
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Quote:
Originally Posted by Ninja Rob View Post
Pics added. Note that I did NOT make any of the damage on the parts, the previous owner maybe didn't have the right patience and tools and you can see how rounded some of the parts are. Especially that gold colored one in the 1st and 2nd pic. I gently removed it with a smaller screw driver ( not the one in the pic) and screwed back in but not all the way so I can easily take it out when I clean/replace the part. Gaskets look worn out too. The floats do not rise to the same height. 3rd pic, I think it's called a drain bolt but that thing is really rusted so I'm going to have some trouble removing it and will probably just replace them. I am also going to replace the 8 bolts that hold each carb closed so those I'll get at home Depot. I got the size from that Ninja250 org website. The other needles and parts are in good condition and just need a good cleaning but some of the parts do need to be replaced. I took the carbs apart and put all back together but these were the damage concerns that I have. Any feedback?
I'll try to address all your comments.....the brass colored screw in pic 1 and 2 is the pilot screw (adjusts idle fuel mixture) You need to replace the tiny oring which resides deep inside....also a spring and tiny washer then oring (in that order) should be present on each screw.

Pic 3 is bowl drain screw, a 3mm allen to remove

Pic 4 flattened bowl gaskets (imperative to replace both)

Pic 5 float valves, RH one has come apart (imperative to replace both)

Pic 6 whacked out, high float levels carb on LH side of pic due to broken float valve. You must replace float valves, clean seats and adjust.

of course, every screw needs replacement. I use stainless buttonheads, don't even need washers.

What shape are the diaphragms in?

You plan on splitting them to enable replacement of the rail orings? Also enables access to inspect the vacuum hoses between. Then of course you've got to remove the choke plungers to access the enrichener circuit...then inspect/service the decel valve.. more and more.

Those carbs are pretty rough...consider a refurbed set.
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Old July 23rd, 2019, 06:14 PM   #8
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Quote:
Originally Posted by ducatiman View Post
I'll try to address all your comments.....the brass colored screw in pic 1 and 2 is the pilot screw (adjusts idle fuel mixture) You need to replace the tiny oring which resides deep inside....also a spring and tiny washer then oring (in that order) should be present on each screw.

Pic 3 is bowl drain screw, a 3mm allen to remove

Pic 4 flattened bowl gaskets (imperative to replace both)

Pic 5 float valves, RH one has come apart (imperative to replace both)

Pic 6 whacked out, high float levels carb on LH side of pic due to broken float valve. You must replace float valves, clean seats and adjust.

of course, every screw needs replacement. I use stainless buttonheads, don't even need washers.

What shape are the diaphragms in?

You plan on splitting them to enable replacement of the rail orings? Also enables access to inspect the vacuum hoses between. Then of course you've got to remove the choke plungers to access the enrichener circuit...then inspect/service the decel valve.. more and more.

Those carbs are pretty rough...consider a refurbed set.
Where can I get a quality refurb set? I'm trying to get it running and then sell in the near future. I'm thinking it'll start getting expensive to continue to own it. I'm saving for a newer bike. 😁 I didn't mind learning how to take apart and clean the carbs. It has actually been a good experience so far.
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Old July 23rd, 2019, 06:53 PM   #9
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i'll check my stuff and get back
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Old July 28th, 2019, 06:53 AM   #10
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i'll check my stuff and get back
Got anything?
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Old July 28th, 2019, 08:14 AM   #11
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I'd need to refurb a set....take me a day....$175 shipped

OR could refurb yours for approx $140 shipped (provided no peripheral diaphragm/slide damage or major missing/broken parts)

I do have emergency salvage spare parts if needed, so no delays.

Honest, quick, efficient....I'm sure you've seen my work on the forum here.

Anyways...a couple of options offered ....PM if you'd like to go forward.
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Old July 28th, 2019, 05:03 PM   #12
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Quote:
Originally Posted by Ninja Rob View Post
Where can I get a quality refurb set? I'm trying to get it running and then sell in the near future. I'm thinking it'll start getting expensive to continue to own it. I'm saving for a newer bike. �� I didn't mind learning how to take apart and clean the carbs. It has actually been a good experience so far.
Here's examples of ducatiman's most excellent work. You can't go wrong with his refurb service or pre-rebuilt set of carbs. Mine looked liked this before I sent them to him. They came back pristine and bike ran like brand-new!!! I've gotten multiple carbs done over the years and they all came back perfect!



If you really want to learn about rebuilding carbs, search for "clean carbs ducatiman" and see numerous threads on subject. You'll need to invest in some equipment such as ultrasonic cleaner, caustic radioactive solvents, micro soda-blaster, 10000psi compressor, etc.

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Old July 28th, 2019, 05:55 PM   #13
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@DannoXYZ thank you for kind words.

A long, hard day of yardwork....I've got carb stuff laid out, ascertaining what is needed to get them up to standard. May take a snooze followed by a late night work session.
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Old July 29th, 2019, 11:36 AM   #14
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posting as promised, this set ready to go

105 main, 38 pilot , N16I needles, pilot screws 2.5 turn, throttle plates synched, idle set very close (you'll reset anyway to your chosen RPM when warmed)

You'll need to switch over your fuel hose and rail strainer (if present)

PM comin'
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File Type: jpg july4.jpg (112.9 KB, 6 views)
File Type: jpg july3.jpg (86.0 KB, 7 views)
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Old July 29th, 2019, 01:00 PM   #15
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Originally Posted by ducatiman View Post
posting as promised, this set ready to go

105 main, 38 pilot , N16I needles, pilot screws 2.5 turn, throttle plates synched, idle set very close (you'll reset anyway to your chosen RPM when warmed)

You'll need to switch over your fuel hose and rail strainer (if present)

PM comin'
Why do they need to be switched over? I'm asking because I don't know why. Is it so they can fit in the bike or something related to fitment?
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Old July 29th, 2019, 01:20 PM   #16
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sometimes folks leave their fuel lines and rail strainers on, sometimes not.
These ...not. I don't need fuel lines to be shipped when I clean carbs.

Simply pull off your existing fuel hose and swap it over to the refurbs upon installation.
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Old July 29th, 2019, 03:29 PM   #17
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petcock if needed, salvaged, brought back from the dead

note obvious missing screen...has been relocated internal...will be fully functional provided no rocks, stones, birds, tree branches or small children are finding their way through the tank.
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Old August 10th, 2019, 12:06 PM   #18
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My Ninja is working again. Took a few tries to get it started and spent a while in the Triple digit temperatures of Texas but it's working now. Thank you ducatiman for your carb service. Not sure how to @ someone.
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Old August 10th, 2019, 01:41 PM   #19
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just for you.....
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