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Woody250 Added a reply to 2005 crf250r rebuild
4/10/2026 2:51pm After digging through it I think I may have found the issue. The mid body gasket was smushed. Ordering a new one and going to go from there.
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mxrose3 Liked a reply to forum topic 2005 crf250r rebuild
4/10/2026 9:25am
RedRocket is on point here. I would check the obvious first - Choke plunger, Hot start plunger, and make sure the fuel screw located at the bottom of the carb is there and set at the right number of turns out. I bought a used bike once that the fuel mixture screw had completely dropped out of the carb, but still sort of ran somehow if i kept the throttle cracked. The screw is hard to get to when it is on the bike, and aftermarket companies made a killing on extended thumb screws back then.
This forum topic has 44 replies.
Woody250 Added a reply to 2005 crf250r rebuild
4/10/2026 9:15am Morning guys, It’s a Tokyo mods rebuild kit. The downside is that it did not come with jets. I do have a service manual and have been going through it since the trouble. I’m going to be moving stuff around today. It was starting fine yesterday but is much more difficult to do today. I did clean the hot start...
Woody250 Added a reply to 2005 crf250r rebuild
4/9/2026 4:53pm New news! I took it for a spin around the block. It has a hiccup/ sputter when accelerating between gears but evens out if I stay on it. Could this be the confirmation of needing a smaller leak jet? Thanks dudes!
Woody250 Added a reply to 2005 crf250r rebuild
4/9/2026 1:21pm I’d say it’s a 1 second stream and it does not hit the slide! It did experience some smoking from the exhaust in the initial warm up getting it ready to flush the coolant system but dissipated after warming up.
RedRocket Liked a reply to forum topic 2005 crf250r rebuild
4/9/2026 1:20pm
Hey Woody, like Motörhead said a smaller leak will force more fuel through the accelerator pump circuit. I believe your stock leak jet is a 70, a 55 or a 45 is common as an upgrade. You said you bench tested before taking apart, I presume you also did that after rebuild. While testing did you have a 1 second stream of fuel roughly in the middle of the throat after the slide lifted ? no fuel should be hitting the slide. When / if you replaced the diaphragm did the new one match the old ? I ask because...
This forum topic has 44 replies.
Woody250 Added a reply to 2005 crf250r rebuild
4/9/2026 1:20pm Thanks for sharing! I may have to give that a shot if it gives trouble after a short ride
Woody250 Added a reply to 2005 crf250r rebuild
4/9/2026 1:19pm Good point, hoping to know more after I give it a ride around the block!
PNWMXer Liked a reply to forum topic 2005 crf250r rebuild
4/9/2026 1:18pm
Even the best-tuned carbureted four-stroke can be made to cough/die/bog when not under a load. Whacking the throttle on the stand won’t tell you much.
This forum topic has 44 replies.
Woody250 Added a reply to 2005 crf250r rebuild
4/9/2026 1:18pm I’m going to give that a shot! I’ll come back to let everyone know how it went. I’m flushing the coolant system today then going to take it for a spin. While warming it up today I had a pretty good amount of smoke coming out of the exhaust but dissipated after giving it some throttle & a couple minutes...
96motorhead Liked a reply to forum topic 2005 crf250r rebuild
4/9/2026 1:14pm
It sounds like it might have a lean bog. If it had an air leak the bike would likely pop a lot on deceleration. You can put a smaller leak jet in the carb so that the accelerator pump squirts more fuel at the twist of the throttle. This sounds counter intuitive but a smaller leak jet forces more fuel into the intake by allowing less fuel to bypass back to the bowl.
This forum topic has 44 replies.
Woody250 Added a reply to 2005 crf250r rebuild
4/8/2026 7:37pm Hey guys, I just finished rebuilding the carb today and I’m having some trouble with the performance of said carb. It’s a flat slide carb. It’s cutting out when I wack the throttle. I bench tested the carb prior to taking it apart to make sure the accelerator pump worked. It passed, I did a complete rebuild of the carb...
Outlaw Liked a bike check Kawasaki KX250 1993 Mike Kiedrowski
3/20/2026 2:10pm
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JMCR250 Liked a reply to forum topic 2005 crf250r rebuild
3/20/2026 12:47pm
You've made lots of progress here. Look at the bright side -- you already have the requisite black plastics that came with the bike!
This forum topic has 44 replies.
mgarro385 Liked a reply to forum topic 2005 crf250r rebuild
3/20/2026 12:47pm
I wouldn’t hone it. From the pictures you submitted it looks like there’s visible cross hatch. Like Motörhead said there’s a lot of controversy on honing a nikasil plated cylinder.
This forum topic has 44 replies.
Rider 5280 Liked a reply to forum topic 2025 brand new yz 450 no start
3/15/2026 1:22pm
This may help - similar thing happened to me: https://www.vitalmx.com/forums/Tech-Help-Race-Shop,42/A-brand-new-2020-…
This forum topic has 5 replies.
Woody250 Added a reply to 2005 crf250r rebuild
3/14/2026 7:08am Thanks for sending this over
mxrose3 Liked a reply to forum topic 2005 crf250r rebuild
3/14/2026 6:27am
Pre-2006 CRF250's had soft valve seats that would wear extremely quick and wear out the valves at the same time. If it needs it, You can send the head off to get new valve seats installed, but it may be the same price as a new head. Here is a poor mans leak down test: Cylinder Head Leakdown
This forum topic has 44 replies.
JMCR250 Liked a reply to forum topic Clutch plate defect?
3/12/2026 8:40pm
Definitely not normal. Send them back.
This forum topic has 3 replies.