1991-1996 XR250L Service & Repair Manual

L-~ -- - -~~ 91·96 XR250L •

Important Safety Notice Indicates a stlOng possibi li ty of severe personal injury Of death if instructions are no t followed . CAUTION : Indicates a possibility of equ i pment damage if instructions 8re not followed . NOTE Gives helpful information . Detailed descriptIons of standard workshop procedures. safety principles and saNiee operations are not included. It is important to note that this manual contains some warnings and cautions against some specific service methods which could cause PEASONAllNJURY to service personnel or could damage a vehicle or re nder it unsafe Please understand that those warnings could not cover all conceivable ways In which service, whether or not recommended by Honda, might be done or of the possibly hazardous consequences of each conceivable way , nor could Honda investigate aU such ways . Anyone using service procedures or tools, whether or not recommended by Honda, must slJtlsly himself thoroughly that neither personal safety no r vehicle safety will be jeopardized by the service methods or tools selected .

Introduction This service manual describes the service procedures of the XR250L. This Model Specific Manual includes every service procedure that is of a specific nature to this particular model. Basic service procedures that are common to other Honda Motorcycle/Motor Scooter/ATVs are covered in the Common Service Manual. This Model Specific Service Manual should be used together With the Common Service Ma nual in order to provide comp lete service information on all aspects of this motorcycle. Follow the Maintenance Schedule (Section 3) recommendations to ensure that the vehicle is in peak operating condition and the emisson levels are Within the standards set by the U.S. Environmental Protection Agency and the California Air Resources Board. Perfo rming the first scheduled maintenance is very Important . It compensates for the initial wea r that occurs du ring the break-in period. Sections 1 and 3 apply to the whole motorcycle. Section 2 illustrates procedures for removal/ installation of components that may be required to perform service described in the following sections . Sections 4 through 16 describe parts of the motorcycle, grouped according to location . Find the section you want on thiS page, then turn to the table of contents on the first page of the section . Most sections describe the service procedure through system illustration. Refer to the next page f or det ail on how to use t h iS manual. If you don "t know the source of the trouble , go to section 17 Tr ou b leshooti ng . o • .:: ~ ." o "tl o • ~ Contents General Information Frame / Body Panels/ Ex haust Sy stem Mainten a nce Lubrica tion Sy ste m Fuel System Engine Remova l/In stal l ation Cy lind er Head/ Cylinder / Pi ston c: Clutch / Kickstarter / Gearshift Linkage Jf ~===================================== Crankshaft / Transmi ss ion / Balan ce r Front Wheel / Suspension / Steering Rear Wheel / Suspension Brake System Charging System / Altern ator Ignition System Light s/ Meters / Switches Wiring Di agram Trouble s hooting Ind ex

How To Use This Manual Finding Informati on You Ne ed This manual is divided into sections which cove r each of the major components of the moto rcycle. To quickly find the section you are inte rested in, the fir st page of each section is marked with a black tab that lines up with one of the thumb index tabs before this page. The first page of each section lists the table of contents within the section. Read the service information and troubleshooting related to the section before you begin working. An index of the entire book is provided in the last chapter to directly locate the info rmat ion you need. Explanation M ethod Of This Manual The removal and installation of parts are for the most part illustrated by large and clear illustrations that should provide the reader with visual aid in understanding the major point for servicing. The system illustrations are augmented by caliouts whose numbers or letters indicate the order in which the parts should be removed or installed. The sequence of steps represented numerically are differentiated from the ones represented alphabetically to notify the reader that they must perform these steps seperately . For example. if the steps prior and up to camshaft removal are performed with the engine installed, but the subsequent steps like cylinder head removal require engine removal, the callouts are grouped in numerical and alphabetical order . The illustrations may contain symbols to indicate necessary service procedures and percautions that need to be taken . Refer to the next page for the meaning of each symbol. Also in the illustration is a chart that lists information such as the order in which the part is removed/installed, the name of the part, and some extra notes that may be needed. Step by step instructions are provided to supplement the illustrations when detailed explanation of the procedure is necessary or illustrations alone would not suffice. Service procedures required before or after the procedure described on that particular page, or inspection / adjustment procedures required following the installation of parts, are described under the title Requisite Service. Standard workshop procedures and knowledge covered in the Common Service Manual are abbreviated in this manual. Symbol , System illustration 1\~~~~V~~TAlUOON -- I 1\ ' ~, \ f:'A ... -~~ Step . " ~ ~ . '.' "- / sequence ~J.j' ~ 't" "'" (numerals /' ,C . r\ ,. .~-'_~" 0' "Ph'bm'r;;_ , __ ____ " ~ ~=~:~ ::::' .... -":'- ., ::=~,,:,~._._ -_. '~ ~::: :::: =- ,- " - . . , '-- -< -- ; :=::::.- -_ .. - ::~=":.!:.. - / / e-, ----" --------.- ____ M_'·M __ ~"_ .. _ --...~. -.--~----~-'- _",_A_ --.----.--- .. _--- -- -,---~- ,- - -. --~-- .. - -- .... .... -".~ --.- " .~ .. , ~- , ... Part name Number of parts Extra notes or precautions related to the service procedure Detailed description of the procedure c~ .... ",c ......... " ,. e,

