Page 2 HOW TO USE THIS MANUAL GENERAL INDEX This Manual Workshop describes the Features Techniques & the Procedures Service For the Honda XR250 (Saddle high/ Saddle low). To Ensure Perfect Conditions/Operation Vehicle, Follow the Recommendations the Table Maintenance (Section Performing the first scheduled maintenance is...
Page 3 XR250 Information General Symbols the symbols used in this manual indicate service procedures . The supplementary information concerning these symbols will be xplained specifically n the text, without the use of them. Replace the part(s) with a new one before mounting. Use the recommended engine oil, unless a different one is specified.
Page 5 1-15 Pass OF Cables TIGHTENING TORQUE Values SERVICE RULES 1. Use only genuine, HONDA spare parts, oils and lubricants recommended by HONDA or its equivalents. Spare parts that do not meet HONDA specifications may damage the motorcycle. 2. Use tools specially designed for this vehicle to prevent damage or incorrect assembly.
Page 6 XR250 Information General MODEL IDENTIFICATION CHASSIS Serial NUMBER ENGINE Serial NUMBER the serial number of the chassis is engraved on the right the engine serial number is engraved on the left side of side of the steering column. the engine housing. CARBURETOR IDENTIFICATION NUMBER the carburetor identification...
Page 7 XR250 Information General TECHNICAL SPECIFICATIONS General Item Specifications Dimensions Total length High saddle 2,147 mm Low saddle 2,130 mm Total width 845 mm Total height High saddle 1,198 mm Low saddle 1,161 mm Wheelbase High saddle 1,427 mm Low saddle 1,416 mm Height of the seat High saddle...
Page 8 XR250 Information General GENERAL (Continuation) Item Specifications Clutch system Clutch with multiple discs in oil bath Transmission Clutch operating system Mechanical Transmission 6 gears constantly geared Primary reduction 3,100 (62/20) Final reduction 2,846 (37/13) Transmission ratio 2,769 (36/13) 1,882 (32/17) 1,333 (28/21) 1,083 (26/24) 0.923 (24/26)
Page 9 XR250 Information General LUBRICATION SYSTEM Unit: mm Item Range Service Limit Engine oil capacity When draining 1.5 l — Changing the filter 1.5 l — By dismantling 1.8 l — Recommended engine oil MOBIL SUPERMOTO 4T — API Service Classification: SF Viscosity: SAE 20W-50 Oil pump Slack between internal and external...
Page 10 XR250 Information General CYLINDER HEAD/VALVE Unit: mm Item Range Service Limit Cylinder compression 1,128 kPa (11.5 kgf/cm — 163.6 psi) at 400 Cylinder roll — 0,10 Camshaft Lobe height 37.00 - 37.24 36,94 37.03 - 37.27 36,97 Eccentricity 0,02 0,10 24,959 - 24,980 —...
Page 11 XR250 Information General CYLINDER/PISTON Unit: mm Item Range Service Limit Cylinder 73,000 - 73,010 73,11 Ovalization — 0,05 Taper — 0,05 Roll — 0,05 Piston, bolt Piston steering mark "IN" mark facing side of — admission piston rings Piston DIA 72,950 - 72,970 72,87 —...
Page 12 XR250 Information General ALTERNATOR/STARTER CLUTCH Unit: mm Item Range Service Limit Start-up Run Gear Highlight DIA 45,660 - 45,673 45,63 TRANSMISSION Unit: mm Item Service Limit Range Transmission Gear DIA 20,000 - 20,021 20,08 23,000 - 23,021 23,07 23,000 - 23,021 23,07 25,020 - 25,041 25,09...
Page 13 XR250 Information General CRANKSHAFT/BALANCER Unit: mm Item Range Service Limit Connecting 0.05 - 0.50 Side clearance of crank head 0 - 0.008 0,05 adial crank head clearance Crankshaft eccentricity — 0,02 FRONT WHEEL/SUSPENSION/STEERING SYSTEM Unit: Unidad: mm Item Range Service Limit Minimum tire groove dedepth —...
Page 14 XR250 Information General HYDRAULIC BRAKE Unit: mm Item Range Service Limit Specified brake fluid DOT 4 — Brake pad wear indicator — Up to the slot Brake disc thickness 3.3 - 3.7 Brake disc roll — 0,25 12,700 - 12,743 12,755 Internal diameter of master cylinder...
Page 15 XR250 Information General IGNITION SYSTEM Item Specifications Spark plug Range CR8EH-9 (NGK) spark 0.8 - 0.9 mm Opening the plug electrodes Ignition coil peak voltage 100 V minimum Ignition pulse generator peak voltage 0.7 V minimum 8th APMS (idling)) Mark "F" of ignition point ELECTRIC START SYSTEM Unit: Unidad: mm...
Page 16 XR250 Information General TIGHTENING TORQUE VALUES Tightening Tightening Type of fixer Type of fixer torque torque Hex screw and 5mm nut 5 (0.5) 5mm screw 4 (0.4) Hex screw and 6mm nut 10 (1.0) 6mm screw 9 (0.9) (including SH flange screw) con 6 mm flange and nut bolt 12 (1.2) Hexagonal screw and 8 mm nut...
Page 17 XR250 Information General Chassis Thread Tightening Item Amount Note torque Diameter (mm) Chassis/ Fairing / Exhaust System: Silencer Clamp Bolt 20 (2.0) Exhaust pipe junction nut 18 (1.8) Silencer Mounting Bolt (Front) 26 (2.6) Silencer Mounting Bolt ( Rear) 26 (2.6) Exhaust pipe guard bolt 18 (1.8) Engine Disassembly/Installation: /...
Page 18: Table Of Contents
XR250 Information General Tools Tool number Description Note section. Accessory, 24 x 26 mm 07746-0010700 Accessory, 32 x 35 mm 07746-0010100 11, 13 Accessory, 37 x 40 mm 07746-0010200 Accessory, 42 x 47 mm 07746-0010300 11, 13, 14 Accessory, 52 x 55 mm 07746-0010400 Accessory, 72 x 75 mm 07746-0010600...
Page 19 XR250 Information General LUBRICATION AND SEALING POINTS Engine Location Material Note Camshaft stumps and lobes Molybdenum External sliding surface of valve actuator Valve stem (sliding surface of bisulfide-based and valve valve guide stem tip solution engine (50% internal and external sliding upper surfaces of the clutch bell guide oil mixture with 50% Outer surface of the piston bolt Internal a molybdenum bisulfide-...
Page 20 XR250 Information General Chassis Location Material Note Multipurpose grease Steering column bearings Swing Arm Pivot Backsman's Lips Bearings Shock Joint Needle Bearings Swing Arm Pivot Lips Came swing arm joint dust guard and rear brake shaft Sliding surface of the rear brake panel anchor pin Inside the speedometer gearbox Rear Brake Came Dust Guard Lips Clutch Lever Pivot...
Page 21 XR250 Information General PASSING CABLES AND CABLING CLUTCH CABLE ACCELERATOR CABLES FRONT BRAKE HOSE RIGHT LEFT FRONT FLASHER 3P CONNECTOR OF THE Lighthouse speedometer CABLE 1-17...
Page 22 XR250 Information General FRONT BRAKE HOSE SPEEDOMETER CABLE ACCELERATOR CABLES STARTER ENGINE CABLE CLUTCH CABLE 1-18...
Page 23 XR250 Information General FRONT BRAKE HOSE REGULATOR/RECTIFIER IGNITION SPARK PLUG CABLE HORN CABLING MAIN CABLING 1-19...
Page 24 XR250 Information General ACCELERATOR CABLES CLUTCH CABLE ENGINE HOUSING VENT DRAIN TUBE REAR BRAKE LIGHT SWITCH AIR FILTER VENT TUBE WIRING 1-21...
Page 25 XR250 Information General ALTERNATOR WIRING/IGNITION PULSE GENERATOR/DE POWER CONTROL SWITCH MODULE (ICM) STARTING RELAY MAIN CABLING ACCELERATION SCREW POSITIVE BATTERY SIDE STAND SWITCH WIRING TERMINAL 1-20...
Page 26 XR250 Information General RIGHT REAR FLASHING WIRING MAIN CABLING LEFT REAR FLASHER WIRING 1-22...
Page 27 Under certain conditions, when exposed to sunlight, hydrocarbons react produce moistness and photochemical fog. Carbon monoxide does not react in the same way. Still, it's toxic. Moto Honda da Amazsnia Ltda. uses "poor" mixture adjustments of the carburetor, as well as other procedures, in order...
Page 28 XR250 Information General NOTES 1-24...
Page 29 CHASIS XR250 SERVICE INFORMATION FUEL TANK Saddle BREAKDOWN INVESTIGATION Side COVERS TAILTAIL REAR EXHAUST SYSTEM LICENCE PLATE SUPPORT SERVICE INFORMATION GENERAL INSTRUCTIONS • Gasoline (nafta)Naphtha Is extremely flammable and explosive under certain conditions. KEEP IT Out OF THE REACH OF Children. •...
Page 30 XR250 CHASIS/FAIRING/EXHAUST SYSTEM Saddle Saddle Disassembly Remove the side panels (see below). Remove bolts and nuts. Push the saddle back. Installation BOLTS/NUTS Install the saddle hook on the fuel tank holder. Align the Hooks Saddle With the Support Tank Fuel. Install the saddle.
