I have a 1985 Honda 250SX which I have had since it was essentially new (original owner bought it as a Christmas present for his wife, she refused it so he put it up for sale). It started to behave like it had a clogged fuel filter several years ago. By the time I got around to working on it, the carb was horribly clogged up by deposits from fuel, and refused to run even after cleaning the fuel filter. I finally pulled the carb to go through it this week. I was following the directions in the Clymer service/repair manual for this model. The throttle valve was completely stuck in its bore, but it eventually loosened up with PB blaster. I soaked and cleaned the whole mess in carb cleaner. The needle jet was stuck, and I was never able to completely remove it (the manual says not to use anything metallic on the jet). I was able to run some brush bristles through the jet and clean it out. After removing all the various jets, I turned the carb over and a very small washer (about the diameter of the jet threads) came out, but I'm not sure where it came from. <u>Does anyone know what this washer is? </u> The only semi-logical place seemed to be between the needle jet holder and needle jet, but I haven't tried running with it there yet (I just left it out when initially assembling).

When I got everything back together (and starting with the default 2-turns out position of the pilot screw), it will only start and run if the choke is fully engaged. It will also immediately die if I back off the throttle. I can rev it up, but it stumbles badly until the RPMs are high (in other words, a bad off-idle stumble). I backed off the pilot screw (eventually 4 full turns), and it will at least idle without additional throttle input, but only with the choke fully engaged. Any ideas?

Also - the manual mentions a retrofit kit which is supposed to be installed on all 250SX's, a "Cold Start Carburetor Kit". Does anyone know of this? The local dealer had no idea. I'm pretty sure mine does not have it unless it came from the factory.

Thanks,
Michael Pliska

 

that cold start retrofit didnt make it to ll the 85 es and sx models I was told to drill out the pressed in jet to .0080 and then there was someting about a breather tube fix? in that same kit