1986 Honda XL 250 Owners Manual

The 1986 Honda XL 250 is a versatile dual-sport motorcycle featuring a 249cc air-cooled four-stroke single-cylinder engine, 5-speed transmission, front and rear drum brakes, and dual-purpose tires. This manual covers essential information for safe operation, maintenance, specifications, and troubleshooting of your XL 250 motorcycle.

1. Features at a Glance 2. Safety Information 3. Controls and Instruments 4. Specifications 5. Operation Instructions 6. Maintenance Schedule 7. Basic Maintenance Procedures 8. Troubleshooting 9. Storage Guidelines 10. Warranty Information

Features at a Glance

Key components: 249cc OHC engine, dual-purpose design, electric start with kick starter backup, full instrumentation, and rugged construction for on/off-road use.

Feature	Description
Engine Type	249cc air-cooled four-stroke single-cylinder
Transmission	5-speed constant mesh
Starting System	Electric with kick starter backup
Brakes	Front and rear drum brakes
Suspension	Telescopic front fork, dual rear shocks
Fuel Capacity	2.4 gallons (9.1 liters)
Seat Height	33.5 inches (850mm)
Weight	264 lbs (120kg) dry
Tires	Front 3.00-21, Rear 4.60-18

Safety Information

Always wear proper protective gear and follow safe riding practices.

Always wear DOT-approved helmet, eye protection, gloves, and protective clothing.
Never operate under the influence of alcohol or drugs.
Follow all traffic laws and regulations.
Perform pre-ride inspection before each use.
Ride within your skill limits and road conditions.

WARNING! Motorcycles are inherently dangerous. Always ride defensively and assume other drivers may not see you.

Controls and Instruments

Familiarize yourself with all controls before riding.

Control	Function
Right Handlebar	Throttle control, front brake lever, engine stop switch
Left Handlebar	Clutch lever, light switch, turn signals, horn
Instrument Panel	Speedometer, odometer, trip meter, neutral indicator
Foot Controls	Gear shift lever (left), rear brake pedal (right)
Key Switch	Ignition and steering lock

Specifications

Engine: 249cc OHC four-stroke single
Bore x Stroke: 74.0 x 58.0mm
Compression Ratio: 9.3:1
Carburetor: 30mm Keihin
Ignition: CDI electronic
Transmission: 5-speed, wet multi-plate clutch
Final Drive: #520 chain
Frame: Semi-double cradle steel
Ground Clearance: 9.8 inches (250mm)
Fuel: Unleaded gasoline, 86 octane or higher

Operation Instructions

Starting and riding procedures for your XL 250.

Pre-ride inspection: Check tires, controls, lights, oil level, and fuel.
Starting: Turn fuel valve ON, pull choke (cold engine), turn key ON, press start button or use kick starter.
Warm-up: Allow engine to warm for 1-2 minutes before riding.
Shifting: Use clutch lever to shift gears smoothly.
Braking: Use both front and rear brakes together for maximum stopping power.

CAUTION! Always use both brakes for stopping. Avoid locking either wheel.

Maintenance Schedule

Regular maintenance ensures long life and reliable performance.

Item	Every 600 mi	Every 2400 mi	Every 4800 mi
Engine Oil	Change	Change	Change
Oil Filter	-	Replace	Replace
Air Filter	Clean	Clean	Replace
Spark Plug	Check	Replace	Replace
Chain	Adjust/Lube	Adjust/Lube	Adjust/Lube
Brakes	Check	Check	Inspect pads

Basic Maintenance Procedures

Essential maintenance tasks you can perform yourself.

Oil Change: Warm engine, drain oil, replace filter, refill with 1.7 quarts SAE 10W-40.
Air Filter: Remove side cover, clean foam element in solvent, re-oil and reinstall.
Chain Adjustment: Maintain 1-1.5 inches of free play at center of bottom run.
Tire Pressure: Check cold - Front 21 psi, Rear 28 psi (adjust for load/conditions).
Spark Plug: Clean and gap to 0.024-0.028 inches, replace if worn.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	No fuel, weak battery, fouled plug	Check fuel valve, charge battery, clean/replace spark plug
Poor performance	Dirty air filter, clogged carburetor	Clean air filter, inspect carburetor jets
Hard shifting	Low oil, worn clutch	Check oil level, adjust clutch cable
Electrical issues	Blown fuse, loose connection	Check 10A main fuse, inspect wiring
Brakes weak	Worn pads, contaminated	Inspect brake pads, clean with brake cleaner

Storage Guidelines

Proper storage prevents damage during extended non-use.

Add fuel stabilizer and run engine for 5 minutes.
Change oil and filter.
Remove spark plug and add teaspoon of oil to cylinder.
Clean entire motorcycle thoroughly.
Inflate tires to maximum pressure and elevate off ground.
Store in dry, covered location with battery disconnected.

CAUTION! Never store with fuel in carburetor without stabilizer.

Warranty Information

1986 Honda XL 250 comes with limited warranty coverage. Contact authorized Honda dealer for warranty claims. Keep maintenance records for warranty validation. For dealer locations and service, contact American Honda Motor Co., Inc.