The 1986 Honda XR250R is a 249cc air-cooled four-stroke dual-sport motorcycle featuring a 5-speed transmission, front and rear drum brakes, 23-inch front/18-inch rear wheels, and a dry weight of 256 lbs. This manual covers maintenance procedures, specifications, troubleshooting, and repair instructions for engine, transmission, chassis, electrical systems, and routine service intervals. Below are key sections for specifications, maintenance, troubleshooting, and repair procedures.
Key specifications for the 1986 Honda XR250R dual-sport motorcycle.
| Specification | Description |
|---|---|
| Engine Type | 249cc air-cooled 4-stroke single cylinder |
| Bore x Stroke | 73.0mm x 59.5mm |
| Compression Ratio | 10.0:1 |
| Carburetor | 26mm Keihin PD |
| Ignition | CDI electronic ignition |
| Transmission | 5-speed constant mesh |
| Final Drive | #520 chain |
| Front Suspension | 35mm leading-axle fork, 9.8 inches travel |
| Rear Suspension | Pro-Link single shock, 9.1 inches travel |
| Front Brake | Single leading shoe drum, 110mm |
| Rear Brake | Single leading shoe drum, 110mm |
| Fuel Capacity | 2.4 gallons (9.1 liters) |
| Dry Weight | 256 lbs (116 kg) |
Recommended service intervals for optimal performance and longevity.
WARNING! Always use genuine Honda parts and recommended lubricants for optimal performance.
Procedures for engine maintenance, valve adjustment, and top-end service.
CAUTION! Engine must be cold for valve adjustment. Use proper torque specifications.
Front fork oil capacity: 14.5 oz (430ml) per leg, SAE 10W
Fork Service: Disassemble, inspect bushings, replace seals if leaking
Rear Shock: Check for oil leaks, test damping performance
Wheel Bearings: Inspect for smooth rotation, replace if rough or noisy
Steering Head: Adjust bearing preload, check for notchiness
Frame Inspection: Check for cracks, especially around stress points
Battery: 12V 4Ah, Charging system: AC magneto
Tip: Use dielectric grease on electrical connections to prevent corrosion.
Keihin PD carburetor specifications and adjustment procedures.
WARNING! Use fresh fuel and stabilize if storing more than 30 days.
Drum brake service and adjustment procedures.
Front Brake: Adjust cable for proper lever feel, inspect shoes for wear
Rear Brake: Adjust pedal height and free play, check linkage for binding
Brake Shoes: Replace if lining thickness less than 0.08 in (2mm)
Critical lubrication points and recommended lubricants.
| Component | Torque Value |
|---|---|
| Cylinder Head Nuts | 20 ft-lb (27 Nm) |
| Spark Plug | 13 ft-lb (18 Nm) |
| Engine Oil Drain Bolt | 22 ft-lb (30 Nm) |
| Front Axle Nut | 47 ft-lb (64 Nm) |
| Rear Axle Nut | 65 ft-lb (88 Nm) |
| Sprocket Nuts | 22 ft-lb (30 Nm) |
| Fork Clamp Bolts | 16 ft-lb (22 Nm) |
| Handlebar Clamp | 16 ft-lb (22 Nm) |
| Symptom | Possible Cause | Corrective Action |
|---|---|---|
| Hard starting | Fouled spark plug, incorrect valve clearance | Replace spark plug, adjust valves to spec |
| Poor idle | Clogged pilot jet, air leak | Clean carburetor, check intake manifold |
| Loss of power | Clogged air filter, worn piston rings | Clean/replace air filter, perform compression test |
| Oil consumption | Worn valve guides, piston rings | Inspect cylinder, replace rings/valve seals |
| Transmission noise | Worn gears, low oil level | Check oil level, inspect transmission components |
| Electrical failure | Bad connections, failed stator | Check wiring, test stator output |
| Brake fade | Contaminated shoes, worn components | Replace brake shoes, clean drums |
| Handling issues | Worn bearings, improper tire pressure | Check steering head/wheel bearings, adjust pressure |
Service Note: Always refer to complete service manual for detailed procedures.
Honda Support: Contact authorized Honda dealer for technical assistance