… It's a shame you can't bring your 250 Tornado back. Used them in Morocco - a brilliant bike. None of the above bikes will match that as an all-rounder in the real world of the 'Adventure Zone'.
Tyres would make a big difference but unless it was really cheap, a stock GS500 would not offer much on a trans-Af over a similarly large-tanked YBR250 at some 40kg? less weight. Just might cost 50% more.
Did I mention shims? Oh, someone else did but hard to believe 4k intervals. The whole point of fiddly shims is they greatly outlast tappet intervals, no?

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Morocco Overland 4 (2025) • Trans Morocco Trail

Hmm, thanks Chris. Food for thought. I often wished I could bring this XR250 back home as it really is a solid little tourer for off-road stuff and trails, with it's only weakness really being carb work for altitude and low capacity stock tank.

Do you mean you had to rejet for high alts?
That's the great thing with efi, especially in South Am.
At what height would a Tornado begin to struggle?
Got any pix or reports of XR in South Am? Just writing about them now.
As for tank - you're lucky its not a CRF-L

Hi Chris,

I wrote an account of the trip and obviously took me some photos and thinking about posting report, probably when I get back to UK and boot up my MAC, as would like to process my pictures, etc.

Briefly, the Tornado (made in Brazil) has been fantastic, and very sturdy too. The only problem being the alt, you could feel it from above 2,000m and if you were two-up or with luggage more so. On stock jet (132), above 3,000m wasn't much fun at all and you'd really be struggling up hills, basically going no more than 40kph and sneezing all the way up (I describe it as so, in other words engine cuts out a moment and cuts back in, presumably from being flooded with too much gas without sufficient air to burn it?). At Potosi in Bolivia (over 4,000m) literally couldn't get up half the steep stone hills without run up, so that forced me to finally rejet (which I wish I did much earlier).

Running a 125 was much better, and quite happily cruised around Peru and Bolivia with luggage and could maintain speeds of 80kps without pinning it up hill, even 100kph really, yet when I returned to Chile and did some of the high alt national parks, even with the 125 I was getting issues and not running as nice as in Bol/Peru, no idea why this would have been but probably because air filter was not brand new (but clean, still makes a big difference) and the only thing different was I was using high-octane fuel - does higher octane fuel need more air to burn or something) I've never understood the difference between octane fuels...

I just put it all down to the bike being fussy at alitude, next time I'd jet down to 120 for 4k, and use the 125 for anything between 2,5k and 4k. Stock was fine below that. Other issues I had is the XR is hard to start sometimes, cold mornings, etc, especially at altitude but always gets going with some encouragement. The glaring error (imo) Honda made with this bike was not putting a kick on her, that's really ruined some of my mornings and is in fact why I am here typing this and not driving down to Patagonia (don't want to leave town without new battery as current one doesn't have enough charge to safely start on cold mornings and without kick this causes issues!).

The bike is hard to work on as well and compared to the DR200 for example, which looks like it was designed by zen monks by comparison, getting to the carb and stuff is very fiddly, annoying given the need to change jets. You need to have the top off to check the valves but thankfully the bike being pretty solid you don't need to do much to it often. But well that's me bitching, the good side is as said very reliable, very solid - takes falls and offs well, lightweight and fun to ride, bit edgy on highways loaded up but doable, can just buy stock, load up and ride off. Overall, if you know how to get the most from the little 250 engine, definitely a solid bike for touring S.america - if it had a kick and EFI would be perfect for my ends! Would rather have the little Tornado over a clapped out KLR any day. I especially love it as it has that "go anywhere" lightness to it, so I can really get off-road to find a nice, quiet wildcamp. Never let me down and only issues I had realy were my own fault! Hope that helps.

There aint nowhere you can't go on a 250

I've had a fair few and always been happy riding proper mixed terrain.

My Honda XR250L was very similar to the tornado.

As for no kick and charging, what about a cheap solar charger that you just leave on when your not riding, I havnt one myself but a mate says his is simply brilliant.

Currently loving my CL400 its just like a 250 only with a tad more oomph, sometimes on cold mornings I wish it had a leccy starter

The reason why it would be hard to start at altitude could be if you only changed the main jet. That'll make no difference at all to idle mixture. You need to change the slow jet. But that's another fiddly annoying thing to be playing at.

Dropping your needle helps as well, but short term 'fixes' include taking the cover off your airbox if it has one, running with no air filter, and trying to partially close your fuel tap so the float bowl can't stay full.

Looks like a handy little bike. Are the clutch cover and internals compatible with any of the older xr models? If they are you might be able install the kickerstarter. (you can do that on the xr650l and dommie for example)

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UK to Mongolia 2009, on a DR350