FAQs

On an almost daily basis I get asked questions about the setup of my Honda CRF250 Rally that I’ve kitted out ready for my trip to Mongolia and what gear am I taking with me. Since I’m often asked the same question over and over I thought I’d put the definitive set of answers here in a blog post so that I can just refer everyone to the same place, so here goes!

Q: Have you made any modifications to the engine or exhaust to get more power? Are you using an EJK ECU? Have you fitted an FMF exhaust?

Simple answer is No.

I’ve not made any changes whatsoever to the engine, ECU, exhaust or any other component connected to the engine. I’ve deliberately kept the engine completely original so that I have maximum reliability.

When I purchased the bike I knew it only had 24HP and I am happy with that. If I’d wanted more power then I would had bought a bigger bike.

Q: What tank bag are you using?

I have fitted a Givi 6 Litre GRT706 tank bag that fits nicely on the tank and doesn’t get in the way when I’m riding in either the seated or standing positions. The tank bag is mainly for carrying my Canon 1300D DSLR camera and a map that’s visible in the clear plastic water proof top pocket.

Q: What USB device is that you have and where can I get one?

The dual USB and 12v socket with integrated voltmeter I picked up from Ebay. All the information of how to wire it into the AUX 12v feed already on the bike is in this post on the blog. For completeness I’ve also included the details of where you can get the 12v connector really cheaply.

Q: What folding mirrors are you using?

I’m using just a pair of cheap folding mirrors from Amazon.

Q: Have you fitted heated grips?

Yes! I was fortunate enough to negotiate a free pair of Oxford Heated Grips when I purchased the bike from my local Honda dealership. They really do get hot and are great in the winter months. All the information on how to fit and wire them to the CRF250 Rally can be found in this blog post.

Q: How will you keep your chain lubricated during the trip?

For many years I’ve used the Tutoro Chain Oilers on my motorcycles. The reason I prefer them is that they are simple to maintain, need no electrical or vacuum feed from the injection system and are really easy to fit.
I’ve already written a detailed post with photos on the oiler and how to fit it.

Q: What crash bars are they you have fitted? What skid plate do you use?

I use a great integrated skid plate and crashbar combo from Inpreda/GPKompozit. The bike has been dropped a few times on the trails now and it’s protected everything really well. The bash plate has also taken a few hits and has done a great job at protecting the engine sump.

All the information on fitting etc can be found on my blog post here.

Q: What pannier frame have you fitted?

I’ve fitted a Tusk pannier frame to the bike, it’s really solid and can handle the weight I’m going to put on it. All the details on fitting it correctly and the adjustments I had to make are detailed in my blog post here.

Q: What size Rotopax fuel canisters are you using?

Due to the cost I decided not to use Rotopax fuel canisters however, I do need to be able to carry extra fuel with me to make it between fuel stops on the trip and so after much research I went with some ChinoPax fuel canisters that I found sensibly priced on Ebay. They are really well put together and are very strong. They’re made from a very thick plastic that isn’t brittle and so they can take a fair amount of bashing. Noraly of Itchyboots fame uses the same cans and has dropped her bike on them many times without incident.
I got 3 x 5L canisters with fittings for less than the cost of 1 x 1 Gallon Rotopax can. Since the two front canisters will only be used on certain parts of the trip when fuel is difficult to get I didn’t see the point in spending a fortune on Rotopax cans when they would be empty most of the time.

I’ll also being using petrol to cook with and so the rear 5L tank will always have fuel in it so that I can cook at the end of each day. Full info on fitting etc is on the blog right here.

Q: Are you using hard or soft panniers?

I’m using soft panniers from Givi as I didn’t want the extra weight and bulk of the hard panniers. I looked at a lot of soft pannier options including the very cheap Lomo throw over bags but, eventually I settled on the Givi GRT709 Canyon 35L lockable soft panniers.

I really like the Givi soft panniers, they’re well put together, have a separate waterproof inner bag and have a separate water proof bottle carrier on the rear facing side of each pannier making it easy to gain access to drinks without having to open the main bag.

Q: What GPS are you going to be using on your trip?

I’ll be using two effectively, one on my iPhone in the Ultimate Addons waterproof case mounted above the instrument cluster and a Garmin inReach Explorer+ with SOS capability.
I also have a Garmin Zumo 350LM that I may take as backup but it’s worth noting that Garmin do not supply maps for Central Asia for the Zumo GPS units and you have to create your own using OpenStreet Maps.

Q: What side stand foot is that in your photos?

It’s another Chinese made item from Ebay I’m afraid. When it arrived it didn’t actually fit so I had to re-engineer it but, it fits perfectly now.

Q: Have you changed the suspension and if so what have you done?

Yes I have changed the suspension as the OEM suspension isn’t really fit for the kind of punishment I’m going to be giving it on the trip. There are quite a few options available suspension wise for the CRF250 series of bikes these days but I opted for the HyperPro uprated progressive spring for the front forks and a completely new custom built Hagon shock for the rear.

The difference these two changes have made is stunning! The bike now handles so much better and to date I’ve not managed to bottom out the front or rear suspension even hammering along the trails.

