Recommended modifications for the CRF 250 Rally

Before anyone goes off the chain, the following are MY recommendations based on MY riding style and riding conditions. There is no right or wrong. This list is comprised simply because I often get asked what the “recommended” or “must do mods” are.

MODIFICATION WHY LINKS
Proper hand guards DO Saves you a lot of grief by protecting the levers / bars in case of a fall. Barkbusters hand guard installation on Honda 250 Rally
New handlebar CONSIDER The OEM bars are a bit soft and prone to bending. I haven’t bent mine in my minor falls, but others have reported them to bend easily. Honda 250 Rally handlebar diameter
USB-charging socket DO I use a phone as GPS navigator and it also allows me to charge my camera and GoPro on the go. USB Charging plug / power socket
Rear rack DO A solid mounting point for luggage is a necessity for me. Rear rack options

PM Racks luggage rack

Side racks DON’T The stock suspension is on the soft side and loading the bike with additional racks and excessive luggage is not for me.
Tail tidy DON’T No real need to get rid of the OEM fender. DRC Edge 2 tail tidy for Honda 250 Rally
Fuel controller DON’T Based on user experiences, adding a fuel controller does not really do much.
Aftermarket exhaust DON’T I like my bikes quiet and the mod does not provide significant power increase. Weight saving is not enough motivation to spend the cash.
Crash bars DON’T Nice thing to have, but I don’t want the extra weight. Crash / engine guards for CRF 250 Rally
Heavy duty bash plate CONSIDER A good idea in rocky terrain, but not something I need in here where it’s mostly sandy / muddy. Honda 250 Rally bash plate / engine guard

Bash plate for Honda 250 Rally

Folding mirrors CONSIDER Not absolutely necessary, but a nice upgrade.
Aftermarket seat DON’T The stock seat works fine for me even on longer days.
Grip heaters CONSIDER I opted for heated gloves instead. Definitely a good thing in colder climates.
Aux lights CONSIDER Necessary only if riding in the dark is frequent thing. Aux light project for Honda 250 Rally
Smaller front sprocket DON’T I found little change to the OEM one. The bike pulls fine as stock. Smaller front sprocket
New levers DON’T Not necessary even if I have fiddled with mine a lot. D.I.Y. 2 finger clutch experiment

Rally 490 super short levers for Honda 250 Rally

Yet another pair of levers

Bigger foot pegs CONSIDER A good addition, but in no way a necessity. The bike’s frame is soft and larger pegs may do more damage in case of a fall. Frame bending at the peg mounting point has been a reported issue since the 250 L. Bigger foot pegs for the 250 Rally
Phone mount DO I navigate with OsmAnd app so I absolutely need a phone mount. GPS / accessory bar dimensions

Cleaner & better GPS / phone mounts for the 250 Rally

Yet another Phone/GPS mount solution – The GUB G-86 phone holder

Bar risers CONSIDER The bars are a little low for riding standing up. Not a necessity though and depends on rider height. Handlebar risers for Honda Rally
Rear suspension upgrade CONSIDER Depends on your riding. Stock will work up to a point. If you are a big fella, load up a lot of stuff on the bike and/or do serious off roading a suspension upgrade may be in order. Rear suspension adjustment
Front suspension upgrade CONSIDER Same as above.
Battery tender plug CONSIDER A convenient thing if the bike sits unused for longer periods of time. Battery tender plug & charge indicator
Headlight guard DON’T I personally have never had a cracked headlight in any of my bikes, but rocky terrain may call for one.
ECU upgrade CONSIDER The 250 R ECU swap is an interesting idea. I have no personal experience, but maybe worth considering. ADV Rider.com post (#4792)
Side stand exstension plate DO Good to have if you are ever stepping of the pavement.
Tire upgrade DON’T Stock tires work well enough so you can ride them until they are done and then put on something different. Honda 250 Rally OEM tires
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5 Comments Add yours

  1. Alex says:

    Great post, incredible web!! An essential source of information for any Rally owner. Always waiting from Spain for new posts. I can’t thank you enough your dedication.

    Btw, the OEM handlebar is extremely fragile. Instead of install bar risers I do recommend change the handlebar for a stronger and higher one.

    Like

  2. Andrew King says:

    Interesting, and like you say these are YOUR opinions. I agree on the most part. Especially hand guards!

    I would highly disagree about the tyres and tail tidy.
    Stock tyres are garbage on mud – they don’t clear themselves of mud, and have no lateral grip UK greenlanes feature large ruts and these tyres cause the bike to slide down into them and it’s impossible in most cases to get out!

    The tail tidy is purely cosmetic, but let be honest the stock rear mudguard is ugly!

    Liked by 1 person

  3. Jonathan Welsh says:

    You feel that side-racks should fall under the “Don’t” category because of their weight (bike is indeed undersprung) but I also feel that rear sideracks can provide excellent crash protection in the event of a tip-over. Also, because of my weight (88kgs) I’m planning on installing a stiffer rear shock spring anyway. I feel that the structure of the rear racks provide an excellent platform for soft luggage AND give me the added benefit of crash protection. (But you have owned your Rally for far longer than I have…I might change my mind and end up agreeing with you ;).

    Like

    1. 250rally says:

      You are right about the crash protection. Side racks can also become a real necessity if you are doing longer trips. There is only so much you can pack on the bike using the rear rack alone.

      Like

  4. Mr.X says:

    Amazing! Thanks so much for doing all this.

    Liked by 1 person

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