
XR250L Project
September ‘94
Page 2
Carburetor and Jetting
The accelerator pump carb on the XR-L looks like it has potential. Pumper
carbs can be jetted to get rid of that nasty four-stroke hesitation on the bottom
and give good power on top too. However, the non-pumper carb from the XR is
ultimately a better performer because it is designed for more air/gas flow. The
needle and seat on the pumper carb are designed to make the bike EPA legal
(lean) and are the biggest impediment to performance.
But, if you want to stick to the stock pumper carb, there are a few things you
can do. The carb is jetted too lean. If you do any of the intake or exhaust
mods, then it will be way too lean. Install a 125 or 128 main and a 40 or 42
pilot as a start (sea level jetting). While you have the float bowl off, remove the
pilot adjusting screw. Be careful with the spring, metal washer, and o-ring.
Heat the end with the small ear on it, and the ear will fall off. Reinstall the
screw before remounting the float bowl. The pilot air screw can now be
adjusted throughout its range.
There are too many hoses on the California model carb. If you don’t need to be
EPA legal, remove the purge control valve and canister and two extraneous
hoses. Consult pages 1-22, 1-27, and 5-10 in the Service Manual to see which
hoses to remove. Seal the holes in the carb body with short lengths of hose
that have been plugged with shoe goo or something similar. You can seal the
carb body directly if you trust yourself.
Besides hoses, there are two other differences between the California and
49-state carbs: the part numbers are different for the throttle slide and carb
top. I don’t know the extent of the physical differences, but I would guess that
the slide cut-away is different, and the carb top has a throttle limiter.
The XR250R and XR-L carb bodies are nearly identical. The complete XR-L
carb was derived by drilling out the extra channels that were already cast into
the standard XR body. Extra hoses were added, and a different float bowl,
choke mechanism, and jets were used. The similarities and differences are
summarized below:
XR250R XR-L
Main jet
Pilot jet
Needle
Pilot air screw
Float bowl
Choke
Accelerator pump
Actuation
Float bowl vent
Float bowl overflow
Emissions hoses
long hex head, 125
raised thread, large aerator
holes, 40
adjustable
adjustable
tall, allows main jet access
via removable bottom plug
lever on carb body
none
push/pull cables
1
2
none
short top hat, 122
same except small aerator
holes, 38 or 40
fixed
limited adjustment (ear)
short, no main jet access
remote via cable
yes
same
same
same
none on 49-state model,
2 on Cal model
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