There are a number of articles on the blog with regard to suspension. Links to all the articles are detailed below:

General discussion on suspension and the options available

The Custom Built Hagon Rear Shock I purchased

Suspension upgrade, was it worth it?

Most suspension questions should be answered between those 3 articles.

Q: Does the Hagon shock reduce static sag? If so, what is the seat height?

Yes, the Hagon shock with the spring that I have along with the Hyperpro fork spring reduces static sag considerably. With the bike off the side stand and standing free without load the seat height is increased to 93cm (930mm).

Q: What tyres are you using on your trip?

I’ll be setting off on a pair of Continental TKC80s. These are great 50/50 tyres for road and off-road use. I am aware that people with high power bikes complain that they wear quickly on the tarmac but, on my little 24HP CRF250 this isn’t going to be an issue. Whether I’ll be able to get another pair of TKC80s as I travel I don’t know, so it may be a case of just buying whatever is available when they wear out. I imagine I am going to need 3 or 4 pairs of tyres over the duration of the trip so we’ll see what I end up using as time goes on.

Q: What hand guards are you using? Are they any good?

I’ve fitted a pair of Zeta XC hand guards to the bike. I like them because the plastic hand guard can be unscrewed and replaced if it gets broken and the aluminium mount bar provides great protection for the brake and clutch levers in the event of a drop.

Are they any good? Well they saved my hands a few times now from bushes and branches and the levers didn’t get broken in the falls I’ve had off-road so, I guess that must mean they are good.

Q: Where do you get your stuff from?

A multitude of places! Ebay, Amazon, local motorcycle dealerships, overseas … there are many. I’ve put together a list of suppliers on my suppliers page.

Q: Are you going to change the chain and sprockets?

Yes, I’ve got rid of the cheap and nasty OEM chain and sprockets and replaced them with a DID 520VX3 chain and JTS sprockets. I’ve kept the sprocket sizes standard, 14/40.

Q: Have you changed the handle bars and/or fitted bar risers?

Yes, both! On my first venture off-road with the CRF250 Rally it was immediately clear to me that I needed to raise the handle bars up a bit as I was having to lean over too much to reach them when standing.

I decided to change the bars for a better quality item as the OEM handles bars flex very easily and I could see them getting bent out of shape very quickly.

I decided to go with Renthal bars and a pair of adjustable 2in max risers. All the info is detailed in my blog post where I also detail the fitting of the heated grips.

Q: What cameras are you taking with you?

I’ll be taking 4 cameras with me, 2 x Crosstour 4K video/timelapse cameras mounted on the bike/helmet, a Canon 1300D DSLR with a selection of lenses and my trusty iPhone 7 Plus.

Q: What helmet are you choosing for your trip?

This is a good question! I’ve spent ages trying on different skid lids trying to find one that really fits me well and that isn’t too heavy or noisy in the wind. Time and time again I kept coming back to the Nolan N702X. I have a Nolan helmet for road riding and really like it and this 702X really works for me. It’s great in that it’s convertible so I can remove the peak if I want, remove the chin bar and make it an open face helmet and wear it with the visor or goggles. It just ticks all the boxes. The other great thing is that my Sena headset will also fit. Money now spent, I’m really pleased with my decision.

Q: Are you wearing KLIM motorcycle clothing for the trip?

Simple answer is No.
KLIM maybe nice clothing but it should be. At almost £2000 for a pair of trousers and a jacket they ought to be gold plated too!
I’ve been using RST motorcycle clothing for some time and really like it but, it’s a bit hot in the summer months.
After looking around and trying many different outfits on I opted for the Rev’It OffTrack jacket and Sand3 trousers. The reason I got the different trousers is that no one in Europe had the Offtrack trousers in stock and there wasn’t going to be another manufacture run until mid 2020. On the plus side, the Sand3 trousers are made of a slightly heavier material which should wear better especially when kneeling fixing punctures or repairing the bike. Both the trousers and jacket can zip together and have the complete 3 layer system meaning that in the really hot areas like the Gobi Desert I can remove the inner water proof layer and the warm quilted layer leaving me with just the thin outer shell with the back, elbow and shoulder protection.

Q: What tools are you taking with you?

I’ve based my tool pack on the tools I’ve needed to do the jobs on the bike during the preparation stage. I’m sure there are tools in the pack that others wouldn’t take and tools that others take that I’m not. It’s a personal thing and also takes into account my attitude towards risk which may be different to everyone else.

The above image shows all the tools that I’ve included in the pack so lets go through what we have here.

Spanners: 19/12/10/8mm.
Tyre Levers: 3 x including a Motion Pro tyre lever/ring spanner combo for the rear axle.
Allen Keys: 6mm Long and short, 5mm long and short, 4mm & 3mm Long.
Electrical Screwdrivers: Large, medium and small flat head and large and medium cross head.
Sockets: 17/14/13/12/10, 10mm Sparc plug socket, 17/14mm Hex for front axle, Bahco 1/4in socket set and 3 x socket to ring spanner converters so that I don’t need to take a socket wrench with me.
Electrical: Multimeter, cable/zip ties, insulation tape and a length of electrical cable.
Miscellaneous: Valve removal tool, pliers with wire cutter edge, stanley knife, Hagon rear shock C spanner, Tutoro priming magnet, plastic fuse puller and tyre pressure gauge.

