1986 Honda XR250R Manual

The 1986 Honda XR250R is a 249cc four-stroke dual-sport motorcycle featuring air-cooled single-cylinder engine, 5-speed transmission, front disc brake, rear drum brake, dual-purpose tires, and electric start. This manual covers safety precautions, technical specifications, maintenance procedures, troubleshooting, and operational guidelines for proper use and maintenance of your XR250R.

Features at a Glance

Key components: 249cc air-cooled four-stroke engine, 5-speed transmission, front disc brake, rear drum brake, dual-purpose tires, electric starter.

Feature	Description
Engine Type	249cc air-cooled four-stroke single cylinder
Transmission	5-speed constant mesh
Starting System	Electric starter with kick starter backup
Front Brake	Hydraulic disc brake
Rear Brake	Mechanical drum brake
Fuel Capacity	2.4 gallons (9.1 liters)
Seat Height	34.6 inches (880mm)
Dry Weight	249 lbs (113 kg)
Tire Size Front	3.00-21
Tire Size Rear	4.60-18

Installation & Assembly

Unpack and inspect contents. Assemble components as required.

1. Handlebar installation: Mount handlebars to triple clamp, tighten bolts to specification.
2. Front wheel installation: Install wheel between fork legs, align axle, torque to 65 Nm.
3. Battery connection: Connect positive terminal first, then negative terminal.
4. Fuel system: Add fresh unleaded gasoline, check for leaks.

WARNING! Motorcycle is heavy; use proper lifting techniques. Ensure all fasteners are properly torqued.

First-Time Setup

Complete pre-ride inspection and setup procedures.

1. Fluid levels: Check engine oil, brake fluid, coolant levels.
2. Tire pressure: Inflate to recommended pressures (15 psi front, 18 psi rear).
3. Chain adjustment: Adjust drive chain to 1.2-1.6 inches (30-40mm) free play.
4. Control operation: Verify throttle, clutch, brake operation before riding.

CAUTION! Always wear proper protective gear. Never operate without proper training.

Specifications

• Engine: 249cc air-cooled four-stroke SOHC
• Bore x Stroke: 73.0 x 59.5mm
• Compression Ratio: 10.0:1
• Carburetor: 30mm Keihin constant velocity
• Ignition: CDI electronic ignition
• Transmission: 5-speed, wet multi-plate clutch
• Final Drive: #520 chain
• Suspension Front: Telescopic fork, 9.8 inches travel
• Suspension Rear: Pro-Link single shock, 9.4 inches travel
• Fuel Type: Unleaded gasoline, 86 octane or higher

Controls and Operation

Familiarize yourself with all controls before operation.

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

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

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 (right).

Maintenance Procedures

Regular maintenance ensures optimal performance and longevity.

1. Engine oil change: Every 600 miles or 6 months
2. Oil filter replacement: Every other oil change
3. Air filter cleaning: Every 300 miles in dusty conditions
4. Chain lubrication: Every 200 miles
5. Brake inspection: Check pads and fluid monthly
6. Tire inspection: Check pressure and condition before each ride

Tip: Keep detailed maintenance records for service intervals.

Engine Service

Basic engine maintenance procedures.

1. Valve clearance: Check every 1500 miles, adjust to 0.002-0.003 inches
2. Spark plug: Replace every 6000 miles, gap to 0.024-0.028 inches
3. Carburetor adjustment: Adjust idle speed to 1400 ± 100 rpm
4. Compression test: Should read 150-170 psi
5. Timing chain: Check tension every 3000 miles

WARNING! Engine components get extremely hot. Allow to cool before servicing.

Electrical System

12-volt DC electrical system with battery and charging system.

Component	Specification
Battery	12V 5Ah
Charging System	AC generator
Headlight	12V 35/35W
Tail Light	12V 5/21W
Fuse	15A main fuse

Care & Cleaning

Proper cleaning maintains appearance and prevents corrosion.

1. Wash with mild soap and water, avoid high-pressure sprays
2. Dry thoroughly with soft cloth
3. Apply protectant to plastic and rubber components
4. Lubricate control cables and pivot points
5. Wax painted surfaces to protect finish

CAUTION! Avoid spraying water directly at electrical components, bearings, or air intake.

Regulatory Information

Manufactured to meet applicable DOT and EPA standards. This vehicle conforms to all applicable federal motor vehicle safety standards in effect at time of manufacture. Honda and the Honda wings emblem are registered trademarks of Honda Motor Co., Ltd. For technical support, contact authorized Honda dealership or Honda Customer Relations at 1-866-784-1870.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, compression	Check fuel level, spark plug, compression; verify kill switch position
Poor performance	Air filter, carburetor	Clean air filter; check carburetor jets; verify proper fuel flow
Electrical failure	Battery, connections	Check battery voltage; clean connections; verify fuse condition
Brake issues	Pads, fluid, adjustment	Inspect brake pads; check fluid level; adjust brake lever/pedal
Chain problems	Tension, lubrication	Adjust chain tension; clean and lubricate; check sprocket wear

Service: Contact authorized Honda dealer for complex repairs.

Parts: Use only genuine Honda parts for optimal performance.