Page 31 XR250 CHASIS/CARENADO/SYSTEM DE Escape LICENCE PLATE SUPPORT BOLTS/ SLEEVES/ Rubbers Removal Remove the saddle, side covers, and tail (see page 2-2). Disconnect the 3P connecter from the flashlight/brake light. Remove bolts, sleeves and rubbers. Remove the support from the license plate. Disassembly Remove the bolts and the flashlight/brake light assembly.
Page 32 XR250 CHASIS/FAIRING/EXHAUST SYSTEM Visor Front FRONT Removal SPEED Remove the headlight adjustment bolts. Remove the two bolts and the front visor. Disconnect the headlight switch. Disconnect the 3P switch from the speed sensor and speed sensor. Disassembly Remove the bolts and headlight. Remove the fixing screws, then remove the front visor from headlight.
Page 33 XR250 CHASIS/CARENADO/SYSTEM DE Escape BOLT OF THE BOLT PERNO EXHAUST SYSTEM Disassembly Do not service the exhaust system while it is hot. Remove the saddle (page 2-2). Remove the side covers (page 2-2). Muffler Remove the bolt from the muffler clamp. BOLT/NUT Remove the two bolts/lock/nuts.
Page 34 XR250 CHASIS/FAIRING/EXHAUST SYSTEM Installation 26 N.m (2.6 kg.m) 26 N.m (2.6 kg.m) 18 N.m (1.8 kg.m) 18 N.m (1.8 kg.m) JOINT NUTS Install the new exhaust pipe seal. Install the exhaust pipe assembly and muffler. Temporarily install all bolts and lock nuts. Tighten the exhaust pipe junction nuts to the specified torque.
Page 35 XR250 CHASIS/CARENADO/SYSTEM DE Escape Tighten the front locking bolt of the muffler the specified torque. TIGHTEN TO: Muffler Front Fixing Bolt.m (2.6 kg.m) BOLT/NUT Tighten the rearlock nut/bolt of the muffler to the specified torque. TIGHTEN TO: 26 N rear muffler fixing bolt (2.6 kg.m)
Page 36 XR250 CHASIS/FAIRING/EXHAUST SYSTEM NOTES...
Page 37 3. Maintenance XR250 SERVICE INFORMATION BRAKE FLUID FUEL LINE WEAR OF THE BRAKE PADS/SHOES MAINTENANCE TABLE BRAKE SYSTEM BRAKE LIGHT SWITCH HEADLIGHT THE IGNITION Spark Plug Engine STEERING HOUSING ADJUSTMENT CLUTCH SYSTEM ENGINE OIL Nuts BOLTS AND WHEEL/TIRE STEERING COLUMN BEARINGS TRANSMISSION CHAIN SLIDING GUIDE SERVICE INFORMATION...
Page 38 XR250 Maintenance Specifications Item Specifications Free throttle grip play Spark plugs Range CR8EH-9 (NGK) spark 0.8 - 0.9 mm Opening the plug electrodes Valve clearance 0.12 mm 0.15 mm Recommended engine oil MOBIL SUPERMOTO 4T Service Rating: SF Viscosity API: SAE 20W-50 Engine oil capacity When draining...
Page 39 Maintenance XR250 MAINTENANCE TABLE Period Item Operations 1,000 km 3,000 km 6,000 km every .. km Fuel condition Check 3.000 Fuel filter Clean 3.000 Accelerator Check and adjust 3.000 Strainer Check and adjust 3.000 Air filter Clean (note 1) 3.000 Change 18.000 Engine VENT...
Page 40 XR250 Maintenance FUEL LINE FUEL LINE Inspect the fuel line and connections for deterioration, damage and leakage. Replace the line if necessary. FUEL VALVE FUEL FILTER under • Gasoline (nafta) is highly flammable and explosive certain conditions. KEEP IT Out OF THE REACH OF Children. •...
Page 41 Maintenance XR250 OPERATION OF THE ACCELERATOR Check throttle cables replace them in case they are damaged, bent or damaged. Check if the throttle handle operates smoothly. Check if it returns completely and automatically, from the fully open position, in all handlebar positions. If the handle does not return accelerator properly, lubricate the throttle cables, disassemble and inspect...
Page 42 XR250 Maintenance Adjuster Larger settings are made with the adjuster. bottom Loosen the lockers and turn the adjuster to get the game free. Tighten the counter-twists after you have made the adjustment. Check the free game again. Locknut AIR FILTER AIR FILTER COVER Remove the saddle (page 2-2).
Page 43 Maintenance XR250 Engine Breather Breather Tube Note Perform more frequent services when driving in rain, with maximum acceleration or after washing or overturning the motorcycle. Perform services in case the level of tanks can be seen in the transparent section of the respite drain pipe. Remove the drain plug from the VENT tube to clean any tank.
Page 44 XR250 Maintenance To prevent damage To the cylinder Head, manually tighten the spark Plug before using the Spark Plug wrench to tighten it To the specified torque Reinstall the spark plug into the cylinder head and tighten manually. Next, press it to the specified pair. TIGHTEN TO: 12 N.m (1.2 kg.m) NOISE-SUPPRESSING LAYER Replacement of the Spark plug...
Page 45 Maintenance XR250 Turn the Crankshaft In the Sense Schedule Align the Brand INDICATOR Notch "Nice stay" In the Steering wheel Engine With the Notch Indicator In the side cover Left the Housing Engine. Make sure the piston is in the upper de in the compression stroke.
Page 46 XR250 Maintenance Calculate the Thickness of the new shim Using the Following Equation: A= (B - C) + D A: Thickness of the new shim B: Valve clearance measured C: Specified valve clearance D: measured shim thickness Note thickness • Properly measure the of the Shim using To micrometer.
Page 47 Maintenance XR250 Check the Conditions the Rings O-rings. Install the Tops the O-RINGS Holes Timing Crankshaft. Tighten the timing and crankshaft hole caps to the specified torque. TIGHTEN TO: Top Timing hole cover 10 N.m (1.0 kg.m) Crankshaft hole cover 8.
Page 48 XR250 Maintenance Change Oil Engine If it Is necessary To perform services with the engine in operation, make sure that the work premises Are well ventilated. Never operate the engine in enclosed Areas. Exhausted Gases contain poisonous carbon monoxide,which Can cause loss of consciousness and even Death.
Page 49 Maintenance XR250 Apply Oil Engine In the New Ring O-rings. Install In the Slot OIL FILTER Lid Filter Oil. Install the spring between the tabs of the new oil filter. Install the filter with the "OUT-SIDE" (external side) mark facing outwards.
Page 50 XR250 Maintenance REAR AXLE NUT LOCK NUT Adjustment Loosen the rear axle nut. Loosen the lockers of the two transmission chain adjusters. Rotate the two adjustment nuts until the correct clearance of the transmission chain is obtained. Make sure that the ends of the two adjusters are Aligned with the same swing arm reference marks.
Page 51 Maintenance XR250 Inspection: crown and pinion transmission Worn Inspect crown and drive pinion teeth for wear or damage. Replace the crown and sprocket, if necessary. Never use a new drive chain with worn sprockets. the transmission chain, as well as the crown and sprocket, must be in good condition.
Page 52 XR250 Maintenance Remove the Excess Links the New Chain Transmission Master Link Using the Tool Specified. Note master Include the link when counting the chain links. . Specified number of links: 104 Replacement chain: DID 520 VD 104 Links O-RINGS Never reuse chain, master link, plate or O-rings.
Page 53 Maintenance XR250 Rivet the Pins Link Master Using the Tool the Chain Master Link Transmission. Tool: Transmission chain tool 07HMH-MR10103 Note To prevent excessive riveting, gradually rivet the pins, checking the diameter of the riveted area with a measuring tool. TRANSMISSION CHAIN TOOLS For Make sure What the Pins Link Master Are Set Correct, Measuring tool...
Page 54 XR250 Maintenance BRAKE FLUID • Do not mix different types of fluid, as these may not be supported. foreign • Do not allow materials To enter the system during tank supply. • Prevent fluid from splashing on painted, plastic or rubber parts. Place To cloth over these parts whenever you perform services in...
Page 55 Maintenance XR250 BRAKE HOSE BRAKE SYSTEM FRONT BRAKE Firmly operate the front brake lever and make sure there is no penetration into the system. the lever is too soft or elastic when applied, purge the system air. Inspect the brake hose and connections for eterioration, cracks, and leakage signals.
Page 56 XR250 Maintenance HEADLIGHT Adjustment Incorrect headlight adjustment can impair other drivers' vision and even not illuminate the road safe distance. Note Adjust the headlight focus according to local traffic laws and ADJUSTMENT BOLT regulations. Place the motorcycle on a level surface. Loosen the headlight adjustment bolt and adjust the spotlight vertically.
Page 57 Maintenance XR250 Side Stand Support the motorcycle on a level surface. Inspect the Side stand bracket spring for damage or loss of tension. Check if the Side Stand bracket assembly moves freely. Lubricate the pivot, if necessary. Check the Side Stand bracket ignition cutting system: –...
Page 58 XR250 Maintenance Refer to Section 14 for information regarding shock services. NUTS, BOLTS AND FIXERS Make sure that all bolts and nuts in the chassis are tightened to the correct tightening torque (p. 1-13). Check if all cleft pins, safety pins, hose, clamps, and cable brackets are located and fixed correctly.
