07 Carburetor Rebuild

JayVapes · August 19th, 2020, 02:37 PM

Hello everyone,

I'm rebuilding an 07 EX250 and have started by taking apart the carburetor, I am interested in knowing what rebuild kits you all have purchased and what sort of mistakes you came across.

I have found that my pilot jet head was broken off and now i need to track down the proper drill bit and screw extractor bit in order to take it out.

I also found that my floats are orange and not white like the ones I've seen in many videos and photos.

In addition I found that the needle on the side with the broken jet head had heavy build up.

The coasting enricher diaphragm was cracked and the spring had been replaced and I believe there was jb weld on covering a hold in the middle of the outer cap.

I have not purchased a rebuild kit yet, but I do intend to replace:
- all the jets
- gaskets
- diaphragms and springs
- needle
- float and float needle

Follow along on Tik Tok @honoriosotojr

DannoXYZ · August 19th, 2020, 09:32 PM

Hi Honorio, not sure there’s a “kit” available as each restoration job is different with requiring different parts to be replaced with new OEM parts. Which can be ordered from any number of suppliers.

You’ll also want to split carbs and replace:

- fuel-rail O-rings
- pilot jet O-rings, washers, springs
- float-bowl seals

Do search here for “clean carbs ducatiman” to get feel for what’s involved and required. Needs lots of manual labour with scrubbing, flossing and poking.

jkv45 · August 20th, 2020, 07:36 AM

This section has a lot of info and photos - https://faq.ninja250.org/wiki/Intake

ducatiman · August 20th, 2020, 10:25 AM

remember, clean carbs matter

and a clean carb is a happy carb

SibSerge · August 24th, 2020, 06:52 PM

Quote:

Originally Posted by JayVapes

Hello everyone,

I'm rebuilding an 07 EX250 and have started by taking apart the carburetor, I am interested in knowing what rebuild kits you all have purchased and what sort of mistakes you came across.

I have found that my pilot jet head was broken off and now i need to track down the proper drill bit and screw extractor bit in order to take it out.

I also found that my floats are orange and not white like the ones I've seen in many videos and photos.

In addition I found that the needle on the side with the broken jet head had heavy build up.

The coasting enricher diaphragm was cracked and the spring had been replaced and I believe there was jb weld on covering a hold in the middle of the outer cap.

I have not purchased a rebuild kit yet, but I do intend to replace:
- all the jets
- gaskets
- diaphragms and springs
- needle
- float and float needle

Follow along on Tik Tok @honoriosotojr

One mistake I have NOT made (thanks to this forum) while cleaning my carbs is replacing the perfect OEM jets and other metal parts with the cheapo parts from the kit. I gave them very good cleaning instead and they looked like way better made than those which came with the kit.

Kawinoob217 · September 1st, 2020, 09:31 AM

Yellowing of the floats is normal with gas sitting around them. OEM replacements from Kawasaki can be a bit expensive. I'd submerge them in some water and keep them there for a bit to see if they take on any liquid. If not that I'd have no problems not replacing them. Also, if you're going to be taking them apart and cleaning them and tuning quite a bit (I know I was when I first got my bike working), I'd look at replacing the screws that bolt the carb bowls to the carb body. Correct me if I'm wrong but I think they come with phillips head screws? I'd take one of those bad boys down to the local hardware store and replace it with some hardware that you can crank with hex key Allen wrenches. You're a lot less likely to strip those.

DannoXYZ · September 1st, 2020, 10:07 AM

Not phillips, it's JIS. Using phillips screwdriver will strip screw heads.

https://www.motorcycle.com/ask-mo-an...-phillips.html
https://www.motorcyclistonline.com/d...s-head-screws/

Good idea with socket-head, much more secure connection with tool. Be careful about over-tightening.

August 19th, 2020, 02:37 PM	#1
JayVapes ninjette.org member Name: Honorio Location: Rio Grande Valley Join Date: Aug 2020 Motorcycle(s): Ninja EX250 Posts: 118 Blog Entries: 8	07 Carburetor Rebuild Hello everyone, I'm rebuilding an 07 EX250 and have started by taking apart the carburetor, I am interested in knowing what rebuild kits you all have purchased and what sort of mistakes you came across. I have found that my pilot jet head was broken off and now i need to track down the proper drill bit and screw extractor bit in order to take it out. I also found that my floats are orange and not white like the ones I've seen in many videos and photos. In addition I found that the needle on the side with the broken jet head had heavy build up. The coasting enricher diaphragm was cracked and the spring had been replaced and I believe there was jb weld on covering a hold in the middle of the outer cap. I have not purchased a rebuild kit yet, but I do intend to replace: - all the jets - gaskets - diaphragms and springs - needle - float and float needle Follow along on Tik Tok @honoriosotojr

August 19th, 2020, 09:32 PM	#2
DannoXYZ ninjette.org certified postwhore Name: AKA JacRyann Location: Mesa, AZ Join Date: Dec 2011 Motorcycle(s): CB125T CBR250R-MC19 CBR250RR-MC22 NSR350R-MC21 VF500F CBR600RR SFV650 VFR750F R1M ST1300PA Valkyrie-F6C Posts: A lot. MOTY - 2018, MOTM - Nov '17	Hi Honorio, not sure there’s a “kit” available as each restoration job is different with requiring different parts to be replaced with new OEM parts. Which can be ordered from any number of suppliers. You’ll also want to split carbs and replace: - fuel-rail O-rings - pilot jet O-rings, washers, springs - float-bowl seals Do search here for “clean carbs ducatiman” to get feel for what’s involved and required. Needs lots of manual labour with scrubbing, flossing and poking.

August 20th, 2020, 07:36 AM	#3
jkv45 Rev Limiter Name: Jay Location: WI Join Date: Jul 2013 Motorcycle(s): '06 SV650n, '00 Derbi GPR, '64 CA77 Dream 305, '70 CL450 Scrambler, numerous dirt bikes Posts: A lot. MOTM - Jun '18, Oct '16	This section has a lot of info and photos - https://faq.ninja250.org/wiki/Intake

September 1st, 2020, 09:31 AM	#6
Kawinoob217 ninjette.org member Name: Ethan Location: South Lyon, Michigan Join Date: Jul 2017 Motorcycle(s): 1998 Kawasaki Ninja 250 Posts: 24	Yellowing of the floats is normal with gas sitting around them. OEM replacements from Kawasaki can be a bit expensive. I'd submerge them in some water and keep them there for a bit to see if they take on any liquid. If not that I'd have no problems not replacing them. Also, if you're going to be taking them apart and cleaning them and tuning quite a bit (I know I was when I first got my bike working), I'd look at replacing the screws that bolt the carb bowls to the carb body. Correct me if I'm wrong but I think they come with phillips head screws? I'd take one of those bad boys down to the local hardware store and replace it with some hardware that you can crank with hex key Allen wrenches. You're a lot less likely to strip those.

September 1st, 2020, 10:07 AM	#7
DannoXYZ ninjette.org certified postwhore Name: AKA JacRyann Location: Mesa, AZ Join Date: Dec 2011 Motorcycle(s): CB125T CBR250R-MC19 CBR250RR-MC22 NSR350R-MC21 VF500F CBR600RR SFV650 VFR750F R1M ST1300PA Valkyrie-F6C Posts: A lot. MOTY - 2018, MOTM - Nov '17	Not phillips, it's JIS. Using phillips screwdriver will strip screw heads. https://www.motorcycle.com/ask-mo-an...-phillips.html https://www.motorcyclistonline.com/d...s-head-screws/ Good idea with socket-head, much more secure connection with tool. Be careful about over-tightening.