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Old 02-29-2012, 06:44 PM   #1 (permalink)
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02 trx250 carb change,help

Have a 02 trx250ex, I've been fighting carb problem with this bike for a while. So I finally decided to buy the rebuild kit for it, after a short search on ebay. I found the rebuild kit was around $20.00 but I could buy a new in the box. Carb for $40.00, just a parts change. No issues removing plastic, carb and other needed parts. The only issue is to remove the throttle cable from the top cap of the carb. It spins free, tried everything but distructivly removing it. Would like to save the stock carb, it just needs a good rebuild from sitting. Can someone throw me a bone here and tell me how to remove this. Thanks.......
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Old 02-29-2012, 06:56 PM   #2 (permalink)
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Welcome to the forum.Just unscrew the whole top and put it all in the new carb slide and all.If you would rather use the new slide and needle you have to pull the top off anyways.You may want to download a free service manual here in the schematics section.
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Old 02-29-2012, 07:04 PM   #3 (permalink)
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I matched the new to the stock and the caps are different. It will have to be changed as a assembly. So for instance you broke a throttle cable, how would you change that?
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Old 02-29-2012, 07:07 PM   #4 (permalink)
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take the cap off and there it is clipped into the slide.It's hard to describe but take the cap off and follow the cable into the slide you should be able to see how it comes out.
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Old 02-29-2012, 07:14 PM   #5 (permalink)
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Pulled all the guts off of the cable. Just need to remove the cap from the cable.
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Old 02-29-2012, 07:22 PM   #6 (permalink)
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It should just come off it's not bolted on or anything that I can think of.Maybe get a manual downloaded and see if that can help you.I'm going off of 8 month old memories with a lot of other car and atv work in between.Sorry I couldn't help.
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Old 03-01-2012, 06:59 PM   #7 (permalink)
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So there is a grove in the end of the elbow at the end of the cable with a snap ring in the cap. Took a little persuading but it came loose. Now the every thing is installed. Touch the starter and fires up and idles like new. Run it 1/2 mile or so to get the motor warmed up. Now it needs adjusting. Runs perfect at idle but has bad hesitation with no quick response. If you ease on the throttle it spins up but if you get in the pipe it breaks down. Where to from here????????
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Old 03-01-2012, 07:18 PM   #8 (permalink)
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Does it have a stock pipe or any other mods?If it does then you will probably need to put a larger main jet and set the needle to the center position.
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