Page 59 Maintenance XR250 Note • Pressure should be inspected with COLD tyres. • Check it out, out, using To Pull pressure gauge. RECOMMEND PRESSURE AND TIRE DIMENSION Front Rear Tire pressure 150 kPa (1.50 150 kPa (1.50 kgf/cm , 22 psi) kgf/cm , 22 psi) Tire dimension...
Page 60 LUBRICATION SYSTEM XR250 Maintenance DIAGRAM OF THE SYSTEM LUBRICATION SERVICE TROUBLESHOOTING OIL PUMP SERVICE INFORMATION GENERAL INSTRUCTIONS • Services and Airports in the oil pump Can be performed with the engine installed in chassis. • the procedures described in this section should be performed after engine oil drainage. •...
Page 61 LUBRICATION SYSTEM XR250 LUBRICATION SYSTEM DIAGRAM...
Page 62 XR250 LUBRICATION SYSTEM TROUBLESHOOTING Oil level too low • Normal oil consumption • External oil leakage • Improper wear or installation of piston rings • Wear of the guide or oil retainer of the valve stem Low oil pressure • Oil hole obstruction •...
Page 63 XR250 LUBRICATION SYSTEM OIL PUMP MANDATED GEAR OIL PUMP Disassembly Drain the engine oil (page 3-12). Remove the right side cover from the engine housing (page 9-3). Remove the command gear from the oil pump and shaft. PUMP AXIS Remove the three bolts and the oil pump assembly. Remove the two guide nipples.
Page 64 XR250 LUBRICATION SYSTEM Remove the three bolts and the oil pump cover. INTERNAL ROTOR guide SPIKES ROTOR Remove the internal and external rotors. Remove the guide nipples. EXTERNAL ROTOR Inspection Clean all removed parts completely. Temporarily install the internal and external rotors in the oil pump housing.
Page 65 XR250 LUBRICATION SYSTEM Measure the clearance between the rotors and the flank of the pump housing, using a thickness calibrator and a precision ruler. ASSEMBLE INTERNAL Rotor GUIDE Spike O-Ring EXTERNAL Lid the Pump Oil Spike guide EXTERNAL ROTOR Installation Before assembly, completely clean all parts removed with solvent and dry them.
Page 66 XR250 LUBRICATION SYSTEM GUIDE SPIKES Install the guide nipples and oil pump cap. Install the three bolts tighten them firmly. Bolts Install the two guide nipples. GUIDE SPIKES Install the oil pump assembly. Install the three bolts tighten them firmly.
Page 67 XR250 LUBRICATION SYSTEM Install the pump shaft by aligning the flat surfaces of the shaft and internal rotor. OIL PUMP AXIS Install the command gear of the pump, aligning the flat surfaces of the gear hole and pump shaft. Install the nipple and O-ring on the oil pump connection.
Page 68 XR250 LUBRICATION SYSTEM OIL RADIATOR Disassembly Remove the side baffle plates (page 2-3). Drain the engine oil (page 3-12). Release the bolts and upper connections of the radiator oil tubes, removing the two bolts. Bolts Remove the fixing bolts from the oil radiator and spacers.
Page 69 XR250 LUBRICATION SYSTEM RADIATOR OIL TUBE/ENGINE OIL TUBE Disassembly Drain the engine oil (page 3-12). Remove the side baffle plates (page 2-3). RADIATOR OIL TUBE Remove the bolts from the upper connections of the radiator oil tubes (oil radiator side /page 4-8). Remove the bolts from the lower...
Page 70 4. FUEL SYSTEM XR250 LUBRICATION SYSTEM SERVICE INFORMATION FAULT INVESTIGATION AIR FILTER BOX REMOVAL OF CARBURETOR Start ENRICHMENT VALVE (SE) DISASSEMBLY OF CARBURETOR ADJUSTING THE PILOT SCREW SERVICE INFORMATION GENERAL INSTRUCTIONS under certain • Gasoline is highly flammable and explosive conditions.
Page 71 XR250 FUEL SYSTEM...
Page 72 XR250 FUEL SYSTEM Specifications Item Specifications Carburetor identification number VEA1A Main supplier Idling supplier Initial opening of the pilot screw 3 turns out Float level 18.5 mm Idling rotation 1,400 ± 100 rpm Free throttle grip play Tool Float level calibrator 07401-0010000...
Page 73 XR250 FUEL SYSTEM TROUBLESHOOTING the engine spins, but does not start the engine watertight, starts with difficulty • there's no fuel in the tank irregular idling • there's no fuel in the carburetor • Fuel line restriction – Fuel filter clogged •...
Page 74 XR250 FUEL SYSTEM AIR FILTER BOX DISASSEMBLY/INSTALLATION Remove the following components: – Fuel Tank (page 2-4) – Rear Mudguard (page 2-3) – Battery (page 16-4) – Magnetic Start Switch (page 18-11) Loosen the air filter connection tube clamp screw. SCREW CLAMP SCREWS AIR BOX AIR FILTER HOUSING Disconnect the VENT tube from the motor housing.
Page 75 XR250 FUEL SYSTEM CARBURETOR ADJUSTERS CARBURATOR REMOVAL Remove the fuel tank (page 2-4) CLAMP SCREW Loosen the screws on the isolator clamp and the connecting tube clamp. Remove the clutch cable. Loosen the lockers on the throttle cable adjusters and adjusters.
Page 76 XR250 FUEL SYSTEM SCREWS VACUUM CHAMBER Remove four screws, tube supports, and vacuum chamber cover. Note the compression spring is very long. When removing the lid, be careful so that the spring does not jump out of the carburetor. SCREWS/SUPPORTS COMPRESSION SPRING Remove the compression spring and vacuum diaphragm/piston from the carburetor body.
Page 77 XR250 FUEL SYSTEM SUPPORT FROM AIR CUTTING VALVE CABLE AJUSTADORES ADJUSTING SCREWS Remove the two screws and the cable adjuster hole Remove the Lid the Valve, the Spring the Diaphragm. Note the spring of the air cutting valve is under pressure. When removing the lid, be careful so that the spring does jump.
Page 78 XR250 FUEL SYSTEM BAFFLE PLATE Remove the baffle plate. FLOAT Remove the float pin, float, and valve. Check the float for damage, formation or fuel presence. FLOAT VALVE FLOAT VALVE Check the following: – Valve and valve seat with respect to scratches, obstruction or damage.
Page 79 XR250 FUEL SYSTEM Remove the pilotscrew, spring, washer and O-ring. SPRING , O-RING SEAT Check the pumps for wear or damage. Replace them, if necessary. Check the pilot screw for wear or damage. Clean the pumps Spring with a cleaning solvent and blow them with compressed air.
Page 80 XR250 FUEL SYSTEM SPRING O-RING SEAT FLOAT BUCKET Install the pilot screw and move it back to its original position, according data record during disassembly. If you have installed a new pilot screw, adjust it (page 5-15). PILOT SCREW Supplier If the pilot screw is excessively tightened, it's Seat may be Damaged.
Page 81 XR250 FUEL SYSTEM FLOAT BUCKET O-RING Install the new O-ring in the float bucket slot. Screws Bucket Float Install the float bucket tighten the four screws. Spring DIAPHRAGM/AIR CUTTING VALVE Install the /válvula air-cutting diaphragm/valve and spring. Install and hold the valve cover. Note Be careful not to hold the diaphragm.
Page 82 XR250 FUEL SYSTEM Adjust the cable adjuster bracket to the correct position, according to the illustration. Tighten the two screws. DIAPHRAG PISTON SCREWS Vacuum VACUUM CHAMBER Install the needle in the vacuum piston. Install the spring in the needle hole .
Page 83 XR250 FUEL SYSTEM Turn the needle hole clockwise, while pressing it, until it becomes locked. After turning, make sure that the support flanges and piston slots are tightly fitted. Install the vacuum diaphragm/piston into the / carburetor body. Lift the bottom of the piston with your finger to adjust the diaphragm on the carburetor body notching.
Page 84 XR250 FUEL SYSTEM SCREWS Install the lid, tube supports and tighten the four screws firmly. SCREWS/SUPPORT DRAIN TUBE/VENT TUBE Connect the fuel pipe, VENT pipe, and drain pipe. Install the acceleration bolt. ACCELERATION BOLT CARBURETOR INSTALLATION Install the carburetor body to the isolator and connecting tube. Install the throttle cables on the throttle drum.
Page 85 XR250 FUEL SYSTEM START ENRICHMENT VALVE (SE) Remove the start enrichment valve (SE) (page 5-5). Inspect the start enrichment valve (SE) for markings, scratches, or wear. Check the SE valve tip seat for excessive wear. Replace the SE valve assembly, if necessary. Start ENRICHMENT the parts are installed in the reverse out of disassembly.
Page 86 XR250 FUEL SYSTEM NOTES 5-16...
Page 87 DISASSEMBLY/installation motor XR250 SERVICE INFORMATION DISASSEMBLY OF THE TRANSMISSION PINION SERVICE INFORMATION GENERAL INSTRUCTIONS • Use a crane or suitable stand to support the motorcycle during engine disassembly and installation. • Use a floor jack or other adjustable stand to support and bike the motor. •...
Page 88 XR250 FUEL SYSTEM 5-18...
Page 89 DISASSEMBLY/INSTALLATION OF THE ENGINE...
