XR250L Project
September ‘94
Page 4
Air Box
The inlet air tract is too restrictive.
Remove the inlet air duct by drilling out the two pop-rivets that fasten it to the
top of the air box. These pop-rivets will be difficult to drill out unless you can
keep them from turning. Grind them off if necessary but keep the air box from
melting by applying water to the rivets as you grind.
Remove the internal metal brace by drilling out the pop-rivets on each end of
the brace. Grind the middle off at the welds and leave the metal plate mounted
in the air box, so you don’t have to mess with holes in the back of the air box.
Don’t let the plastic melt; apply water during drilling and grinding operations.
Replace the stock air filter with a K&N air filter. You can use the large capacity
air filter for the XR600R, if you remove the metal brace from the air box. The
larger filter is a tight fit and the stay arm must be bent a little, but it works.
You can make a longer stay arm fastening loop from 1/8" welding rod and then
the stay arm doesn’t need to be bent.
Remove the breather canister from where it is mounted on the left side of the
frame by the shock reservoir. Remove the mounting tab from the frame.
Disconnect all hoses from the canister. Remove the hose from the crankcase
vent tube and install a K&N crankcase vent filter directly on the crankcase vent
tube. Remove the hose from the left front of the air box and plug both ends of
the plastic tube on the airbox with shoe goo. Remove the hose from the bottom
of the air box and replace it with an XR air box drain valve.
K&N air filter ........................................................... CHAP HA-1312
K&N large capacity air filter..................................... CHAP HA-1315
K&N crankcase vent filter, 2"d x 1.5"h x .5" clamp ...CHAP 62-1330
Tube, drain.............................................................. HON 17359-KK0-000
Clip, breather tube .................................................. HON 17316-611-000
Gas Tank
The stock tank is steel and will dent permanently if you fall on it very hard.
IMS and Clarke make replacement plastic tanks.
The IMS tank holds 3.5 gallons and comes in white or XR flash red (orange
looking). The red/orange tank is semi-transparent and is exactly the same
color as the seat and red/orange XR fenders. The tank mounts on the stock
donuts at the front and has a trick metal bracket at the rear. You use the
stock petcock. IMS provides a plastic non-locking gas cap (unlike the Honda
49-state metal locking gas cap). The tank does not feel any wider than the
stock tank; most of the extra capacity is obtained by drooping the front and
raising the top. The upper triple clamps just kiss the tank at full lock. The
tank does wobble when you press with your knees.
Clarke makes a 4.0 gallon tank with a very solid mounting system; a threaded
rod passes through a pre-existing hole in the frame and the front of the tank.
The tank is narrow at the back, like the IMS tank. I tried both tanks and liked
the Clarke tank the best.
3.5 gallon plastic gas tank, red or white................... IMS
4.0 gallon plastic gas tank....................................... Clarke
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