Symbols The symbols used throughout th is manual show specific service procedures. If supplementary information is required pertain- ing to these symbols , it would be explained specifically in the text without the use of the symbols . .. " - Replace the part (s) with new one(s) before assembly. ( ~ -;- 00\. ) Use special tool {o.'"7 "", I Use optional tool. These tools are obta ined as you order parts . e Torque specification. 10 N·m ( 1.0 kg -m, 7.2 ft-Ibl 10 ( 1.0, 7.2 1 'I Use recommended engine oil, unless otherwise specified . ~ Use molybdenum oil solution (mixture of the engine oil and molybdenum grease with the ratio 1 11. -~ Use mult i- purpose grease i Lithium based mu lti -purpose grease NLGI #2 or equivalent ) Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide , NLGI #2 or .... equivalent~ Example: Molykote '!. BR -2 plus manufactured by Dow Corning, U.S .A. Multi -purpose M-2 manufactured by Mitsubishi Oil Japan Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NlGI 112 or equivalent ~ ~ Example: Molykote f!. G-n Paste manufactured by Dow Corning, U.S.A. Honda Moly 45 (U.S.A. only ) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan ..-'iSitt Use sil icone grease o, m Apply a locking agent. Use the agent 01 the middle strength, unless otherwise specified. --- J '@ru Apply sealant I Use brake fluid. DOT 3 or DOT 4. Use the recommended brake fluid. unless otherwise specified .. Use Fork or Suspension Fluid .

General Safety 1-1 Model Identification 1-3 Specifications 1 -4 Torque Values 1- 14 Tools 1-16 General Safety Carbon Monoxide If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an enclosed area . The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness and may lead to death . Run the engine in an open area or with an exhaust evacuation system in an enclosed area. Gasoline Work in a well ventilated area. Keep cigarettes. flames or sparks away from the wo rk area or where gasoline is stored. Gasoline is extremely flammabl e and is explosive under centain conditions. KEEP OUT OF REACH OF CHILDREN. Hot Components exhust system parts very hot remain hot for some time after the engine is run. Wear insulated gloves or wait until the engine and exhaust system have cooled before handling these 1. General Information Lubrication & Seal Points 1-18 Cable & Harness Routing 1 -20 Emission Control System 1- 28 Emission Control Information Labels (U .S.A. Only) 1-30 Used Engine/ Transmission Oil Used engine oil (or transmission oil in two-strokes) may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unl ess you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil . KEEP OUT OF REACH OF CHILDREN. Brake Dust Never use an air hose or dry brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate method approved by OSHA, designed to minimize the hazard caused by airborne asbestos fibers. disease and cancer. Brake Fluid CAUTION Spilling fluid on painted , plastic or rubber parts will damaga them . Place a clean shop towel over these parts whenever the system is serviced. KEEP OUT OF REACH OF CHILDREN. 1-1 II