Page 90 XR250 DISASSEMBLY/INSTALLATION O F T H E E N G I N E Specifications Item Specifications Engine weight (dry) 35.3 kg Engine oil capacity when disassembling 1.8 l TIGHTENING TORQUE VALUES Transmission pinion fixing plate bolt10 N.m (1.0 kg.m) Motor front locking bolt/nut49 N.m (4.9 kg.m) Motor front bracket bolts/nuts26 N.m (2.6 kg.m) Motor Top Front Lock Bolt/Nut49 N.m (4.9 kg.m) Motor bottom front locking bolt/nut49 N.m (4.9 kg.m)
Page 91 DISASSEMBLY/INSTALLATION Engine XR250 TRANSMISSION PINION CHAIN PROTECTOR DISMOUNT Remove the two bolts, the pinion cover and the drive chain guard. PINION CAP ADJUSTMENT NUT Loosen the Nut Axis butt, the Locknut the Nuts Adjustment the Chain Transmission. COUNTER-TWIST BRAKE STEM Remove the brake arm stem (page 14-3).
Page 92 XR250 DISASSEMBLY/INSTALLATION O F T H E E N G I N E DISASSEMBLY/INSTALLATION Engine Disassembly Note information on parts Refer to page 6-1 for Page To be engine removed Prior To disassembly. Place a floor jack or other adjustable bracket unr the motor. Remove the bolt/nut caps from the swing arm pivot.
Page 93 DISASSEMBLY/INSTALLATION Engine XR250 Installation Note • Locate the floor Jack or other adjustable bracket under the Engine. floor • the height of the Jack must be continuously adjusted in order To Relief pressure and facilitate the installation of bolts. Place the engine in the chassis. Install, without tightening, all bolts, nuts and fixing plates.
Page 94 XR250 DISASSEMBLY/INSTALLATION O F T H E E N G I N E Install the Guard the Chain the Lid Pinion Transmission. Tighten the pinion cover bolts firmly. PINION CAP ADJUSTMENT NUT Adjust the transmission chain clearance (page 3-14). COUNTER-TWIST BRAKE STEM Tighten the rear axle nut to the specified torque.
Page 95 DISASSEMBLY/INSTALLATION Engine XR250 NOTES...
Page 96 7. CYLINDER XR250 DISASSEMBLY/INSTALLATION O F T H E E N G I N E HEAD/VALVES SERVICE INFORMATION GENERAL INSTRUCTIONS • This section scribes the service procedures for stocks, valves, and camshafts. • Repairs and services in the cylinder head, valves and camshafts can be performed with the engine installed in the chassis. •...
Page 97 XR250 VALVES...
Page 98 CYLINDAR HEAD/VALVES XR250 SPECIFICATIONS Unit: mm Item Range Service Limit Cylinder compression 1,128 kPa (11.5 kgf/cm — 163.6 psi) at 400 rpm Cylinder roll — 0,10 Camshaft Lobe height 37,00 – 37,24 36,94 37,03 – 37,27 36,97 Eccentricity 0,02 0,10 DIA of the stump 24,959 - 24,980 —...
Page 99 XR250 CYLINDER HEAD/VALVES Tools Valve spring compressor07757-0010000 Spring compressor accessory07959-KM30101 Valve guide impeller, 5.0 mm07942-MA60000 Sponsor Accommodation Protector, 24 x 25.5mm07HMG-MR70002 Valve guide reamer, 5.0 mm 07984-MA60001 Valve seat cutters – Valve seat cutter, 24 mm (45o ESC)07780-0010600 – Valve seat cutter, 27.5 mm (45o ADM)07780-0010200 –...
Page 100 CYLINDAR HEAD/VALVES XR250 Compression Cylinder NOISE-SUPPRESSING LAYER If it is necessary to perform services with the engine in operation, make sure that the work premises Are well ventilated. Never operate the engine in enclosed Areas. Exhausted gases contain poisonous carbon monoxide, which Can cause loss of consciousness and even Death.
Page 101 XR250 CYLINDER HEAD/VALVES CYLINDER CAP DISMANTAL THE CYLINDER HEAD RUBBER BOLT/WASH Remove the following components: – Fuel Tank (page 2-4) – Radiator Oil Tube (page 4-9) Remove the noise-suppressing layer from the spark plug. Remove the bolts from the lid, rubber washers and cylinder cover. Board Remove the gasket.
Page 102 CYLINDAR HEAD/VALVES XR250 ACTUATOR PLUG Loosen the tensioner actuator plug, but do not remove it yet. Remove the tensioner actuator from the distribution chain and gasket, alternately loosening the two bolts. TENSIONER ACTUATOR/DISTRIBUTION CHAIN guide JOINT Remove the three bolts and the distribution chain guide. CHAIN SPORTS OF THE Remove the six bolts and supports from the camshafts.
Page 103 XR250 CYLINDER HEAD/VALVES Inspection DEL Camshaft SUPPORT Camshaft support Inspect the surface of the camshaft support stumps for excoriations, scratches, or signs of poor lubrication. Inspect the oil holes in the housings for obstruction. Height Lobe Tree Cams Inspect camshaft lobe surfaces for excoriations, scratches, or signs of poor lubrication.
Page 104 CYLINDAR HEAD/VALVES XR250 Note Do not rotate the camshaft during inspection. Carefully install camshaft supports and distribution chain guide. Tighten the bolts in cross-sequence, in several steps. TIGHTEN TO: 12 N.m (1.2 kg.m) Remove the camshaft supports and measure the width of each compressed plastigage.
Page 105 XR250 CYLINDER HEAD/VALVES DISTRIBUTION CHAIN guide TOGETHER Remove the cylinder distribution chain guide. Remove the gasket and guide nipples. GUIDE SPIKES Remove the Bolts the Insulator Carburetor. Insulator Bolts DISASSEMBLE/INSPECTION CYLINDER HEAD Note During disarm, identify, each removed part and then reinstall in its original position.
Page 106 CYLINDAR HEAD/VALVES XR250 Remove the keys from the valve springs, spring retainers, springs and valves, using the special tools, according to the illustration. Tools: Valve Spring Compressor07757–0010000 Spring Compressor Accessory 07959–KM30101 Ⅰ voltage Springs To avoid loss, Do not compress the more to remove the than necessary...
Page 107 XR250 CYLINDER HEAD/VALVES VALVE ACTUATOR ACCOMMODATION Check the accommodation of each valve actuator for scratches, damage or abnormal wear. Measure the DIA of each rocker follower accommodation. VALVE ACTUATOR Check each valve actuator for scratches, damage, or abnormal wear. Measure the DIA of each valve actuator. Valve Springs Measure the free length of the internal and external valve springs.
Page 108 CYLINDAR HEAD/VALVES XR250 VALVE guide REAMER Use the valve guide reamer to remove possible carbonite posits before measuring the guides. Insert the reamer into the cylinder on the side of the camshafts. Always turn the reamer clockwise. Tool: Valve guide reamer, 5.0 mm07984–MA60001 Measure and write down the DIA of each valve guides.
Page 109 XR250 CYLINDER HEAD/VALVES VALVE guide IMPELLER Ⅰ • Do not use flame torch to heat the cylinderhead, as this may cause roll of it. the contact • Be careful not to damage surfaces of the stock. Support the stock and use special tools to remove valve guides and O- rings from your accommodations, from the combustion chamber side of the cylinder head.
Page 110 CYLINDAR HEAD/VALVES XR250 Remove the Valve e Inspect the Surface Your Seat. shall the surface of the valve seat be in accordance with the specified and uniform width throughout its circumference. Ⅰ Valves cannot be rectified. If a valve is burned or excessively worn, or has uneven contact with the seat, replace it.
Page 111 XR250 CYLINDER HEAD/VALVES It is Recommend the Use Strawberries/Rectifiers Specific For HIGH Previous Seat Seats Valves, For the Correction Seats Worn. WIDTH Rectify the valve seat with a 45-gree cutter whenever you replace the guide. 32nd If the contact surface is too high, use a 32-gree flat cutter to lower Previous Seat the seat.
Page 112 CYLINDAR HEAD/VALVES XR250 Using A Strawberry Finish 45 grease, Rectify the Seat wi Specified. Seat WIDTH Make sure you have removed any roughness and irregularities. Rectify the valve seat again, if necessary. Note the correct location of Seat with respect to the contact surface the valve Is Essential To Ensure 45th...
Page 113 XR250 CYLINDER HEAD/VALVES Clean the cylinder head assembly with solvent and blow with compressed air through each oil duct. Valve Seat Spring Install the valve spring seats. Install the new stem oil retainers. Lubricate the sliding surfaces of the valve stems with motor oil. Insert each valve into your guide, slowly rotating it to avoid damage to the stem oil retainer.
Page 114 CYLINDAR HEAD/VALVES XR250 Note Apply grease to the keys for easy installation. Install the keys on the valves using the special tools according to the illustration. Tools: Valve spring compressor07757–0010000 Spring compressor accessory 07959–KM30101 Ⅰ power To avoid loss Do not compress the springs more than necessary To install the Keys.
Page 115 XR250 CYLINDER HEAD/VALVES CHAIN GUIDE Distribution Board CYLINDER HEAD INSTALATION Remove any gasket material residue from the cylinder contact surfaces. Install the distribution chain guide on the cylinder head. Make sure that the highlights of the distribution chain guide fit into the grooves of the engine housing and Cylinder.
