DIY XT225 Carb Removal & Jet Change w/Air Filter Change

Discussion in 'The Garage' started by Moto Psycho, Jun 26, 2011.

  1. Moto Psycho

    Moto Psycho Adventurer

    Joined:
    Feb 27, 2007
    Oddometer:
    98
    Location:
    Far Nor-Cal
    The first thing I did was to get everything prepared and ready to go.

    I moved the toolchest out..
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    I had cut up a cardboard box, laid it out and rolled my XT onto it.

    My baby before her surgery..
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    First thing to do is take off the side plastics, seat, tank scoops and tank. Remember to remove all the lines from the tank to the carb (and charcoal cannister if Cali model).

    After removing all this..
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    Next loosen the carb joint clamps. Then go to the right side of the bike and rotate the carb to the left, this will expose the four float bowl screws (which are JIS (Japanese Industrial Standard) screws).

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    If you do strip, will more than likely have to take the carb off the bike, as I had to do. I found out the best way to remove the carb is to remove the screws holding the airbox on. I found this out after trying to put the carb back in (Thanks Road Rash for the tip), and thought if I had done it before removing the carb, it would have been alot easier. Also, I labeled all lines and hoses that needed to be removed from the carb (plus taking pics as I went along help).

    The carb removed..

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    Now with the carb out, you can see the stripped screws..

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    With the screws stripped, I got looked for help on removal from our great site here. With the suggestion from Chartman, I ordered a Dremel tool for the removal task...

    About a week goes by, and I received my Dremel tool (400 XPR) and my Dremel vise.

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    I set up the vise on the lip of the laundry tub, 'cause it was at the perfect height.

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    The carb in the vise..

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    Now the surgery begins....:jkam
    #1
  2. Moto Psycho

    Moto Psycho Adventurer

    Joined:
    Feb 27, 2007
    Oddometer:
    98
    Location:
    Far Nor-Cal
    On the Dremel, I used the part# 402 mandrel and part# 426 1 1/4" fiberglass reinforced cut-off wheel.

    This is so you can cut a slot in the screws to change them from the JIS phillips to a slot head (flathead). I just wish the cut-off wheel was a little smaller as I ended up nicking the float bowl a few times while trying to cut the screws on the side with the recess. I even cut into the hole where the screw goes, but it didn't look deep enough to affect anything.

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    The screw that gave me the most problem and made me cut into the float bowl..

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    ....:jkam
    #2
  3. Moto Psycho

    Moto Psycho Adventurer

    Joined:
    Feb 27, 2007
    Oddometer:
    98
    Location:
    Far Nor-Cal
    Now with the screws all cut, I take the vise into the house and attach it to my desk, put the carb in the vise and start on the jet removal.

    Carb with the float bowl off..

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    Nick that I cut into the screw hole..

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    Original screws..

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    New screws (SS allen head)..

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    Stock jets out(125 main & 40 pilot)..

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    New jets in (130 main & 42.5 pilot)..

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    Carb back together with new allen head screws..

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    I forgot the guide for the CA cannister hose so I put that back on..

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    ....:jkam
    #3
  4. Moto Psycho

    Moto Psycho Adventurer

    Joined:
    Feb 27, 2007
    Oddometer:
    98
    Location:
    Far Nor-Cal
    With the carb ready to go, it's time to reinstall (remember to connect the choke plunger to the carb while it is still off of the bike, as you can't get a wrench in to tighten it once the carb is on the bike). After awhile of struggling with getting it in, I get back on our great site to find out the easiest way to get the carb in without using brute force and risk breaking that plastic piece on the side that isn't replaceable. Road Rash gives me the tip to loosen the airbox and move it back (Thanks Road Rash).
    Remove this screw at left side of bike on airbox..

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    Then remove these screws inside of rear wheel..

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    With these removed, I was able to move the airbox back and I stuffed an old shirt between the frame and airbox to hold it into place. You can see to the left of the airbox where I put tape on the frame, 'cause before I moved the airbox it was a tight fit and I was getting some scratches in the paint (don't need to do this with the airbox moved)

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    This allowed me to pop the carb right in..

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    Then I connected the throttle cables and attached all the hoses..

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    Now carb is done....:jkam
    #4
  5. Moto Psycho

    Moto Psycho Adventurer

    Joined:
    Feb 27, 2007
    Oddometer:
    98
    Location:
    Far Nor-Cal
    Since I had the bike apart, I decided to also install my new Uni filter.

    For the filter change, you start off by removing the 3 screws in the corners of the airbox.

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    Inside the airbox..

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    Original filter removed..

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    Inside airbox with filter removed..

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    I could not figure out how to remove the screen, so I just left it alone.
    The airbox check tube..

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    ....:jkam
    #5
  6. Moto Psycho

    Moto Psycho Adventurer

    Joined:
    Feb 27, 2007
    Oddometer:
    98
    Location:
    Far Nor-Cal
    Next I got everything set up.

    Uni filter (NU-3237ST), No Toil filter oil, bucket for oiling and gloves..

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    Filter in the bucket soaking up filter oil..

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    Squeezing out oil (remember to just squeeze out the oil and Do Not wring it out like a washcloth)..

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    Filter on the frame and put into the airbox..

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    I put some No Toil airfilter rim grease in the groove of the airbox cover to help keep out debris..

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    Now just attach cover and tighten cover screws....:jkam
    #6
  7. Moto Psycho

    Moto Psycho Adventurer

    Joined:
    Feb 27, 2007
    Oddometer:
    98
    Location:
    Far Nor-Cal
    I also installed my newly altered Turbocity Borrego rack. I wanted a little more rack, so I had an extended hoop added at the back of the rack, that extended a little past the taillight.

    A teaser pic..

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    With the bubble wrap off..

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    ....:jkam
    #7
  8. nuggets

    nuggets It's all my fault...

    Joined:
    Jul 13, 2010
    Oddometer:
    4,175
    Location:
    Virgina
    I highly reccomend getting an impact driver (~$7-20)
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    They are great tools for getting stuck phillips head screws out without damaging the heads. Plus you get to whack things with a hammer :evil

    Much cheaper in time and cost than dremeling and new fasteners.


    Nice writeup and photos.

    #8
  9. rhollamby

    rhollamby Been here awhile

    Joined:
    Jul 2, 2012
    Oddometer:
    341
    Location:
    80831
    Thanks for the write up!
    #9