I also have an electric 12v tyre pump and head torch that are not shown in the picture.

I also recommend you take a look at Matt Boyle’s video about his tool kit that he takes on his CRF250 Rally adventures.

Q: What spare parts are you taking with you?

I’m taking the following spares with me:

Complete clutch plate set and clutch housing gasket.
Front and rear brake pads.
5 x oil filters and gaskets.
1 x air filter
Front and rear wheel bearing kits
Head stock bearing kit
2 x spark plugs
Spare bulbs and fuses
Puncture repair kit
Spare inner tubes
Front and rear sprockets

Well I think that just about covers all the questions I get asked regularly online. If I have any more I’ll add them to this page.

Givi GRT 709 Soft Panniers

When I fitted the Tusk rack to my CRF250 Rally I had already decided to try out the Lomo soft panniers as they were cheap and seemed to get good reviews.

At £50.00 the Lomo soft panniers really are very cheap and on first inspection appear to be well made.

So for the Thetford Safari event I loaded them up, strapped them to the bike and headed off.

The first problem I had was that no matter how tightly I strapped the bags on they moved around a lot. I used the straps that they came with and two Rok straps on each side but still the bags would move around. This movement resulted in the back of the bags getting worn, which eventually would lead to a hole and water ingress so it was time to have a rethink.

Looking at the market place there are quite a few options for soft panniers available with many costing more than metal panniers.

After much research I decided to purchase the new Givi GRT709 Soft panniers. They’re some £200.00 cheaper than other manufacturers offerings but provide the same storage capacity and water proof solution.

The Givi GRT709 Panniers come with the mounting plate included for the total price of £400.00. This is £200.00 less than the Kriega soft panniers that don’t come with their mounting plate which then costs another £130.00 on top of the £600.00 pannier price tag making them extremely expensive.

The Givi mounting plate fits perfectly onto the Tusk frame and the panniers then lock to the plate using a key lock, something the Kriega offering doesn’t have.

Water proofing is a two part system. Firstly there is the outer pannier which has a solid back and attaches to the mounting plate secondly, there is the inner dry bag that can be removed from the outer shell with ease and comes complete with a shoulder strap to make it easy to carry.

Givi GRT709 Soft Pannier on Honda CRF250 Rally

The panniers provide 35L of storage each (5L more than the Kriega bags) and also have a waterproof bottle storage pod on the rear of each bag. This extra storage is great for carrying a water bottle or fuel for the camping stove.

I’ve used the bags now in all weather conditions including very heavy rain and everything has stayed completely dry.

This is a much better solution than the Lomo soft panniers as the bags don’t move around at all, are securely attached to the bike by key lock and provide more storage.

With a cost of £400.00 I think this is the best pannier solution for the CRF250 Rally, albeit not the cheapest.

Fitting the Tusk Pannier Frame to the CRF 250 Rally

The fitting of the Tusk pannier frame got off to a bit of a bad start.

When it arrived from the USA the box was a dreadful mess and it was obvious that bits were going to be missing!

Not quite what I had in mind!

So after carefully unpacking it I found that the frame itself was actually all still there, a huge plus! The same couldn’t be said for the fixings though.

I knew straight away that I was going to have to contact the seller in the USA and get some replacement fixings sent. Not wanting to be perturbed I got on with the mounting of the frame to the bike to see how it matched up.

Initial lineup looked good and with the use of some spare bolts and fixings I had in the workshop I started to get the frame onto the bike.

Generally the frame itself is very well put together and pretty solid however, some of the holes for fixing it to the bike and for attaching the rear rack weren’t in the right places and so some extra drilling and fiddling was required to get the frame to fit the bike with ease and without stressing all the components to make it line up.

Hole alignment was not the best!

Another issue was with the spacers that fit either side of the seat, as supplied they were some 4mm to 6mm too long which meant if they were persuaded to fit the seat would no longer fit. This resulted in taking it apart again and cutting and refinishing the spacers to get the frame to fit such that the seat would also fit at the same time. This alone took most of one evening to achieve to ensure I didn’t cut too much off the spacers.

It’s clear that some of the fixings are off the shelf items and not specifically manufactured for the frame. Fortunately I’ve got a fairly well equipped workshop and this kind of thing is fairly easy to do but for someone who doesn’t have the same facilities this is going to be an issue.

It’s also interesting to note that the two spacers end up being different lengths to fit, something I need to remember the next time I want to take the seat off.

After much time was spent re-drilling holes and cutting down spacers I finally got the frame to mount with ease and without everything being stressed to line up. This means that should I have the need to remove the frame in the future it should come off easily and more importantly, go back on easily.

It’s a nice looking bit of kit and I hope it proves to be as good as it looks as it wasn’t cheap. Total cost including shipping and import taxes took the price to a whopping £291.25 UK Pounds.

I’ve now ordered the Lomo soft panniers to go onto the frame and so will put together some information about how they look, fit and feel once they arrive.