Page 116 CYLINDAR HEAD/VALVES XR250 Turn Slowly the Crankshaft In the Sense Against Schedule, Holding INDICATOR the Chain Distribution, For Align the Brand "Nice stay" In the Notch Steering wheel Engine With the Notch Indicator Hole Timing In the Lid Side of the Housing Engine. Chain Distribution Apply molybdenum disulfide oil to camshaft stumps in the stock, camshafts and their respective supports.
Page 117 XR250 CYLINDER HEAD/VALVES INSTALLATION OF THE DISTRIBUTION CHAIN TENSIONER ACTUATOR Remove the tensioner actuator plug. Check the operation of the tensioner actuator: – the tensioner shaft should not enter the body when pressed. – When rotated clockwise, with a screwdriver, the tensioner shaft must be retracted into the body .
Page 118 CYLINDAR HEAD/VALVES XR250 o-Ring Remove the tensioner actuator limiting tool. Install a new O-ring in the tensioner actuator seal. Install the tensioner actuator plug. Tighten the tensioner actuator plug. ACTUATOR STOPPER BOLTS ACTUATOR PLUG Check again if the reference marks on the distribution gear remain Aligned with the top surface of the cylinder head while the "T"...
Page 119 XR250 CYLINDER HEAD/VALVES Board Install a new gasket on the cylinder cover. Lid the Cylinder head Washer GOMA/PERNO Install the new rubber washers and tighten the cylinder head cover bolts to the specified torque. TIGHTEN TO: 12 N.m (1.2 kg.m) Install the spark plug noise suppressor layer.
Page 120 8. CYLINDER/PISTON CYLINDAR HEAD/VALVES XR250 SERVICE INFORMATION PISTON DISASSEMBLY CYLINDER DISASSEMBLY SERVICE INFORMATION GENERAL INSTRUCTIONS • Before performing repair services on the Cylinder/piston remove the motor. • Be careful not to damage the cylinder wall and piston. • When using a screwdriver to remove the Cylinder, be careful not to damage the contact surfaces. •...
Page 122 XR250 CYLINDER/PISTON...
Page 124 XR250 CYLINDER/PISTON TROUBLESHOOTING Compression too low, difficult start or poor low rotation performance • Damaged cylinder gasket • Worn, damaged or jammed piston rings • Worn or damaged cylinder or piston • Valve roll, or damaged valve seats Compression too high, overheating or "rattle" •...
Page 125 XR250 CYLINDER/PISTON Cylinder CYLINDER REMOVAL Remove the stock (Section 7). Remove the Cylinder. Do not hit the cylinder excessively. When using a screwdriver during disassembly, be careful not to damage the contact surface. Completely clean the top of the Cylinder. Ⅰ...
Page 126 XR250 CYLINDER/PISTON a precision ruler and thickness calibrator to check the top of the cylinder against roll. Piston PISTON REMOVAL Note around the Before disassembly, place a clean cloth the bolt crank to prevent fasteners from falling into the motor housing. Remove the fasteners from the bolt, using a pliers.
Page 127 XR250 CYLINDER/PISTON Inspection Inspect the piston for cracks or other damage. Inspect piston grooves for excessive wear and carbon posit formation. Measure the O.d. Piston. Note Measure outer diameter of the piston at a point 16 mm from the base of the skirt and 90 degrees from the bolt hole Calculate the clearance between the piston and the Cylinder.
Page 128 XR250 CYLINDER/PISTON Note Always replace piston rings as a set. Inspect the piston rings and replace them, if worn. Temporarily reinstall the piston rings (page 8-7) in their respective slots. Press the piston ring until its outer surface is virtually level with the piston.
Page 129 XR250 CYLINDER/PISTON Note Brand • than • • • Top RING Piston SECONDARY RING SIDE RINGS Top RING Piston SECONDARY CONTACT SURFACE Note When cleaning the cylinder contact surface, place a clean cloth in the cylinder opening to prevent dirt dust or from entering the engine.
Page 130 XR250 CYLINDER/PISTON Install the New Fasteners Piston pin. Ⅰ Always wear fasteners. Never reuse fasteners, as this can cause serious engine damage. Note • Make sure that the piston pin fasteners are firmly seated. • Do not align the ends of the bolt fasteners with piston cutting.
Page 131 XR250 CYLINDER/PISTON NOTES...
Page 132 XR250 CYLINDER/PISTON CLUTCH/GEAR SELECTOR SERVICE INFORMATION PRIMARY Control Gear FAULT INVESTIGATION Gear Selector DISASSEMBLY OF THE RIGHT Side INSTALLING THE RIGHT Side COVER OF COVER OF THE ENGINE HOUSING THE ENGINE HOUSING Clutch SERVICE INFORMATION GENERAL INSTRUCTIONS • Clutch repair and gear selector services can be performed with the engine installed in the chassis. •...
Page 133 XR250 CLUTCH/GEAR SELECTOR 108 N.m (10.8 kg.m)
Page 134 XR250 CLUTCH/GEAR SELECTOR TROUBLESHOOTING Clutch lever too hard • Dirty, jammed or damaged clutch cable • Wrong pass of clutch cable • Damage to the clutch drive mechanism • Faulty clutch bearing • Incorrect installation of the clutch drive guide Clutch does not couple or motorcycle vibrates with coupled clutch •...
Page 135 XR250 CLUTCH/GEAR SELECTOR CLUTCH CABLE DISASSEMBLE THE TOP RIGHTOP SIDE OF THE ENGINE HOUSING Drain the engine oil (page 3-12). Remove the clutch cable. Remove the following components: – Right Support Pedal Bracket (page 14-18) – Radiator Oil Tubes (page 4-9) OIL TUBES OF THE BOLT RADIATOR SEALING WASHERS...
Page 136 XR250 CLUTCH/GEAR SELECTOR CLUTCH RETURN DRIVE SPRING CLUTCH DRIVE ARM Inspection Remove the clutch drive arm and return spring from the right side cover of the engine housing. Check the clutch drive arm spindle for wear or damage. Check the return spring for damage. SIDE RIGHT COVER OF THE ENGINE HOUSING...
Page 137 XR250 CLUTCH/GEAR SELECTOR CLUTCH ARANLACUBE Remove the conical washer and washer. Remove the bucket from the clutch. CONICAL WASHER DISCS PLATES Remove friction discs and clutch plates. CLUTCH BELL SUPPORT WASHER Remove the clutch hood, pressure plate, and support washer. CLUTCH BELL guide Remove the clutch hood guide.
Page 138 XR250 CLUTCH/GEAR SELECTOR Inspection CLUTCH CLUTCH DRIVE PLATE Clutch bearing Inspect the clutch bearing for damage. Rotate the inner bearing track with your finger. the bearing should rotate silently and smoothly, without noise or excessive play. Make sure that the external track does not have excessive play on the clutch drive plate.
Page 139 XR250 CLUTCH/GEAR SELECTOR Clutch plates Check the clutch plates for fading. Check the roll of the clutch plates on a flat surface, using a thickness calibrator. Note Replace friction discs and plates as an assembly. CLUTCH PLATE CLUTCH CUBE Clutch cube Check the clutch hub for grooves, notch, or abnormal wear caused by clutch plates.
Page 140 XR250 CLUTCH/GEAR SELECTOR CLUTCH BELL guide Installation Apply engine oil to the clutch hood guide and install it on the main axle. PRESSURE PLATE SUPPORT WASHER Install the clutch hood. Install the pressure plate and support washer. Apply new engine oil to friction discs and clutch plates.
Page 141 XR250 CLUTCH/GEAR SELECTOR REED AND DOWN SHALLOWER Note Install the "A" disc tabs external on the shallower clutch hood bottoms. EXTERNAL CLUTCH DISC Brand CUBE L Washer "OUT SIDE Clutch Install the Cube Clutch. Install the washer on the main shaft. Install the new conical washer with the "OUT-SIDE"...
Page 142 XR250 CLUTCH/GEAR SELECTOR BOLT/SPRING DRIVE PLATE Install the clutch springs, drive plate and respective bolts on the pressure plate. Tighten the bolts in crisscrossed sequence, in several steps. Right away, squeeze them tightly. Install the right side cover of the engine housing (page 9-12).
Page 143 XR250 CLUTCH/GEAR SELECTOR Washer Apply motor oil to the thread and the settlement surface of the primary drive gear nut. Right away, install it in the crankshaft. Using the special tool tighten the primary drive gear nut to the specified torque. Tool: Clutch hub hole 07724-0050002...
Page 144 XR250 CLUTCH/GEAR SELECTOR LIMITING ARM OF THE CHANGE OF GEAR Lift the limiting arm using a screwdriver. Install the guide pin and gear shift cam plate. Note with Align the, pin hole on the cam plate the gear shift drum guide nipple. GEAR SHIFT CAM guide PIN Apply chemical lock to the gear shift cam plate bolt thread.
Page 145 XR250 CLUTCH/GEAR SELECTOR Board Spikes guide Install the command oil pump gear on the pump shaft, aligning its flat surfaces. Apply engine oil to the new O-ring and install it in the oil pump slot. Install the guide nipples and a new gasket. GEAR RING O IL PUMP Install the side cover Right of the Housing Engine...
