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2005 xv250 float level

PostPosted: Mon Sep 12, 2016 6:37 am
Author: FordF
Hi, Can anyone help with the float level setting on a 2005 xv250. There were photos on an old post but are no longer available. I have a factory manual which gives a setting of 15 - 16 mm below a mark on the carby. However the diagram is not clear where the correct mark is. I have tried setting the level and it is either higher than the 15 - 16 mm or if I try to lower it there is no fuel flow at all. If someone has clear photos and info on setting the level it would be much appreciated. I have looked every where on the net with no luck.

Cheers FordF

Re: 2005 xv250 float level

PostPosted: Mon Sep 12, 2016 7:36 pm
Author: CX Rancher

Hasty pics and I fell into a cactus..

There is a cast line on the float bowl. near the top and near the forward quadrant. That is the Fuel Level Indicator.
First pic shows cast line above the vacuum hose. Second pic attempts a pointer to the cast line with flash.

Make a J shape with clear tubing and attach it to the Float Bowl Drain port at the bottom of the bowl. Direct the J up and above the casting mark on the bowl and open the drain screw. Set the petcock to PRIME.
you may have to tap on the tube a bit but the fuel level will rise to the bowl level.

You can do this off the bike as long as you have an elevated fuel source connected to the carby. Just steady the carb level on a can or large socket. Float adjustments mean you have to take the bowl off again but just adjust the level the same amount of fuel level offset and you should be within 1mm of the cast mark.

Re: 2005 xv250 float level

PostPosted: Tue Sep 13, 2016 4:58 am
Author: FordF
Thanks for the info. That clears up how to do it, I found the cast mark on the carby, but the manual states it should be 15 -16 mm below that. After trying without success I came to the conclusion that the book was wrong!! Maybe that setting is for a dry float height. When I first checked the level it was close to the line anyhow. The bike wouldn't idle correctly and a couple of times it flooded when idling, which was why I wanted to check the level. However I found the choke cable was rusty and holding the choke valve partly open. Since I fixed that it idles a lot better, so now I will check the float level and all should be good again. Once again thanks for your help.

Re: 2005 xv250 float level

PostPosted: Tue Sep 13, 2016 5:40 am
Author: CX Rancher
you got it! :GJ:

Re: 2005 xv250 float level

PostPosted: Tue Sep 13, 2016 7:39 pm
Author: CX Rancher
Hey, FordF.

If the XV250 manual says to measure X distance from soemwhere... the cast mark then is a point of reference as I recall and that is the real spec.
My brain says 17mm from X so although I do not remember the exact procedure or value, the cast mark is a point of reference.

I think that you have it going as it should be. After you get it sorted its still good to pull the plugs and check their colour tone.

Cheers to you.
The choke plunger and the cable are traditional fits of attention/repair on these lil guys. Keep the plunger lubed and the cable also.

Re: 2005 xv250 float level

PostPosted: Wed Sep 14, 2016 2:31 pm
Author: RupertC
Since I was there recently, here is with removed vacuum(?) line there you can see two marks with pen, upper is marked line on carb, lower is marked about 17mm lower by me... and with clear hose attached to drain port, you can adjust correct fuel level.