I got the carb back on there and took the torque drill to start it again and it started up! Of course, after the third time...and after the engine kicked the first couple tries and every tool I had on the bike went flying. I got a lot of white smoke out the tail pipe but there is less of it every time I start it up.

It has a pretty weak sounding idle. The engine kind of has a kick to it. I should adjust all the pilot air scew, throttle stop screw, and everything else to factory settings and see how it sounds. Now if I can just find that darn cable that attaches to the thumb throttle than Y splits off to the choke and throttle cable and I should be good. If I close the choke attached to the starter plunger it will shut off, that might be too long of a spring on there.

Now I just gotta troubleshoot the electrical system so I can get the push button start to work.

 

Surprising on an old 29 year old machine that you got it running. If you can't get the old throttle cable to work right,possible you can make a later model cable work.http://www.ebay.com/itm/Polaris-Trail-Boss-250-1989-1999-Throttle-Cable-7080375-7080531-/261824278080?hash=item3cf5f16e40&vxp=mtr Or possible find a single throttle cable since your not using the oil pump anyway.http://www.aaenperformance.com/2S_P2.asp
Block Off Kits
Convert back to using pre-mixed gas for racing application. Competition mix ratio is 32:1. Use single cable with the oil block off kit. Starter block off kit is also available.
Oil Pump Block-Off (350-400) ACA20020 $39.00
Oil Pump Block-Off (250 's) ACA20018 $39.00
Single Thr. Cable (Thru 98) ACA20021 $49.00
Single Thr. Cable (99-04) ACA20021-99 $49.00
Starter Block-Off Kit (350-400) ACA20019 $45.00

 

Thanks for finding prices for me. I actually made the mistake of cleaning my carb with a can that had nearly no pressure in it. The engine started and would idle till I turn it off. I also made the mistake of putting the dirty gas line and filter back on the carb, which gunked it up again. So it wasn't starting up when I cranked it, the carb for sure was gunked up I could see the grime that came out of the carb in the cleaner.

I cleaned it with legit carb cleaner and now when I plug in the gas line, gas leaked a ton out of the overflow valve. So I guess my cleaning job did something at least. I checked the float level and everything looks okay. The engine still cranks just fine with the torque drill. There is just no gas in the carb! What should I investigate as the cause of the gas leaking out of the overflow on the carb? Its as if I just get one issue after another with this old quad. The On/off valve for the gas line on the tank is also just a bolt, which is stripped down so it's a hassle to keep turning on/off but it gets there.

 

Sounds like you need a new needle and seat or simply get a carb kit. Kit is cheaper than a dealers needle and seat only,but the jets may be a little different and you may have to use your old pilot and main jet as it's hard to find a kit specific for and old 86. But still the best way to go with the 89 up kit that's basically the same carb. 20 bucks for the kit..http://www.ebay.com/itm/Polaris-Trail-Boss-250-2x4-1989-1999-CARBURETOR-Carb-Rebuild-Kit-Repair-P250-/171565173208?hash=item27f214c9d8&vxp=mtr

 

nice! Not expensive. I do need this kit. The rubber gasket is broken into two, I'm missing a spring that should go around the air intake needle, and i just noticed the jet needle is not pointed at the top it looks worn. I'm also missing two rubber washers that should go under the needle and seat. I guess there must have been something gunking up the carb, it wasn't leaking out the overflow till I cleaned it and after I cleaned it the first time with that can that had low pressure squrting the solvent out it was running and would idle, but had a lot of white smoke and it had a weak idle, and the engine kicked every few seconds.

I'll rebuild it with a kit, hope all is well after that. $20 isn't too much of an investment to take a chance that this machine might not even work right to be a reliable thing to take riding.

 

Does it run better if you pull choke on when your driving it? If it does it's lean and somewhere there is a restriction in the fuel system. If it runs worse the carb is flooding and should be rebuilt.

 

I never got it driving before because the throttle cable is broken. When I had it at idle and I pulled the choke, the engine actually shut off. I know when I cold start it I should pull the choke to start. It wouldn't start with the choke pulled while cold. Even if I pulled the choke up 1mm it shut off, so I must have to adjust it.

I'm solving this gas leak out of the overflow before I buy anything else.