Page 146 ALTERNATOR/STARTER CLUTCH XR250 CLUTCH/GEAR SELECTOR SERVICE INFORMATION ALTERNATOR'S SERVICE INFORMATION GENERAL INSTRUCTIONS • the services presented in this section can be performed with the engine installed in the chassis. • This section scribes the alternator, motor steering wheel, and start clutch service procedures . These components can be removed with the engine installed in the chassis.
Page 147 XR250 STARTER CLUTCH ALTERNATOR/ 103 N.m (10.3 kg.m) 10-0...
Page 148 XR250 ALTERNATOR/STARTER CLUTCH ALTERNATOR STATOR DISASSEMBLY OF THE LEFT SIDE COVER OF THE ENGINE HOUSING Remove the three bolts and the intermediate gear cover from the start. Start INTERMEDIATE Gear COVER INTERMEDIATE START GEAR TOGETHER Remove the gasket. Remove the intermediate gear from the start and the respective shaft from the left side cover of the motor housing.
Page 149 XR250 ALTERNATOR/STARTER CLUTCH REDUCE GEAR TOGETHER/WASHERS Remove the gasket and guide nipples. Remove the starter reduction gear and washer. GUIDE SPIKES Stator Bushing Gum DISASSEMBLY OF THE IGNITION STATOR/PULSE GENERATOR Remove the screw from the cable pin and the pin. Remove the two screws and the other pin.
Page 150 XR250 ALTERNATOR/STARTER CLUTCH NEEDLE BEARING SPACER Remove the needle bearing, spacer, and Woodruff key from the crankshaft. Washer START CLUTCH Disassembly Remove the flywheel from the motor (page 10-3). Remove the command gear from the start, turning it clockwise. Remove the washer. GEAR SENT FROM START BOLT TORX Hold the motor flywheel, using the special tool.
Page 151 XR250 ALTERNATOR/STARTER CLUTCH Check the reduction gear for wear or damage. ONE-WAY CLUTCH REDUCTION GEAR Check the starter clutch hood and unidirectional clutch for abnormal wear, damage or irregular movements. Inspect the internal contact surface of the unidirectional clutch hood for abnormal wear or damage.
Page 152 XR250 ALTERNATOR/STARTER CLUTCH Clean and apply chemical lock to the threads of the Pin Torx torx bolts for fixing the starter clutch. Install the starter clutch assembly on the engine Lock flywheel. Install the Torx bolts. Hold the motor flywheel, using the special tool. Tighten the Torx bolts.
Page 153 XR250 ALTERNATOR/STARTER CLUTCH Apply oil to the thread and settlement surface of the motor flywheel bolt. Next, install the special washer and bolt. Hold the motor flywheel, using the special tool . Then tighten the bolt to the specified torque. Tool: Engine flywheel hole 07725-0040000...
Page 154 XR250 ALTERNATOR/STARTER CLUTCH o-Ring Lubricate a new O-ring with engine oil and install it in the starter slot. Install the left side cover of the motor housing. the alternator cover (stator) is ) magnetically attached Engine to the steering wheel. Be careful not To turn your fingers on during installation.
Page 155 Lubricate A New Ring O-rings With Oil Engine e Install In the Lid Gear Intermediate Start. Install the starter intermediate gear cover and tighten the four bolts firmly. Start INTERMEDIATE Gear COVER GENERAL INSTRUCTIONS Guide Correct the Wiring Alternator (Page 1-21). Plug in the alternator and pulse generator connectors on/ switch.
Page 156 XR250 ALTERNATOR/STARTER CLUTCH Transmission SERVICE INFORMATION 11-1 TRANSMISSION DISASSEMBLE 11-4 FAULT INVESTIGATION 11-2 TRANSMISSION ASSEBLE 11-8 • This section scribes transmission service procedures, including forks, selector drum, and gear shift spindle. Refer to Section 12 for information regarding crankshaft and balancer services.
Page 157 XR250 TRANSMISSION 11-0...
Page 158 XR250 Transmission Item Range Service Limit Gear shift DIA of the gear shift fork 13,000 - 13,021 13,05 fork, fork Thickness of 4.90 - 5.00 the gear shift fork shaft and R, C 4.93 - 5.00 claw selector drum DIA of the gear shift fork axis 12,966 - 12,984 12,90 DIA of the tambor selector drum on the right extremity...
Page 159 XR250 Transmission SEPERATEING ENGINE HOUSING Remove the starter (page 18-4) and the cylinder head (page 7-8). Remove bolts from the lower connections of the oil pipe from the cylinder head, sealing washers, and oil tube from the cylinder head. BOLT/WASHER OIL TUBE FROM THE SEALING STOCK...
Page 160 XR250 Transmission GUIDE SPIKES Remove the gasket and guide nipples. Board DISASSEMBLE TRANSMISSION Disassembly Release the gear selector plate from the gear shift drum, separating it from the drum and removing the gear shift spindle. GEAR SELECTOR PLATE TAMBOR Axis the Forks Change Marches Pull the fork shaft away from the gear...
Page 161 XR250 Transmission Inspection Gears Inspect gear coupling highlights downsticks for excessive wear or damage. Inspect gear teeth for excessive wear or damage. Measure the DIA of each gear. 20.08 mm 23.07 mm 23.07 mm Service Limit 25.09 mm 25.07 mm 22.07 mm Bushings Inspect the bushings for wear or damage.
Page 162 XR250 Transmission Inspect the gear-shifting drum stump on the right half of the engine housing for excessive wear or damage. Measure the DIA of the drum stump. Axle of gear shift forks Check the axle of the gear shift forks for damage and roll. Measure the DIA of the fork shaft, according to the illustration.
Page 163: Pilot, 15 Mm
XR250 Transmission Transmission bearings Rotate the inner track of each bearing with your finger. Bearings should rotate smoothly and without noise. Also check if the external track of each bearing is firmly embed in the motor housing. Replace bearings, if necessary. Bearing REPLACEMENT OF TRANSMISSION BEARINGS Main axle bearings and counter-axis...
Page 164 XR250 Transmission NEEDLE BEARING Inspect the needle bearing for wear or damage. Replace it, if necessary. Bearing After installing the bearings, install the new oil retainer on the countershaft. Inspect spindle oil retainer for wear or damage. Replace it, if necessary. OIL RETENTIONS TRANSMISSION ASSEMBLY Clean...
Page 165 XR250 Transmission MAIN AXIS GEAR M2 (17D) GEAR M6 (27D) GEAR M4 (24D) GEAR M3 (21D) SUPPORT GEAR M5 WASHER (26D) PRESSUR E RING FLUTED WASHER PRESSURE RING PRESSUR E RING DIRECTION OF THE SUPPORT WASHER AND PRESSURE RING: FLUTED WASHER Axis Main (M1: 13D) : Sliding surfaces of gears, bushings and...
Page 166 XR250 Transmission MAIN AXIS AND COUNTEREJE If the crankshaft has been removed, install it first, along with the balancer (page 12-5). Apply motor oil to the lips of the countershaft retainer. Install the main axle and counter-axis as a set, in the left half of the engine housing.
Page 167 XR250 Transmission RETURN SPRING Install the pressure rings, return spring, and replacement spring on the gear shift spindle, according to the illustration. PRESSURE RING Pin Spike Lubricate the oil retainer of the gear shift spindle with engine oil. Install the gear shift spindle by aligning the tips of the return spring with the nipple bolt, while keeping the gear selector plate away.
Page 168 XR250 Transmission ENGINE HOUSING BOLT Make sure that the contact surfaces of the motor housing are evenly supported. Install the bolts on the left half of the engine housing. Tighten them in crisscrossed sequence, in several steps. VENT PLATE/BEARING/BOLT FIXING PLATE Install and tighten the bolt on the right half of the engine housing.
Page 169 XR250 Transmission Install the distribution chain in the control gear. DISTRIBUTION CHAIN Install the following components: – Engine flywheel (page 10-6) – Oil pump (page 4-5) – Clutch & Primary Control Gear (9-10) – Gear Selector (page 9-11) – Piston and cylinder (page 8-6) –...
Page 170: Pilot, 28 Mm
11. CRANKSHAFT/BALANCER XR250 Transmission SERVICE INFORMATION DISASSEMBLY OF THE CRANKSHAFT FAULT INVESTIGATION SERVICE INFORMATION GENERAL INSTRUCTIONS • This section scribes the service procedures on the crankshaft and balancer. • Separate the two halves of the engine housing, when performing repair services on the crankshaft and balancer.
Page 171 XR250 CRANKSHAFT BALANCER 12-0...
Page 172 XR250 CRANKSHAFT/BALANCER DISASSEMBLE Crankshaft Balancer Separate the two halves of the engine housing remove the transmission (Section 11). Use a hydraulic press to remove the crankshaft and balancer from the left half of the engine housing. Support the set so it doesn't fall off. Ⅰ...
Page 173 XR250 CRANKSHAFT/BALANCER Radial Clearance in the Head of the Biela Measure the radial clearance on the crank head using a quadrant indicator. BALANCING GEAR Balancer Gear Check the balancer gear for wear or damage. Crankshaft/Balancer Bearings Rotate the inner tracks of each bearing with your finger. Bearings should rotate smoothly and without noise.
Page 174 XR250 CRANKSHAFT/BALANCER BALANCING EXTRACTOR Use the special tools to remove the bearings from balancer. Tools: Right-side bearing Bearing extractor assembly, 12 mm 07936-1660001 Left side bearing Bearing extractor assembly, 12 mm 07936-1660001 Use the special tools to install the new bearings in the motor housing.
