Edelbrock Honda XR250R Owner's manual

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

9. Adjust pull cable until wide-open
throttle is achieved. Adjust return
cable to take up the slack. Note:
When throttle cables are adjusted
properly, there should be approx.
1/8” of free play in the throttle.
10. After throttle cables have been
adjusted the handle bars should be
rotated from full right stop to full left
stop while opening and closing
throttle to ensure smooth
operation. Also check to make
sure the cables do not catch or
bind on anything, i.e., hand
guards, stabilizers.
11. Secure clamp around air boot onto
back of carburetor.
12. Install remote idle cable into
threaded tab on top of carburetor.
Refer to main instruction for remote
idle cable installation and
adjustment.
13. Disconnect the crank vent lines
from the stock plenum (some
models were not equipped with a
plenum. Instead, they had a tee
similar to the one provided in the
kit. If your motorcycle has a tee
from the factory, disregard this and
go to step 14.) and replace it with
the provided tee fitting. See figure
4.
Figure 4.
14. Reinstall crank vent lines to stock
locations.
15. Install fuel tank and connect fuel
line to petcock and secure with
remaining pinch clamp. Turn fuel
on and check for leaks.
16. Open throttle 3-5 times to prime
accelerator pump. Do not open
throttle any more than 5 times as
this may flood engine!!
17. Once pump is primed, get motor to
TDC and kick through without
opening throttle. If Motor will not
fire with a few kicks, open idle cable
½turn and repeat starting process.
NOTE: If flooding occurs, slowly
open throttle to wide open and
hold. With throttle still open, hold
decompression lever and kick
motor through 5-10 times.
Release throttle and
decompression lever and
proceed with normal starting
procedure.
For any questions regarding
tuning or installation of Edelbrock
products, please call our toll free
tech line M-F 8:00am-12: 30pm,
1:30pm-5:00pm PST.
877-888-7504 ext.2.
Edelbrock #3116 XR250R
Carburetor specifications
Bore Size: 30mm wide X 32mm Tall
Needle: 15E @ 10 clicks
Accelerator Pump Bypass: 1.5
turns out.
Alternate Needles: 13E, 17E
Replacement Throttle Cables:
#9337