Edelbrock Automobile Parts XR250R User Manual

INSTRUCTION SUPPLEMENT FOR  
1996-2004 HONDA XR250R  
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  
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.  
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.  
NOTE: It may be easier to remove sub-  
frame prior to installation.  
Preparing Bike for Carburetor  
installation  
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.  
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 2.  
Figure 1.  
Pull Cable  
Figure 3.  
8. Align carburetor as close to vertical  
as possible and tighten manifold  
clamp.  
Installing the Edelbrock Carburetor  
and Throttle Cables  
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