Page 175 XR250 CRANKSHAFT/BALANCER Installation Crankshaft LEFT HALF OF THE ENGINE HOUSING Clean the contact surfaces of the motor housing. Inspect for wear or damage prior to assembly. Crankshaft Note A If the contact surfaces of the engine housing have small irregularities roughness, replace them with oil sharpening stone.
Page 176 Wheel FRONT/Suspension XR250 CRANKSHAFT/BALANCER 13-1 Handlebar INVESTIGATION OF 13-2 Troubleshooting FRONT ADJUST THE Saddle 13-3 SERVICE INFORMATION General brake • Contaminated disc or brake pads reduce stopping force. Discard contaminated pads and clean the disc with a high-quality degreaser. • Pull Rolling or damaged lightning Damages the safety of the vehicle's operation. •...
Page 177 FRONT WHEEL/SUSPENSION/XR250 24 N.m (2.4 kg.m) 103 N.m (10.3 kg.m) 21 N.m (2.1 kg.m) 32 N.m (3.2 kg.m) 59 N.m (5.9 kg.m) 13-0...
Page 178: 07953-Mj10200
XR250 Wheel FRONT/SUSPENSION/ADDRESS TIGHTENING TORQUE VALUES Fork cover 22 N.m (2.2 kg.m) Fork allen bolt 20 N.m (2.0 kg.m) Handlebar bracket nut (top) 24 N.m (2.4 kg.m) Steering column nut 103 N.m (10.3 kg.m) Steering adjustment nut See Vea page 13-31 Upper bridge fixing bolt 21 N.m (2.1 kg.m) Lower bridge fixing bolt 32...
Page 179 XR250 Wheel FRONT/SUSPENSION/ADDRESS CABLE NUTS FRONT WHEEL Disassembly Lift and support the motorcycle using a secure stand or easel Remove the screw and speedometer cable from the speedometer gearbox. Loosen the shaft lock nuts. Remove the axle and front wheel. Screw Note front...
Page 180 XR250 Wheel FRONT/SUSPENSION/ADDRESS Inspection Axis Place the shaft in two blocks in "V" and measure the eccentricity. the actual eccentricity is half the total reading of the indicator. Turn the Track Internal Each Bearing With Your Finger. Bearings should rotate smoothly and silently. Also check that the outer bearing track is securely fastened to...
Page 181 XR250 Wheel FRONT/SUSPENSION/ADDRESS Overall Remove the left dust guard from the left side of the front wheel. Remove the screws and the wheel hub cover. BOLT SCREWS Remove the mounting bolts from the brake disc and disc. BRAKE DISC Bearing Install the bearing extractor head into the bearing.
Page 182 XR250 Wheel FRONT/SUSPENSION/ADDRESS Remove the Sleeve Separator Remove the Outro Bearing. SEPARATOR ASSEMBLE Bearing SAVE- Grease DUST Grease Bearing Retainer SEPARATOR Grease SLEEVE Grease BRAKE DISC Overall Grease Screws Bolts Cover all bearing cavities with grease. DRIVER ACCESSORY Ⅰ Never reinstall To used bearing; Eleven To bearing You been removed, it must be replaced with To new one.
Page 183 XR250 Wheel FRONT/SUSPENSION/ADDRESS Apply Grease To Sleeve Separator. Install the separator sleeve on the right side. Ⅰ Never reinstall a used bearing; once a bearing has been removed, it must be replaced with a new one. Install a new shoulder bearing the right side with its sealed side facing outwards.
Page 184 XR250 Wheel FRONT/SUSPENSION/ADDRESS Bolts Install the cover and tighten the screws firmly. Balance the Wheel Note • the Balance of the wheel should checked when the Pull Is mounted again. balance • For optimal balance, the tire mark (painted point near on the tyre flank) should be located the valve stem.
Page 185 XR250 Wheel FRONT/SUSPENSION/ADDRESS Collar Apply grease to the lip duster. new left Install the dust guards on the left side of the wheel hub. Install the side collar on the left wheel hub. Overall Align Install speedometer gear retainer on the wheel hub by aligning retainer tabs with the notches.
Page 186 XR250 Wheel FRONT/SUSPENSION/ADDRESS WHEEL SPEEDOMETER GEARBOX Installation Clean the seat surfaces of the shaft supports and each leg of the fork. Install the wheel assembly on the legs of the fork so that the brake disc is placed between the pads taking care to damage them.
Page 187 XR250 Wheel FRONT/SUSPENSION/ADDRESS Bolts Remove the bolts the brake caliper and mounting from clamp. Remove the front wheel (page 13-3). Note Do not operate the front brake lever after you have removed the front wheel so as not to hinder the rear mounting of the brake disc between pads.
Page 188 XR250 Wheel FRONT/SUSPENSION/ADDRESS FORK COVER/ Remove the fork cover and O-ring from the fork tube. SPACER TORICO RING Remove the spacer and spring seat. fork cover is under spring pressure. Be careful when removing it and use eye and face protection. SPRING SEAT Spring Remove the spring from the fork.
Page 189 XR250 Wheel FRONT/SUSPENSION/ADDRESS Overall Remove the dust guard from the fork slide. LIMITING RING Remove the limiting ring from the fork slide slot. Ⅰ Do not scratch the sliding surface of the fork tube. Note Check Fork that the fork tube moves smoothly on the fork slide.
Page 190 XR250 Wheel FRONT/SUSPENSION/ADDRESS Note the hub Do not remove from the fork tube, unless it needs to replaced with a new one. Carefully remove the tube hub from the fork by twisting the groove through a screwdriver until the bushing can be removed by hand.
Page 191 XR250 Wheel FRONT/SUSPENSION/ADDRESS Inspect Visually the Sliding the Bushings Tube the Fork. Bushing SUPPORT RING Replace bushings if they have excessive scratches streaks, Teflon worn so that copper surfaces appear on more than 3/4 of the total surface area. Check the support ring; replace it if it has any distortion at the points shown.
Page 192 XR250 Wheel FRONT/SUSPENSION/ADDRESS OIL RETENTION Install the sliding bushing and support ring on the fork tube. Apply fork oil to the lip of the new oil retainer. Insert the new retainer into the fork tube with the brand side facing up. Bushing Sliding Ring Support Tube PISTON the Fork...
Page 193 XR250 Wheel FRONT/SUSPENSION/ADDRESS LIMITING RING Install the limiting ring inside the slot on the fork slide. Body Drive Push the new retainer into the fork tube until the limiting ring groove is visible, using the special tool. Overall Tools: Fork retainer impeller body 07947-KA50100 Accessory...
Page 194 XR250 Wheel FRONT/SUSPENSION/ADDRESS FORK SPRING Install the fork spring with the tip of the coils more together facing down into the fork tube. O-Ring Upper CAP Apply fork oil to the O-ring and install it on the fork cover. Install the Lid the Fork Within Tube the Fork. Note Tighten the fork cover after installation of the fork tube inside the fork bridge.
Page 195 XR250 Wheel FRONT/SUSPENSION/ADDRESS LOWER BRIDGE FIXING BOLTS Tighten the bridge locking bolts lower than the specified torque. TIGHTEN TO: 32 N.m(3.2 kg.m) Pull the dust protectors to the bottom of the steering column and tighten the clamp screw. Install the front fender (page 2-4). Tighten the upper bridge bolts to the specified torque.
Page 196 XR250 Wheel FRONT/SUSPENSION/ADDRESS BAND CLAMPS Handlebar Disassembly Remove the belt clamps from the cables. Remove right and left rearview mirrors. REARVIEW MIRRORS Disconnect the front brake light switch connectors from the switch. FRONT BRAKE LIGHT SWITCH CONNECTORS MASTER CYLINDER BOLTS Remove the bolts, master cylinder hole, and master Cylinder.
Page 197 XR250 Wheel FRONT/SUSPENSION/ADDRESS INTERUPTOR SCREWS Remove the screws from the right handlebar switch. Remove the switch from the right handlebar. LEVER/CLUTCH SUPPORT SCREWS Disconnect the clutch switch connectors. Remove the screws, clutch lever hole and bracket. HANDLEBAR INTERUPTOR CLUTCH SWITCH CONNECTORS Remove the screws and switch from the left handlebar.
Page 198 Remove the throttle handle from the handlebars (p. 13-20). Remove the throttle handle. Apply Adhesive Honda Bond A to the Surface Internal the Handle Accelerator a the Surface Clean Tube Accelerator. Wait 3 to 5 minutes and install the handle.
Page 199 XR250 Wheel FRONT/SUSPENSION/ADDRESS PUNCH MARKS Install the handlebars and top brackets with their forward- facing punch marks. Temporarily tighten the allen bolts on the top bracket. Loosen the allen bolts on the top bracket and align the punch marks on handlebars with the slits on handlebar brackets.
Page 200 XR250 Wheel FRONT/SUSPENSION/ADDRESS MASTER CYLINDER SUPPORT Install the master cylinder and stand with the "UP" mark facing upwards. Align the end of the master cylinder with the punch mark the handlebars by first tightening the top bolt, then tighten the lower bolt to the specified torque. TIGHTEN TO: 12 N.m (1.2 kg.m) ALIGN MARK "...
