1997-2000 Honda CR250 Keihin Carburetor Rebuild Guide

This is a detailed walk-through of how to service or rebuild your 1997-2000 Honda CR250 Carburetor.

1997-2000 Honda CR250 Carburetor Rebuild

The 1997/1998 Honda CR250 model years used the Keihin PJ28L, and the 1999/2000 Honda CR250 model years used the Keihin PWK00.

*For the 2001 model year, Honda switched to the Mikuni TMX 11a that is not covered in this rebuild.

There are a few carb jetting differences between these carb models, but the most significant difference is the PJ28L had the electronic power jet solenoid option. If your carburetor does not have a power jet solenoid, everything else in this service guide still applies.

Usually, I would include a step-by-step walk-through with pictures for you to follow along with.  However, servicing this carburetor is very easy and does not require much technical knowledge.  I have provided all of the carburetor specifications in the table below the service notes, along with the original walk-through video.

Once you are done, your carburetor should flow freely, so you will need to tune your carburetor back to its normal operating level.  Oh, hey look, a handy 2-stroke carburetor tuning guide.

Carburetor Service Tool List

  • Philips screwdriver
  • 6mm socket
  • 17mm socket
  • Small flat-head screwdriver
  • Needle nose pliers
  • Carburetor cleaner
  • Safety glasses
  • Soft bristle toothbrush
  • Clean rag
  • Hands

Carburetor Replacement Parts List

*The parts listed below are the most commonly replaced parts when servicing a carburetor.

Keihin PJ28L Parts

  • Vent and Drain Hoses – 16199-KZ3-B10
  • Throttle Spring – 16050-KA5-691
  • Throttle Assembly – 16022-KZ3-690
  • Float – 16013-HA2-671
  • Float Valve – 16011-KA3-741
  • Choke Idle Knob – 16046-KS7-004

Keihin PWK00a/b Parts

  • Vent and Drain Hoses – 16199-KZ3-J11
  • Throttle Spring – 16050-KZ3-J11
  • Throttle Assembly – 16022-KZ3-J11
  • Float – 16013-HA2-671
  • Float Valve – 16011-KZ3-J11
  • Choke Idle Knob – 16046-KZ3-J11

You Can Get Parts And Tools Through Our Partner Links HERE!

Before you begin work on your carburetor, make sure your work surface is clean!

Carburetor Rebuild & Service Notes

  • When removing the throttle valve from the carburetor, be careful not to damage the needle.
  • When loosening the bowl screws, make sure the head if clean, and you can get a good bite with the screwdriver.  You may want to hit the screws with some anti-seize before you try removing them.
  • The same applies to the power jet solenoid screws.
  • When removing to bowl, keep the carburetor straight and upside down to avoid losing the float jet in case it falls off.
  • If the main and slow jet is stuck, soak them with anti-seize. If the jet breaks off in the carb body, It will be very difficult to remove.
  • The gasket set containing the bowl, bowl plug, power jet solenoid, and cap O-ring is no longer in production for the ’97/’98 Keihin PF28L.  You will need to reuse these O-rings, so be very careful about removing them.
  • Carburetor Cleaning
    • Clean the carburetor with carb cleaner, NOT all-purpose parts cleaner.  All-purpose parts cleaners contain chemicals that will damage the rubber O-rings if residue remains.
    • Use a SOFT bristle brush when scrubbing the carburetor bore and body to avoid scoring.
    • Always wear safety glasses, carburetor cleaner stings like you would not F*****G believe!
    • Never use water; it can get into small places in the carburetor body and stay there until you install it and run.
    • If debris is stuck in the small parts of the body, use compressed air to remove it.

Click Here To Open The Carburetor Tuning Specifications In a New Window

  • Remember to turn in the Pilot Air Screw until it is lightly seated in the body. Count the number of turns and write what number down for install.
  • If the spring does not come out with the pilot air screw, retrieve it with something metal, NOT a toothpick, or anything else that can break off.
  • When installing the slow jet, power jet, only tighten them, so they are snug in the body
  • When installing the main jet, do not use a ratchet or wrench, take the 6mm socket an extension and tighten the jet until snug.
  • If you need to repair the bowl O-ring with RTV, you will need to let it cure before filling the carb with gasoline.
  • When installing the carburetor, you may want to remove the airbox retaining bolts to give you a little more wiggle room.

If you have any questions or anything to add, please leave them in the comments or on our FaceBook page!

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