Cobra XR-1010 User Manual download pdf

XR250L Project

Fourth edition, September 1994.

This write-up was written when a friend of mine (Gordo) and I each owned

1991 Honda XR250L dual-sport motorcycles. Many, if not all, of the

modifications described apply to subsequent model years also. Part

numbers, part descriptions, vendors, and phone numbers were last checked

for accuracy in 1996. If you find any errors, let me know and I'll fix 'em.

So you just bought a brand new XR250L. Have you noticed how heavy it is?

Have you noticed that it doesn’t have much punch? Are you afraid to ride hard

trails with it because the tires won’t make it? Well all of these thoughts have

occurred to me too. And I did something about it.

My objective was to remove as many parts as I could from the XR-L and still

keep it street legal. My friend Gordo wanted to turn his XR-L into an XR with

shorter suspension that he could occasionally ride on the street. We both got

what we wanted.

My bike weighs 23 pounds less than when I started and has DOT approved

tires that can be used on the street and off-road with some confidence. Gordo’s

bike weighs about the same as mine and has knobbies on it. Gordo uses his

bike in the desert and in the woods. He doesn’t plan to do much street riding,

but he’s legal in most areas and can ride on the street if he needs.

The following pages describe in detail how we modified our bikes. Many parts

from the XR250R (‘86

-‘94) will fit the XR

-L. These parts are sometimes lighter

or give better performance than the XR-L parts. We used standard XR parts

whenever we could.

Working only on weeknights, we each took less than a month to do all the

initial work. We rode on the weekends to check our work. The biggest time

delay was waiting for parts to be delivered.

Cost is not mentioned much, but rest assured, neither of these project bikes

was cheap. Gordo had a NASA budget, while I had a Kitty Hawk budget, so

sometimes I didn’t spend as much on mods as Gordo did.

Gordo and I have “49-state” model bikes. We don’t have an over-aggressive

DMV in our state, and we can get by on a lot less than people in other states.

If you think that some of the things we’ve done might not get by your DMV,

then don’t make the changes. There are more than enough things to do legally.

If you are making a pure off-road bike, then have at it. Where I knew about the

California-specific differences, I mentioned them. I’m sure that I didn’t catch

them all.

At the end of each section is a list containing part descriptions, vendor or

manufacturer abbreviations, and part numbers when available. The key to the

vendor/manufacturer abbreviations is on the last page.

1 2 3 4 5 6 ... 13 14

Summary of Contents

Page 1 - XR250L Project

Page 2 - Carburetor and Jetting

XR250L ProjectSeptember ‘94Page 10TiresI wanted some tires that were better in the dirt than the stock Yokohamas.Everyone I talked to raved about the

Page 3 - Exhaust System

XR250L ProjectSeptember ‘94Page 11Spark Plug and ResistorUse an NGK DPR9Z spark plug, the same as the XR plug, if you do any of theintake, carb, or e

Page 4 - Gas Tank

XR250L ProjectSeptember ‘94Page 12Weight ReductionIn the interest of reducing weight, Gordo and I scoured every inch of the bike,looking for extraneo

Page 5

XR250L ProjectSeptember ‘94Page 13Color SchemeI like my Hondas to be red and blue; Gordo likes them all red. There issomething out there for both of

Page 6 - Tail Light Assembly

XR250L ProjectSeptember ‘94Page 14Unfinished ProjectsI would like to install a Roost Boost Plus, but Answer did not know if the XRversion would work

Page 7 - Sprockets

XR250L ProjectSeptember ‘94Page 2Carburetor and JettingThe accelerator pump carb on the XR-L looks like it has potential. Pumpercarbs can be jetted

Page 8 - Sprocket Details

XR250L ProjectSeptember ‘94Page 3If you want to replace the XR-L carb, get a “take off” carb from XR’s Only forabout $50. XR’s Only takes parts off

Page 9 - Suspension

XR250L ProjectSeptember ‘94Page 4Air BoxThe inlet air tract is too restrictive.Remove the inlet air duct by drilling out the two pop-rivets that fast

Page 10 - Clutch Lever Perch

XR250L ProjectSeptember ‘94Page 5BatteryI wanted to remove the battery because it was heavy and would make me falldown a lot. As it turned out, the

Page 11 - Big Red - the Ultimate

XR250L ProjectSeptember ‘94Page 6One solution is to remove the headlight from the circuit during starting, so thecapacitor will charge quicker, and t

Page 12 - Weight Reduction

XR250L ProjectSeptember ‘94Page 7SprocketsThe XR-L stock gearing is too street oriented for my taste. I wanted somethingmore trail oriented, so I lo

Page 13 - Color Scheme

XR250L ProjectSeptember ‘94Page 8Sprocket DetailsThe following table shows the final drive ratios for several sprocket sizes.Rear Sprocket40 41 42 43

Page 14 - Unfinished Projects

XR250L ProjectSeptember ‘94Page 9SpeedometerI have always liked the ICO odometer/speedometer and magnetic pickup in lieuof the Honda mechanical speed

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