Honda Rebel 250 Carburetor Diagram - Page 2 - Honda Rebel Forum
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post #11 of 16 Old 03-03-2019, 04:10 PM
SoakedKarma's Avatar
Join Date: Jun 2014
Location: Nevada
Posts: 1,216
@haf Accelerator pump seal is an integral part of diaphragm outer edge..
might try torquing the three screws,, diaphragm replacement is indicated..

Honda part #16021-KBG-670 and 16021-KEN-620 are both listed..
Linked pages also shows Related Fitment bikes that may have better parts availability in Greece..

96 VS800 Intruder (sold 2018 ), 87 CMX250C Rebel,
79 CB400 Hawk (sold 93), 75 CB350 (sold 83), 71 CB350 (stolen 74)
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post #12 of 16 Old 03-03-2019, 06:54 PM
Join Date: Dec 2018
Location: Southern Arizona
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whatever you do, DO NOT use Red High-temp RTV gasket sealer.
That stuff might be oil and heat resistant but gasoline dissolves it into a carb clogging mess. I know because I made this mistake.

1985 CMX 250

You look much less stupid locking your handlebar lock every night no matter where you park it than looking at the empty space where your bike was last parked.
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post #13 of 16 Old 06-18-2019, 02:16 PM
Join Date: Jul 2013
Location: Massachusetts
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I've got a bit of a carb rebuild mystery, and some of the info here is helpful but some is still confusing.

The bike's a 2009 CMX250C and I've given the carb a good cleaning and reassembled it with a rebuild kit. I expect an extra part or two (there are two large bowl gaskets and I only need one). The kit came with a new slow jet and a new needle jet set (along with other bits) but not a new needle jet holder. It DOES, however, include a new main jet and that is what is puzzling me.

The parts diagrams I've found resemble the ones linked to by flitecontrol and posted by haf. I have both needle jet parts labeled as part 2, and I've reinstalled the tube part into the hole below the needle jet holder (part 25). The main jet is labeled as part 35 in both of those diagrams (and in the manual I have). My problem is that it can't go where it's supposed to go! The top of my needle jet holder is slotted so I can install it with a screwdriver or wrench. It does not have threads for the main jet and the opening isn't even big enough for the main jet to fit into.

Interestingly, my carb somewhat resembles the original diagram posted at the top of this thread (which I've never seen before). It shows the needle jet holder as part 24, and there is no main jet to screw into it. That looks like my carb. However, the needle jet itself is only one part (part 10) with no tube below it. That does not look like my carb.

Is my main jet supposed to be installed somehow? Do I need a different needle jet holder in order to do that? I don't know that the parts I have are original but they seem OK and the bike started and ran when I reinstalled everything. It was only after I did that that I noticed the missing main jet in the diagrams so I took the whole thing apart again. Here are pics showing these parts before and after installation. Thanks very much for the help!
Attached Images
File Type: jpg Installed.jpg (264.1 KB, 6 views)
File Type: jpg Before Install.jpg (374.4 KB, 5 views)
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post #14 of 16 Old 06-18-2019, 03:20 PM
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Location: Monroe, Louisiana
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This thread and the pictures with it may help.

The needle jet is installed under the main jet tube holder with the concave end facing the needle. The engine won't run well if it is reversed. Don't ask how I know this. Unless your needle and needle jet are damaged, I recommend using the originals. Kit replacements can differ from OEM in diameter and length, which can cause issues.

The main jet is the slotted thing you see at the top of the tube holder. You have to unscrew the old one to get the new one in. Be careful not to damage the tube holder when removing the main jet. Install the tube and then the main jet.

Keepin' all the left over parts. Gonna use 'em to build another bike!

'01 & '09 Rebel 250, '06 Ninja 250, '89 VN 750
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post #15 of 16 Old 06-18-2019, 03:39 PM
Join Date: Jul 2013
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Oh, man, do I feel dumb! Thanks, flitecontrol, for the quick reply. My first reaction was to think, "yeah, I know that but there's no place to put it". But I had been looking around and finally found a photo of the part here on Partzilla:

I measured mine and found it was 1/8" longer. Then I realized that it also had a longer section beyond the left edge of the part in the photo. My main jet was there all along, screwed in place!!! The angle's a little off in the second photo above, but the light oxidation on the part made the two of them look absolutely like one seamless piece. I guess I should have wondered why they put flats for a wrench and a slot for a screwdriver on the same part.

A tight grip with a wrench and a solid twist of a good-fitting screwdriver, and poof - two parts! I'll be shaking my head over that for a long time.....

The original part I just discovered/removed is labeled with a little symbol and "108". The new part has no markings. It appears that the hole in the new part is slightly larger, but the old one might be narrowed from corrosion, etc. Does swapping the "108" for something a little larger sound like a good idea? I definitely belong to the "it always needs a little choke or it will stall" club, so running a little richer is appealing.
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post #16 of 16 Old 06-18-2019, 04:06 PM
Join Date: Aug 2008
Location: Monroe, Louisiana
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That number is the size of the (main) jet. I would think that the replacement would also be marked, so you'd know what you have. The fact that it doesn't concerns me. I didn't mention it in my first post, but I really don't see the need for replacement jets unless the OEM jets are somehow damaged. A larger pilot jet would produce a somewhat richer idle. A bigger main jet shouldn't affect idle at all.

I've had two Rebels that only needed choke in very cold weather. The current ride needs it for every start, no matter the temperature. If your bike needs choke after the engine has warmed up, that's a sign of a dirty carb. Since you've cleaned yours, that shouldn't be an issue now.

Keepin' all the left over parts. Gonna use 'em to build another bike!

'01 & '09 Rebel 250, '06 Ninja 250, '89 VN 750
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