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-   -   04 Suzuki Ozark 250 won’t rev (https://atvconnection.com/forums/suzuki/373942-04-suzuki-ozark-250-wonit-rev.html)

ozark250. 11-06-2017 07:06 PM

Sprayed wd40 on the intake manifold and no idle change. Made sure the intake and air box clamp was tight too. There was just a lot of smoke from the wd40 on the exhaust. I used to be able to do wheelies in 3rd gear. Can’t even get it up in 1st.

ozark250. 11-06-2017 07:35 PM

Sprayed wd40 on the intake manifold and no idle change. Made sure the intake and air box clamp was tight too. There was just a lot of smoke from the wd40 on the exhaust. I used to be able to do wheelies in 3rd gear. Can’t even get it up in 1st. Stumped?

ozark250. 11-06-2017 07:37 PM

Sprayed wd40 on the intake manifold and no idle change. Made sure the intake and air box clamp was tight too. There was just a lot of smoke from the wd40 on the exhaust. I used to be able to do wheelies in 3rd gear. Can’t even get it up in 1st.

ozark250. 11-06-2017 11:40 PM

Sprayed wd40 on the intake manifold and no idle change. Made sure the intake and air box clamp was tight too. There was just a lot of smoke from the wd40 on the exhaust. I used to be able to do wheelies in 3rd gear. Can’t even get it up in 1st.

ozark250. 11-07-2017 04:41 PM

Ok so what i did was replaced the bowl gasket and fixed how the plunger gasket was sitting and it had power, like serious power that i hadnt felt out of it in a long time. But im back here because it had a bog and backfire sometimes at about half throttle. It seems like something catches around this point making the throttle slightly heavier after 50%. Im thinking this is the plunger or the plunger gasket. A vaccum leak there somewhere? Not completely sure. Either that or the plunger is not coming up at this point and not letting enough gas in. Not completely sure these are just ideas because im not a mechanic. Just need some confirmation that my ideas are correct or the actual solution that is happening here. Thanks

old polaris tech 11-07-2017 05:24 PM


Originally Posted by ozark250. (Post 3377946)
Ok so what i did was replaced the bowl gasket and fixed how the plunger gasket was sitting and it had power, like serious power that i hadnt felt out of it in a long time here.

Did you install the kit? It comes with a new bowl gasket,etc..https://www.ebay.com/itm/NEW-SHINDY-....c100507.m3226

ozark250. 11-08-2017 07:59 AM

I had installed the new jets and air screw because everything else looked good. But when there was no vacuum leak in the intake I replaced the bowl gasket and fixed the seating of the plunger diaphragm(that’s what the suzuki carb diagram describes it as). It is now acting like I had described. Should I install the whole rebuild kit cause all of the other parts looked good.

old polaris tech 11-08-2017 10:31 AM

2 Attachment(s)
You can't go by looks on carb parts.. A float needle may be worn,but still look good to the naked eye,same for the seat. O-rings,rubber gaskets,etc can be affected over the years by fuel,especially the crappy ethanol we get today.People seem to forget carb parts are constantly moving,examples are slide needles,slides them selves,diaphragms, float arms and pins,opening and closing of float needles.Over the years a lot of these parts need to be replaced. That's why the most common parts are in kits.Some major parts such as needle jets,slides, air cap diaphragms,etc may have to be ordered from dealers or parts suppliers.Either that or take a chance on an aftermarket carb that may or may not work right.

ozark250. 11-13-2017 06:52 AM

Thanks so much. Put the new needle in and it runs great. Was changing the oil and broke a bolt. Need to take the crankcase cover off to get at the bolt. Ordered a new gasket and the new bolt. I have a remover kit. Hopefully that will go well and it will be good to go.

old polaris tech 11-13-2017 08:11 AM


Originally Posted by ozark250. (Post 3378286)
Put the new needle in and it runs great.

Finally.. :)


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