XR250L Project
September ‘94
Page 6
One solution is to remove the headlight from the circuit during starting, so the
capacitor will charge quicker, and the ignition circuit will work. On some
street motorcycles, a voltage or current clamping device is used to keep the
headlight off until the bike is running. An easier solution is to install a toggle
switch on the low beam headlight circuit. You manually turn the switch off for
starting and then turn it on when you want a low beam. I prefer to leave the
light off to limit distractions in the dark woods. You can mount the toggle
switch on either headlight nacelle side-support flange, and it will be protected
by the number plate. Cut the low beam wire where it leaves the back of the
bulb wiring and re-route it to the toggle switch. I mounted a miniature toggle
switch right on the main light switch housing and cut and re-routed the low
beam wire inside the switch housing. It’s a tight fit.
Just recently, I saw an ad for a White Brothers battery eliminator capacitor.
The ad said the capacitor was for dual purpose bikes and no values were given
for the capacitor. The Radio Shack capacitor works, with the modifications
detailed above. Try what you like.
Capacitor, 4700 µf, 35v
............................................ RadSh 272-1022
Capacitor................................................................. WB
Tail Light Assembly
I installed an EMGO tail light assembly in place of the stock assembly, which
allowed me to remove the brace under the rear fender and save a lot of weight.
I didn’t use the supplied large rubber pad for the license plate; instead, I bolted
the license plate directly to the rear fender. You’ll need an extra nut and
washer for the tool bag mount.
The EMGO wiring harness is not long enough, and the ends don’t match the
XR-L harness. Cut and solder or use crimp hardware.
Use shorter seat mounting bolts (8x12 mm) and shorter fender side mounting
bolts (6x40 mm) to compensate for the reduced thickness due to the missing
fender brace.
I removed the rear-brake switch bracket and zip-tied the switch to the frame,
which gets the switch out of the way of my boot. I drilled a zip-tie hole just
behind the frame tube and between the rear brake mounting lug and lower
passenger peg bracket bolt hole; it’s in the perfect spot to hold the switch. Be
careful when you drill because the brake line is behind the lug.
For added protection, I fabricated a small plastic cover that mounts via a bolt
in the lower passenger peg bracket bolt hole. Gordo made an aluminum cover.
Gregg from California installed an Acerbis taillight. It’s bigger than the EMGO
but much smaller than the stocker. Gregg also installed Lockhart turn signals,
which are very small, have short hard plastic mounting stalks, and fit on the
stock brackets.
Tail light assembly................................................... EMGO, Acerbis
Nut, flange, 6 mm.................................................... HON 94050-06000
Washer, plain, 6 mm................................................ HON 94103-06000
Bolt, seat, 8x12 mm (2)............................................ HON 90190-MG3-000
Bolt, fender mount, 6x40 mm (2) ............................. HON 96300-06040-00
Switch cover ............................................................ hand made
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