General Information Coolant Under some conditions, the eth ylene glycol in engine coolant is combustible and its flame is not visible . If the ethylene glycol does ignite, you will not see any flame. but you can be burned. Avoid engine coolant on the exhaust system or i parts . They may be hot enough to cause th e coolant to ignite and burn without a visible flame . Cool ant (etheylene gl ycol) can cause some skin irritation and is poisonous if swa llowed. KEEP OUT OF REACH OF CHILDREN . Do not remove the radiator cap when the engine is hot. The coolant is under pressure and could scald you. Keep hands and clothing away from the cooling fan , as it starts automaticall y. If it contacts your skin, wash th e affected areas immediately with soap and water. If it contacts your eyes, flash them thoroughly with fresh water and get immediate medical attention. If it is swallowed, the victim must be forced to vomit then rinse mou th and th roat with f resh water before obtaining medical attention. Because of these dangers, always store coolant in a safe place, away from the reach of children. 1-2 Nitrogen Pressure For shock absorbers with a gas-filled reservoir: Use only nitrogen to absorber. The use of an unstable gas can cause a fire or explosion resul ting in serious injuly . The shock absorber contains nitrogen under high pressure . Allowing fire or heat near the shock absorber could lead to an exp losion that could result in serious injuly . Failure to rel ease the pressure from a shock absorber before disposing of it may lead to a possible explosion and serious injury if it is heated 0' To prevent the possibility of an explosion, release the nitrogen by pressing the valve core. Then remove the valve stem from the shock absorbr reservoir. Dispose of the oil in a manner acceptable to the Environmental Protection Agency (EPA) . Be for e disposal of the shock absorber, release th e nitrogen by pressing the va lve core. Then remove the valve stem from the shock absorber. Battery Hydrogen Gas & Electrolyte Th e battery gives off exposive gases: keep spa rk s, flames and cigarettes away . Provide adequate ventilation when charging. The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns . Wear protective clothing and a face shield. - If e lectrolyte gets on your skin, flush with water. - If electrolyte gets in your eyes, flush with water for at lea st 15 minutes and call a physician . Electrolyte is poisonous . - If swallowed, drink large quantities of water or milk and follow w ith milk of magnesia or vegetable oil and call a physician . KEEP OUT OF REACH OF CH ILDREN .

Model Identification (2) The engine serial number is stamped on the lower leh of the crankcase. (4) The color label is attached as shown. When ordering color-coded parts. always specify the designated color code. General Information (1) The frame serial number is stamped on the right side the steering head . (3) The Vehicle Identification Number (VIN) is located on the Safety Certification Label on the left side of the down tube . (5) The carburetor identification number is stamped on the right side of the carburetor body. 1-3

General In fo rm ati on Specifications r General Item Speci fi ca ti ons Dimensions Overall length 2,160 mm (85.0 in) Overall width 860 mm (33. 9 in) Overall height 1,220 mm (48 .0 in) Wheel base 1, 430 mm (56.3 in) Seat height 885 mm (34 .8 in) Footpeg height 383 mm (15 . 1 in) Ground clearance 285 mm (11.2 in) Dry weight r9 1, ·92) 118 .0 kg (260.1 Ibs) (After ' 92) 122.6 kg (269 .7 Ibs) Curb weight (,91, '92) 132.0 kg (291 .0 Ibs) (After ·92) 131 .5 kg (289.3 Ibs) Maximum weight capacity -- Frame Frame type Semi-double cradle Front suspension Telescopic fork Front wheel travel 260 mm ( 10 ,23 in) Rear suspension Swingarm Rear wheel travel 260 mm (10,23 in) Rear damper Double effect type Front tire size 3.00-21-4PR Rear tire size 4.60-18-4PR Tire brand (Bridgestone) -- Tire brand (Dunlop) K360/K360 Tire brand (Yokohama) E -700A/ E -700A Tire brand (iRC) -- Front brake Hydraulic single disc Rear brake Hydraulic single disc Caster angle 26"06· Trail length 105 .2 mm (4.14 in) Fuel tank capacity 9.0 I (2.4 US gal, 2 .0 Imp gal) Fuel tank reserve capacity 1.5 I (0.4 US gal , 0 . 33 Imp gal) Engine Bore and stroke 73.0x59.5 mm (2.87x2.34 in) Displacement 249 cc (15 .2 cu-in) Compression ratio 9. 3: 1 Valve train Silent multi link chain drive and OHC with rocker arm Intake valve opens (at 1 mm lift) 10' 8TDC Intake valve closes (at 1 mm lift) 35 " ABDC Exhaust valve opens (at 1 mm lift) 40' BBDC Exhaust valve closes (at 1 mm lift) 10' ATDC Lubrication system Forced pressure and wet sump Oil pump type Trochoid Cooling system Air cooled Air filtration Oiled polyurethane form Crankshaft type Assembled type Engine weight 34 .6 kg (76.3 Ibsl Firing order -- Cylinder arrangement Single cylinder inclined 1 5" from vertical Cylinder numbering -- 1-4

1991-1996 XR250L Service & Repair Manual

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