1986 XL250R Manual

The 1986 Honda XL250R is a dual-sport motorcycle featuring a 249cc four-stroke 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 care of your XL250R.

Features at a Glance

Key components: 249cc OHC four-stroke engine, 5-speed constant mesh transmission, front hydraulic disc brake, rear mechanical drum brake, electric starter with backup kick starter.

Feature	Description
Engine Type	249cc air-cooled four-stroke single cylinder
Bore x Stroke	74.0mm x 58.0mm
Compression Ratio	9.3:1
Carburetor	Keihin PD61A
Ignition System	CDI electronic ignition
Transmission	5-speed constant mesh
Final Drive	#520 chain
Front Suspension	Telescopic fork
Rear Suspension	Swingarm with dual shocks
Fuel Capacity	2.4 gallons (9 liters)

Pre-Ride Inspection

Always perform these checks before operating your XL250R.

1. Check fuel level: Ensure adequate fuel for your journey.
2. Inspect tires: Check pressure and condition for wear/damage.
3. Test brakes: Verify proper front and rear brake operation.
4. Check controls: Ensure throttle, clutch, and brake levers work smoothly.
5. Verify lights: Test headlight, brake light, turn signals, and horn.
6. Check chain: Inspect for proper tension and lubrication.

WARNING! Failure to perform pre-ride inspection may result in accident or injury. Always wear proper protective gear.

Basic Operation

Starting and operating procedures for your XL250R.

1. Starting: Turn fuel valve ON, set choke for cold starts, turn ignition ON, use electric start or kick starter.
2. Shifting: Use clutch lever to shift gears smoothly through 5-speed pattern.
3. Braking: Apply both front and rear brakes progressively for controlled stops.
4. Turning: Use countersteering technique for smooth cornering.

CAUTION! Always operate motorcycle in well-ventilated areas to avoid carbon monoxide poisoning.

Technical Specifications

• Engine: 249cc OHC four-stroke single cylinder
• Power Output: 22 hp @ 8,500 rpm
• Torque: 18 Nm @ 7,000 rpm
• Fuel System: Keihin PD61A carburetor
• Ignition: CDI electronic
• Transmission: 5-speed constant mesh
• Front Brake: Single hydraulic disc
• Rear Brake: Mechanical drum
• Front Tire: 3.00-21
• Rear Tire: 4.60-18
• Seat Height: 34.6 inches (880mm)
• Dry Weight: 264 lbs (120 kg)

Controls and Instruments

Handlebar controls and instrument panel layout.

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

Left Handlebar: Clutch lever, turn signal switch, headlight dimmer switch, horn button.

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

Additional Controls: Fuel valve (ON/OFF/RESERVE), choke lever, kick starter, gear shift lever.

Routine Maintenance

Scheduled maintenance intervals and procedures.

1. Oil Change: Every 600 miles or 6 months - Use SAE 10W-40 motorcycle oil
2. Oil Filter: Replace every other oil change
3. Air Filter: Clean every 1,200 miles, replace as needed
4. Chain Adjustment: Check every 300 miles, adjust to 1.2-1.6 inches play
5. Spark Plug: Clean every 1,200 miles, replace every 7,500 miles
6. Brake Pads: Inspect every 600 miles, replace when worn to limit
7. Tire Pressure: Check weekly - Front: 21 psi, Rear: 25 psi

Tip: Always use genuine Honda parts for optimal performance and reliability.

Engine Service

Engine maintenance and adjustment procedures.

1. Valve Clearance: Check every 2,400 miles - Intake: 0.05mm, Exhaust: 0.08mm
2. Carburetor Adjustment: Idle speed: 1,300 ± 100 rpm
3. Cam Chain: Check tension every 3,000 miles
4. Compression Test: Should read 142-171 psi
5. Cooling System: Keep cooling fins clean and unobstructed

WARNING! Engine components become extremely hot during operation. Allow engine to cool before performing maintenance.

Electrical System

Battery, charging system, and electrical components.

Battery: 12V 8Ah - Keep terminals clean and tight, check electrolyte level monthly.

Charging System: Output 14V at 5,000 rpm

Fuses: Main fuse 15A, spare fuse included in fuse box

Bulbs: Headlight 35/35W, Brake/Tail 21/5W, Turn Signal 21W

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, compression	Check fuel valve, spark plug, compression; verify choke operation
Poor performance	Dirty air filter, carburetor	Clean/replace air filter; clean carburetor jets
Hard shifting	Chain tension, clutch	Adjust chain; check clutch cable free play
Electrical failure	Battery, fuses, connections	Check battery voltage; inspect fuses; clean connections
Brake issues	Pads, fluid, adjustment	Inspect pads; check brake fluid; adjust rear brake

Reset: Disconnect battery for 30 seconds to reset electrical system if needed.

Storage Guidelines

Proper storage procedures for extended periods of non-use.

1. Fuel System: Add fuel stabilizer and run engine for 5 minutes
2. Battery: Disconnect and store fully charged
3. Tires: Inflate to proper pressure and elevate off ground
4. Cleaning: Wash and dry thoroughly, apply protective coating
5. Cover: Use breathable motorcycle cover

CAUTION! Store in dry, well-ventilated area away from direct sunlight and moisture.

Warranty Information

Limited warranty coverage and service network information.

Standard limited warranty: 12 months from date of purchase with unlimited mileage. Coverage includes defects in materials and workmanship. Normal wear items, routine maintenance, and damage from accident or misuse not covered. For warranty service, contact authorized Honda dealer with proof of purchase.

For technical support and parts ordering, contact Honda Customer Service at 1-800-999-1009 or visit www.honda.com.