1986 Honda XL 250R Owners Manual

The 1986 Honda XL 250R is a versatile dual-sport motorcycle featuring a 249cc air-cooled four-stroke single-cylinder engine, 5-speed transmission, front disc brake, rear drum brake, electric start with kick starter backup, and dual-purpose tires. This manual covers safety information, features, maintenance procedures, specifications, operation guidelines, and troubleshooting for proper ownership and operation of your XL 250R.

1. Features at a Glance 2. Safety Information 3. Controls and Instruments 4. Specifications 5. Operation Guidelines 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 system, comprehensive instrumentation.

Feature	Description
Engine Type	249cc air-cooled four-stroke single-cylinder
Starting System	Electric start with kick starter backup
Transmission	5-speed constant mesh
Brakes	Front disc, rear drum
Suspension	Telescopic front fork, dual shock rear
Fuel Capacity	2.4 gallons (9.1 liters)
Seat Height	33.5 inches (850mm)
Dry Weight	264 lbs (120kg)
Tires	Dual-purpose 3.00-21 front, 4.60-17 rear
Lighting	Full street-legal lighting package

Safety Information

Always wear proper protective equipment 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.
Perform pre-ride inspection of tires, brakes, lights, and controls.
Observe all traffic laws and ride defensively.

WARNING! Motorcycle operation involves risk. Always ride within your skill limits and be aware of road conditions.

Controls and Instruments

Familiarize yourself with all controls before riding.

Left Handlebar: Clutch lever, horn button, turn signal switch, high/low beam switch.

Right Handlebar: Front brake lever, engine stop switch, electric start button, throttle.

Instrument Panel: Speedometer, odometer, trip meter, neutral indicator, high beam indicator, turn signal indicators.

Foot Controls: Gear shift lever (left), rear brake pedal (right), kick starter.

Specifications

Engine: 249cc air-cooled 4-stroke OHC single cylinder
Bore x Stroke: 73.0 x 59.5mm
Compression Ratio: 9.3:1
Carburetor: 30mm Keihin constant velocity
Ignition: CDI electronic ignition
Transmission: 5-speed constant mesh
Final Drive: #520 chain
Fuel Capacity: 2.4 gal (9.1L)
Oil Capacity: 1.7 qt (1.6L) with filter change
Battery: 12V 8Ah

Operation Guidelines

Proper operation ensures longevity and reliability.

Starting: Turn fuel petcock to ON, ensure in neutral, pull choke for cold starts.
Warm-up: Allow engine to warm for 2-3 minutes before riding.
Shifting: Use clutch smoothly, shift at appropriate RPM ranges.
Braking: Use both brakes together, front brake provides 70% stopping power.
Break-in: Vary speeds during first 500 miles, avoid full throttle operation.

Tip: Always use both brakes for maximum stopping power.

Maintenance Schedule

Regular maintenance ensures optimal performance and safety.

Item	Every 600 mi	Every 2400 mi	Every 4800 mi
Engine Oil	Replace	Replace	Replace
Oil Filter	-	Replace	Replace
Air Filter	Clean	Replace	Replace
Spark Plug	Check	Replace	Replace
Valve Clearance	-	Adjust	Adjust
Chain Adjustment	Adjust	Adjust	Adjust
Brake Fluid	Inspect	Replace	Replace

Basic Maintenance Procedures

Essential maintenance tasks for proper motorcycle care.

Oil Change: Warm engine, drain oil, replace filter, refill with 10W-40 motorcycle oil.
Chain Adjustment: Maintain 1-1.5 inches of free play, lubricate regularly.
Air Filter: Clean foam element in solvent, re-oil with filter oil.
Tire Pressure: Check cold - 21 psi front, 25 psi rear (street use).
Valve Adjustment: Check when engine cold, intake: 0.002 in, exhaust: 0.003 in.
Brake Inspection: Check pad wear, fluid level, and lever/pedal operation.

WARNING! Always support motorcycle securely when performing maintenance.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Hard starting	Fouled plug, stale fuel	Replace spark plug, drain old fuel
Poor performance	Dirty air filter, clogged carb	Clean air filter, service carburetor
Battery not charging	Faulty regulator/rectifier	Test charging system, replace components
Chain noise	Loose or worn chain	Adjust tension or replace chain/sprockets
Brake fade	Contaminated pads, old fluid	Replace pads, flush brake fluid

Emergency: Carry basic tools and tire repair kit when riding.

Storage Guidelines

Proper storage prevents damage during periods of non-use.

Fuel System: Add fuel stabilizer, run engine to circulate, turn petcock OFF.
Battery: Remove and store on maintenance charger, or disconnect negative terminal.
Tires: Inflate to maximum pressure, support motorcycle off ground if possible.
Cleaning: Wash and wax motorcycle, apply protectant to rubber and plastic.
Cover: Store in dry location with breathable motorcycle cover.

CAUTION! Never store with fuel in carburetor float bowl.

Warranty Information

Limited warranty coverage for 12 months from date of purchase with no mileage limitation. Warranty covers defects in material and workmanship. Normal maintenance items, tires, and cosmetic deterioration are not covered. Keep purchase receipt and complete warranty registration. For warranty service, contact authorized Honda dealership. For technical support, contact American Honda Motor Co., Inc. at 1-866-784-1870.