INSTRUCTION SUPPLEMENT FOR
1996-2004 HONDA XR250R
Removing stock carburetor and cables
1.
Remove seat and gas tank.
Make
sure fuel petcock is in “off” position.
2. Remove throttle cables paying close
attention to routing, as the new cables
will need too be routed the same.
3. Remove stock carburetor and stock
throttle housing.
4. Stuff a dry, clean rag into the intake
manifold to keep debris from entering
engine.
NOTE:
It may be easier to remove sub-
frame prior to installation.
Preparing Bike for Carburetor
installation
Once stock carb has been removed,
remove all crank case breather lines. The
steel breather barb on the crank case
needs too be rotated clockwise until it
points towards the left frame down tube.
This is needed for carb clearance. It can
by done by simply using a pair of standard
pliers. See figure 1.
Figure 1.
Installing the Edelbrock Carburetor
and Throttle Cables
1. Install the throttle cables into the
supplied throttle housing and place
onto clean handlebar end.
2. Remove the rubber carburetor
alignment tabs from the manifold using
a razor blade or sharp cutters. This
should be done with the rag left in the
manifold.
Be very careful not to
damage the manifold or your hands
while doing this!!
3. Remove the hex pipe plug from the
carb cap using a 11mm or 7/16 wrench.
Do not discard plug, as it will be
needed later.
Install the metering
adjustment tool included in the
hardware kit.
Do not over-tighten as
damage may occur to cap.
4. Install provided fuel line onto fuel inlet
banjo and secure with pinch clamp.
5. Place Edelbrock carburetor into
manifold. Do not tighten clamp yet.
6. Remove the cable bracket end from
cable bracket using #2 phillips.
7. Install pull cable (see Figure 2) end into
the 4:00 position of the cable wheel
and the return cable into the 1:00
position. Secure cables into cable
bracket by replacing end piece and
phillips screw. See figure 3.
Figure 2.
Figure 3.
8. Align carburetor as close to vertical
as possible and tighten manifold
clamp.
Pull Cable
