1988 Honda XR250R Service Manual

The 1988 Honda XR250R is a dual-sport motorcycle featuring a 249cc air-cooled four-stroke single-cylinder 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 operation of your motorcycle.

1. General Information 2. Specifications 3. Periodic Maintenance 4. Engine Service 5. Fuel System 6. Electrical System 7. Chassis & Suspension 8. Brake System 9. Troubleshooting 10. Wiring Diagrams

General Information

This manual provides technical information for the 1988 Honda XR250R. Includes identification numbers, safety precautions, and general maintenance guidelines.

Component	Location/Description
Frame Serial Number	Right side of steering head
Engine Serial Number	Left side of crankcase
Recommended Fuel	Unleaded gasoline, 86 octane or higher
Oil Capacity	1.5 liters with filter change
Spark Plug	NGK DR8ES-L or equivalent

Specifications

Engine Type: 249cc air-cooled 4-stroke OHC single
Bore x Stroke: 73.0 x 59.5mm
Compression Ratio: 9.3:1
Carburetor: Keihin PD28A
Ignition System: CDI
Transmission: 5-speed constant mesh
Front Suspension: Telescopic fork, 220mm travel
Rear Suspension: Pro-Link swingarm, 220mm travel
Front Brake: Single disc, 240mm
Rear Brake: Drum, 110mm
Fuel Capacity: 9.5 liters
Dry Weight: 112 kg

Periodic Maintenance

Regular maintenance schedule for optimal performance and longevity.

Daily/Pre-ride: Check fuel, oil level, tire pressure, chain tension, brake operation
Every 600 miles: Change engine oil, clean air filter, check valve clearance
Every 1200 miles: Replace spark plug, check carburetor adjustment
Every 2400 miles: Replace oil filter, check wheel bearings, service brakes
Every 4800 miles: Check steering head bearings, swingarm pivot, replace air filter

WARNING! Always perform maintenance with engine off and cool. Use proper tools and safety equipment.

Engine Service

Engine disassembly, inspection, and reassembly procedures.

Cylinder Head: Valve adjustment, camshaft service, cylinder head removal
Cylinder & Piston: Piston ring replacement, cylinder inspection
Crankcase: Crankshaft service, connecting rod inspection
Clutch: Clutch plate replacement, cable adjustment
Transmission: Gear inspection, shift mechanism service

Torque Specifications: Cylinder head bolts: 20-22 ft-lbs, Spark plug: 10-13 ft-lbs, Oil drain plug: 22-25 ft-lbs

Fuel System

Carburetor service and fuel system maintenance.

Carburetor Removal: Drain fuel, disconnect cables and hoses
Cleaning: Disassemble and clean all jets and passages
Adjustment: Float level: 12.5mm, Pilot screw: 1-3/4 turns out
Fuel Tank: Inspection and cleaning procedures
Fuel Filter: Replacement schedule and procedure

CAUTION! Work in well-ventilated area. No smoking or open flames near fuel.

Electrical System

Battery, charging system, ignition, and lighting maintenance.

Component	Specification
Battery	12V 5Ah
Charging Output	0.2kW at 5000 rpm
Headlight	12V 35/35W
Tail Light	12V 8W
Fuse	10A

Testing Procedures: Battery voltage, charging system output, spark intensity

Chassis & Suspension

Frame, wheels, tires, and suspension maintenance.

Front Fork: Oil change, seal replacement, spring inspection
Rear Shock: Preload adjustment, damping inspection
Wheels: Spoke tension, rim runout, bearing service
Tires: Pressure: Front 1.5 kg/cm², Rear 1.8 kg/cm²
Chain: Adjustment: 25-35mm free play, lubrication schedule

Brake System

Front disc brake and rear drum brake service.

Front Brake: Pad replacement, disc inspection, fluid change
Rear Brake: Shoe replacement, drum measurement, cable adjustment
Brake Fluid: DOT 4, change every 2 years
Bleeding: Procedure for removing air from hydraulic system

WARNING! Test brakes after service before riding. Replace worn components immediately.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, compression	Check fuel flow, spark plug, compression test
Poor performance	Clogged air filter, carb issues	Clean air filter, service carburetor
Electrical failure	Battery, fuse, wiring	Test battery, check fuses, inspect wiring
Brake problems	Pads, fluid, adjustment	Inspect pads, check fluid level, adjust cables
Transmission issues	Oil level, clutch, gears	Check oil, adjust clutch, inspect gears

Wiring Diagrams

Complete electrical schematics for the 1988 Honda XR250R. Includes color codes, connector locations, and circuit descriptions for all electrical components.

Key Circuits: Ignition system, charging system, lighting circuits, starting circuit

Troubleshooting Tips: Use multimeter for voltage and continuity tests. Check grounds for corrosion.