1986 XR250R Manual

The 1986 Honda XR250R is a versatile dual-sport motorcycle featuring a 249cc air-cooled four-stroke engine, 5-speed transmission, front and rear disc brakes, and durable off-road suspension. This manual covers essential information for maintenance, operation, troubleshooting, and specifications to ensure optimal performance and longevity of your motorcycle.

Features at a Glance

Key components: 249cc OHC engine, 5-speed transmission, front and rear disc brakes, Pro-Link rear suspension, and dual-purpose tires.

Feature	Description
Engine	249cc air-cooled four-stroke single cylinder
Transmission	5-speed constant mesh
Brakes	Front and rear hydraulic disc
Suspension	Telescopic front fork, Pro-Link rear suspension
Fuel Capacity	2.4 gallons (9.1 liters)
Seat Height	34.6 inches (880mm)
Dry Weight	247 lbs (112 kg)
Ignition	CDI electronic ignition
Starting System	Kick start
Tires	Front 3.00-21, Rear 4.60-18

Installation & Assembly

Unpack and inspect all components. Ensure proper assembly before operation.

1. Handlebar installation: Align and tighten clamp bolts to specification.
2. Front wheel assembly: Install wheel with proper axle alignment and torque.
3. Controls connection: Attach throttle, clutch, and brake cables with proper adjustment.
4. Fuel system: Connect fuel lines and check for leaks.
5. Battery installation: Connect positive terminal first, then negative.

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

First-Time Setup

Complete pre-ride inspection and adjustments before initial operation.

1. Fluid levels: Check engine oil, brake fluid, and coolant levels.
2. Tire pressure: Inflate to recommended pressures (15-18 psi off-road, 22-25 psi street).
3. Chain adjustment: Set proper chain slack (1.2-1.6 inches).
4. Control adjustments: Set lever positions and free play.
5. Break-in procedure: Follow recommended break-in schedule for first 500 miles.

CAUTION! Always wear proper protective gear. Complete all safety checks before riding.

Specifications

• Engine Type: 249cc air-cooled four-stroke single cylinder OHC
• Bore x Stroke: 73.0 x 59.5mm
• Compression Ratio: 10.0:1
• Carburetion: 30mm Keihin constant velocity
• Ignition: CDI electronic
• Transmission: 5-speed constant mesh
• Final Drive: #520 chain
• Suspension Travel: Front 9.8 inches, Rear 9.4 inches
• Brakes: Hydraulic disc front and rear
• Fuel Capacity: 2.4 gallons (9.1 liters)

Controls and Operation

Familiarize yourself with all controls before riding.

Right Handlebar: Throttle control, front brake lever, engine stop switch, start button.

Left Handlebar: Clutch lever, lighting controls, horn button, turn signals.

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

Starting Procedure: Turn fuel valve ON, set choke for cold starts, shift to neutral, kick start with proper technique.

Maintenance Procedures

Regular maintenance is essential for safety and performance.

1. Pre-ride inspection: Check tires, controls, lights, oil level, and chain.
2. Oil change: Every 600 miles or 6 months with recommended 10W-40 motorcycle oil.
3. Air filter: Clean every 300 miles, replace as needed.
4. Chain maintenance: Clean and lubricate every 200 miles.
5. Brake service: Check pad wear and fluid level monthly.
6. Valve adjustment: Check every 1500 miles.

Tip: Keep detailed maintenance records for reference.

Engine Care

Proper engine maintenance ensures longevity and reliability.

1. Oil changes: Use only recommended motorcycle-specific oil.
2. Cooling system: Keep fins clean for proper air cooling.
3. Carburetor: Regular cleaning and adjustment for optimal performance.
4. Spark plug: Replace every 3000 miles or as needed.
5. Compression check: Perform if experiencing power loss.
6. Timing chain: Check tension during valve adjustments.

WARNING! Engine components become extremely hot during operation. Allow proper cooling before maintenance.

Safety Features

Key safety systems: Front and rear disc brakes, proper lighting, secure footpegs, and durable frame design.

Care & Cleaning

Clean after each ride to prevent corrosion and maintain appearance.

Use mild soap and water for general cleaning. Avoid high-pressure sprays near bearings and seals. Lubricate chain after cleaning. Wax painted surfaces for protection.

CAUTION! Do not use harsh chemicals that may damage finishes. Avoid direct water spray on electrical components.

Regulatory Information

Meets DOT and EPA standards for street legal operation. Designed for both on-road and off-road use. Always comply with local traffic laws and regulations. For technical support, contact authorized Honda dealerships or visit www.honda.com.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Hard starting	Fuel, spark, compression	Check fuel flow, spark plug, compression; adjust choke/carburetor
Poor performance	Air filter, carburetion	Clean air filter; check jetting; adjust fuel mixture
Chain noise	Worn or loose chain	Adjust chain tension; lubricate; replace if worn
Brake issues	Fluid, pads, contamination	Check fluid level; inspect pads; clean rotors
Electrical problems	Battery, connections	Test battery; check all electrical connections

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

Service: Contact authorized Honda service centers for major repairs.