1987 Honda XR250R Service Manual

The 1987 Honda XR250R is a 249cc air-cooled four-stroke dual-sport motorcycle featuring a single-cylinder OHC engine, 5-speed transmission, front disc brake, rear drum brake, and dual-purpose tires. This service manual covers maintenance procedures, specifications, troubleshooting, and repair instructions for proper upkeep and performance optimization.

1. Specifications 2. Maintenance Schedule 3. Engine Service 4. Transmission & Clutch 5. Fuel System 6. Electrical System 7. Brakes & Wheels 8. Suspension 9. Troubleshooting 10. Torque Specifications 11. Wiring Diagrams

Specifications

Technical specifications for the 1987 Honda XR250R motorcycle.

Component	Specification
Engine Type	Air-cooled 4-stroke OHC single cylinder
Displacement	249cc
Bore x Stroke	73.0 x 59.5mm
Compression Ratio	10.0:1
Carburetor	Keihin PD28A
Ignition System	CDI
Transmission	5-speed constant mesh
Final Drive	O-ring chain
Front Suspension	Telescopic fork
Rear Suspension	Pro-Link swingarm
Front Brake	Hydraulic disc
Rear Brake	Mechanical drum
Fuel Capacity	2.4 gallons (9.1 liters)
Dry Weight	247 lbs (112 kg)

Maintenance Schedule

Regular maintenance intervals for optimal performance and longevity.

After break-in (600 miles/1000 km): Change engine oil and filter, check valve clearance, inspect chain tension
Every 3000 miles/5000 km: Oil and filter change, air filter cleaning, spark plug inspection
Every 6000 miles/10000 km: Valve clearance adjustment, carburetor synchronization, brake fluid change
Monthly: Chain lubrication and adjustment, tire pressure check, brake inspection

WARNING! Always use genuine Honda parts and recommended lubricants. Wear protective gear during maintenance.

Engine Service

Engine maintenance and repair procedures.

Valve Clearance: Intake: 0.002 in (0.05 mm), Exhaust: 0.003 in (0.08 mm)
Oil Change: Use SAE 10W-40 motorcycle oil, capacity 1.7 quarts (1.6 liters)
Cylinder Head: Inspect for warpage, maximum allowable: 0.002 in (0.05 mm)
Piston & Rings: Standard piston diameter: 2.874 in (73.0 mm)
Camshaft: Check chain tensioner and cam lobes for wear

CAUTION! Engine must be cool before disassembly. Use proper torque specifications during reassembly.

Transmission & Clutch

Transmission Oil: SAE 10W-40, capacity 0.84 quarts (0.8 liters)
Clutch Type: Wet multi-plate
Clutch Adjustment: Free play at lever: 0.4-0.8 in (10-20 mm)
Shift Mechanism: Check shift forks and drum for wear
Chain Adjustment: 1.0-1.4 in (25-35 mm) free play

Fuel System

Carburetor specifications and maintenance.

Component	Setting
Main Jet	#122
Slow Jet	#38
Needle Position	3rd groove from top
Float Level	0.59 in (15.0 mm)
Idle Speed	1400 ± 100 rpm

Tip: Clean fuel filter and inspect fuel lines annually. Use fresh gasoline to prevent varnish buildup.

Electrical System

Electrical components and testing procedures.

Battery: 12V 5Ah, maintain fluid level, specific gravity: 1.260-1.280
Spark Plug: NGK DR8ES-L, gap: 0.024-0.028 in (0.6-0.7 mm)
Charging System: Output: 0.2 kW at 5000 rpm
Ignition Timing: Fixed at 15° BTDC at 1700 rpm
Bulbs: Headlight 35/35W, Brake/Tail 21/5W, Turn Signal 21W

Brakes & Wheels

Brake system maintenance and wheel service.

Front Brake: Disc diameter 8.7 in (220 mm), pad thickness min: 0.08 in (2.0 mm)
Rear Brake: Drum diameter 5.1 in (130 mm), shoe thickness min: 0.08 in (2.0 mm)
Brake Fluid: DOT 4, change every 2 years
Tire Pressure: Front 18 psi (1.25 kg/cm²), Rear 22 psi (1.55 kg/cm²)
Wheel Bearings: Inspect for play and smooth rotation

WARNING! Test brakes after service. Never reuse brake fluid.

Suspension

Suspension adjustment and service.

Front Fork: Oil capacity 14.8 oz (435 ml) per leg, oil type SAE 10W
Rear Shock: Spring preload 5-position adjustable
Swingarm: Check pivot bearings for wear and proper lubrication
Fork Alignment: Ensure proper alignment after disassembly

Troubleshooting

Symptom	Possible Cause	Corrective Action
Hard starting	Clogged carb, weak spark	Clean carburetor, check spark plug and ignition
Poor performance	Dirty air filter, incorrect jetting	Clean/replace air filter, verify carb settings
Oil consumption	Worn rings, valve seals	Compression test, inspect cylinder and valves
Transmission noise	Worn gears, low oil	Check oil level, inspect transmission components
Brake fade	Contaminated pads, air in system	Replace pads, bleed brake system

Torque Specifications

Critical fastener torque values.

Component	Torque
Cylinder Head Nuts	20 ft-lb (27 Nm)
Spark Plug	13 ft-lb (18 Nm)
Oil Drain Bolt	22 ft-lb (30 Nm)
Axle Nuts	65 ft-lb (88 Nm)
Sprocket Nuts	25 ft-lb (34 Nm)

Wiring Diagrams

Complete electrical schematics available in official Honda service manual. Key circuits include ignition, charging, lighting, and starting systems. Color codes: R=Red, B=Black, W=White, G=Green, Y=Yellow, Br=Brown, Lg=Light Green.

Service Note: For complex electrical issues, consult professional technician with proper diagnostic equipment.