XR250L Project
September ‘94
Page 3
If you want to replace the XR-L carb, get a “take off” carb from XR’s Only for
about $50. XR’s Only takes parts off of XR250Rs before they mount special
hop-up parts. The XR carb is a perfect fit because the carb bodies are
identical. You will have to use the choke lever on the XR carb body and discard
the XR-L choke cable.
The XR carb is most definitely recommended if you do any of the intake or
exhaust system mods.
XR250R carburetor (“take off”)................................. XR’s
Exhaust System
The XR-L exhaust is somewhat restricted. The exhaust header from an XR is
about 3 mm larger in diameter, and will bolt right up to the engine. Gordo and
I both installed XR headers. However, the XR-L tail piece/muffler will not mate
with the XR header because the diameters are different. You have the following
two choices.
First, you can opt for an aftermarket muffler like a SuperTrapp, Cobra, or
White Brothers Megalloy Exhaust Kit.
Second, you can mount a muffler from a ‘90 or newer XR250R. These models
have rear disc brakes like the XR-L, and their mufflers have a cutout to clear
the disc brake when the suspension is compressed. Honda sells the tail
piece/muffler for over $200. Sometimes XR’s Only has “take off” mufflers for
about $40, but be sure to get the ‘90 or newer muffler.
If you use the Honda muffler, you may want to change to a large diameter
muffler insert from an ‘85 XR350R. Alternatively, you can use the insert in the
XR-L muffler by grinding off the weld. Good luck, the weld is plenty deep.
I installed a ‘90 XR250R muffler with the large diameter insert that I removed
from my now-ruined XR-L muffler. My bike seems peppier and revs out better
than it used to, and it’s still plenty quiet. I can install a small diameter insert
to make it even quieter. The XR muffler is about 1.5" shorter and one pound
lighter than the XR-L muffler.
Gordo installed a SuperTrapp Racing series muffler with 8 discs, and it was
very noisy. He had an insert made to fit inside the hollow middle of the
SuperTrapp. This insert adds another layer of fiberglass insulation and quiets
the bike considerably, but his bike is still noisier than mine. Gordo talked to
the guys at SuperTrapp, and they told him they were planning to make a
Street/Trail Series muffler for the XR-L. This version will be the 4" steel
muffler with integral S bend like they make for earlier model XRs. Lastly,
Cobra makes an aluminum muffler that fits the stock XR-L header.
Pipe comp, ex (header)............................................. HON 18320-KT1-670
Muffler, comp .......................................................... HON 18310-xxx-xxx
Muffler, ‘90 or newer “take off”
................................. XR’s
Band, muffler .......................................................... HON 18376-KG0-003
Packing, muffler....................................................... HON 18391-317-010
Muffler insert, 85 XR350R ....................................... HON 18311-xxx-xxx
SuperTrapp ............................................................. CHAP 813-3253
Cobra, XR................................................................ CHAP 219-7521, 7021
Cobra, XR-L ............................................................ CHAP 219-7523, 7023
Megalloy Exhaust Kit............................................... WB 08-000x
(3 pages)
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