Page 201 XR250 Wheel FRONT/SUSPENSION/ADDRESS Switch Install the fixing screws and tighten the screw on the front first and then the rear screw. Screws SCREW SUPPORT Install the clutch lever hole and bracket on the handlebars. Align the end of the clutch lever hole with the punch mark on the handlebars and tighten the top screw, then tighten the bottom screw.
Page 202 XR250 Wheel FRONT/SUSPENSION/ADDRESS INSTRUMENTS Remove the bolts from the top table and front turn signals. Remove the flashers from flashers. Remove the bolts and the combined instrument (page 19- INTERMITTENT CONNECTED BOLTS Remove the lid. COLUMN SOCKET Remove the nut from the steering column using the special tool.
Page 203 XR250 Wheel FRONT/SUSPENSION/ADDRESS TOP CLAMP lift the upper bridge. KEY WITH STEERING COLUMN SOCKET Remove the adjustment nut from the steering column using the special tool. Tool: column floppy wrench 07916-KA50100 DUST ADJUSTMENT NUT Remove the top dust guard. INTERNAL TRACK OF THE TOP BEARING Hold the steering column with your hand and remove the inner track of the top bearing and the top bearing.
Page 204 XR250 Wheel FRONT/SUSPENSION/ADDRESS LOWER BEARING Remove the direction column from the steering head. Check the bottom bearing, internal and external tracks for wear or damage. STEERING COLUMN ACCESSORY IMPELLER BEARING TRACK REPLACEMENT Note Always replace bearings and tracks as a set. EXTERNAL OUTER TRACK TRACK OF THE...
Page 205 XR250 Wheel FRONT/SUSPENSION/ADDRESS Drive Accessory Press the new outer track of the top bearing inside the head tube using the following tools. Tools: Impeller 07749-0010000 Accessory, 42 x 47 mm 07746-0010300 EXTERNAL TRACK OF THE TOP BEARING OUTER TRACK OF THE LOWER BEARING Press the new outer track of the bottom bearing inside the head tube using the following tools.
Page 206 XR250 Wheel FRONT/SUSPENSION/ADDRESS LOWER BEARING Apply grease to the lower bearing of the steering column. Install the new bottom bearing in the steering column. Install the steering column in the head tube. Column Steering Bearing Upper Apply grease to the new top bearing of the steering column. Install the top bearing.
Page 207 XR250 Wheel FRONT/SUSPENSION/ADDRESS STEERING COLUMN SOCKET Tighten the steering column adjustment nut to the specified torque. Tool: Steering column floppy wrench 07916-KA50100 TIGHTENING TORQUE: 28 N.m (2.8 kg.m) ADJUSTMENT NUT Rotate the steering column to the right and left, from one end outro, at least 5 times until the bearings settle.
Page 208 XR250 Wheel FRONT/SUSPENSION/ADDRESS STEERING COLUMN NUT Temporarily install the front fork. Install the washer and steering column. Tighten the column nut to the specified torque using the special tool. Tool: Locking wrench of the steering column 07716-0020400 TIGHTENING TORQUE: 103 N.m (10.3 kg.m) Make sure the steering column moves smoothly, Washer without play or effort.
Page 209 XR250 Wheel FRONT/SUSPENSION/ADDRESS Adjustment Saddle Height Removal Note • You Can adjust the Saddle height through the procedure below: • Positions the Saddle height can be adjusted in the High (HS Bolts type) or Low (LS type) positions. • there are two types of side support for the High (HS type) PIVOT BOLT and Low (LS type) adjustment positions, respectively.
Page 210 XR250 Wheel FRONT/SUSPENSION/ADDRESS 13. Install the Parts Removed. BOLT/NUT BETWEEN THE TIGHTEN TO: Cushion ARM AND THE Nut between the shock arm and shock stem N.m (4.4 kg.m) OSCILLATING ARM Nut between the shock arm swing arm 78 N.m (7.8 kg.m) Shock lower fixing bolt...
Page 211 XR250 Wheel FRONT/SUSPENSION/ADDRESS NOTES 13-35...
Page 212 • the Balance of the wheels directly affects the stability, driving and Total safety of the motorcycle. • When performing services on the rear wheel, oscillating arm or shock, rest the motorcycle firmly using a crane or something. Honda • Suspension Use only Original replacement bolts and Nuts on suspension pivots and mounting Points.
Page 213 XR250 REAR WHEEL/SUSPENSION 54 N.m (5.4 kg.m) 88 N.m (8.8 kg.m) 44 N.m (4.4 kg.m) 44 N.m (4.4 kg.m) 78 N.m (7.8 kg.m) 88 N.m (8.8 kg.m) 14-0...
Page 214 XR250 Wheel REAR/SUSPENSION Tools 07746-0050500 Bearing extractor head, 17 mm Bearing extractor shaft 07746-0050100 Drive 07749-0010000 Pilot, 17 mm 07746-0040400 Accessory, 42x47 mm 07746-0010300 Accessory, 24x26 mm 07746-0010700 Pilot, 20 mm 07746-0040500 Root wrench C, 5.8x6.1 mm 07701-0020300 Bearing extractor shaft, 20 mm 07936-3710600 Bearing extractor cape 07936-3710100...
Page 215 XR250 Wheel REAR/SUSPENSION REAR WHEEL Disassembly Firmly support the motorcycle using a crane or something. Remove the rear brake adjustment nut and release the brake arm haste. BRAKE ADJUSTMENTT BRAKE ADJUSTMENT NUT/LOCK NUT Loosen the right and left adjusters of the transmission chain. Remove the nut and plate from the rear axle.
Page 216 XR250 Wheel REAR/SUSPENSION Wheel rim eccentricity Check the eccentricity of the rim by placing the wheel on a swivel bracket. Rotate the wheel slowly, and read the eccentricity using a quadrant indicator. the actual eccentricity is half the total reading of the indicator.
Page 217 XR250 Wheel REAR/SUSPENSION SHAFT EXTRACTOR HEAD Wheel bearing removal Install the bearing extractor head inside the bearing. On the opposite si, install the bearing extractor shaft and push the bearing out of the wheel hub. Tools: Extractor head, 17 mm 07746-0050500 Bearing extractor shaft 07746-0050100 Bearing...
Page 218 XR250 Wheel REAR/SUSPENSION Drive Wheel bearing installation Cover all bearing cavities with grease. Accessory Ⅰ Never reinstall an already used bearing; Eleven removed, it should be replaced with To new one. Install a new left shoulder bearing with the wheel and Grease its sealed side facing outwards.
Page 219 XR250 Wheel REAR/SUSPENSION BOLTS/NUTS/WASHERS If the sent sprocket has been removed, clean and apply fixing agent threads of the bolts of the sent flange. Install the sent sprocket and tighten the Lock bolts/nuts and washers. TIGHTEN TO: 30 N.m (3.0 kg.m) Apply grease to the lips of the new dusters, then install...
Page 220 XR250 Wheel REAR/SUSPENSION Collar Install the collar on the left side of the wheel hub. BRAKE PANEL Install the brake panel on the right side of the wheel hub. HIGHLIGHT/SLOT Installation Position the rear wheel between the swing arm, aligning the brake panel slot with the swing arm highlight.
Page 221 XR250 Wheel REAR/SUSPENSION Install the rear brake adjustment nut and connect the brake stem. Adjust the rear brake. BRAKE ROD ADJUSTMENT NUT BRAKE PANEL REAR BRAKE Disassembly Remove the rear wheel (page 14-3). Remove the rear brake panel. Inspection Measure the DIA Drum Brake ass. Springs UNASSEMBLE Note...
Page 222 XR250 Wheel REAR/SUSPENSION BRAKE ACTUATOR ARM Remove the locking bolt from brake actuator arm, nut, and then brake actuator arm. Remove the brake wear indicator plate. BOLT NUT PLATE INDICATOR WEAR Washer Remove the brake came and washer. CAME FROM THE BRAKE Remove the brake panel...
Page 223 XR250 Wheel REAR/SUSPENSION ASSEMBLE CAME FROM THE BRAKE Grease Spring WEAR INDICATOR PLATE BRAKE ACTUATOR Plate BRAKE SHOES BRAKE PANEL Install the new bushings on the brake panel. Bushi Install the washer, aligning the brake panel highlight with Washe the notch. Align 14-10...
Page 224 XR250 Wheel REAR/SUSPENSION CAME Brake Apply grease to the sliding surfaces the brake came. Install the came on the brake panel. WEAR INDICATOR PLATE Install the wear indicator plate on the came, aligning its wir groove with the wi groove of brake came.
Page 225 XR250 Wheel REAR/SUSPENSION Bolts Cushion Note • Do two types of Saddle height adjustment; High Saddle Type and Low Saddle Type. • See Pages 14-23 and 14-24 "How To adjust the saddle height." Disassembly Lift the rear wheel off the ground and place a easel or bench FENDER'S PLATE...
Page 226 XR250 Wheel REAR/SUSPENSION Inspection Visually inspect the shock for damage. Check the following: – If the damping unit has formations or leaks. – If the top junction rubber and the lower junction bushing/rubber have worn out or damaged. SPRING rubber bushing Installation BOLT AND TOP LOCK NUT Install and tighten the bolt and...
Page 227 XR250 Wheel REAR/SUSPENSION SHOCK ABSORBER DISCARD Make a mark with a center point on the shock housing to indicate the drilling center. Drilling point: 30.0 mm from the top surface. Place the shock in a plastic bag. Turn the shock back up into a mechanical screw as shown. Through the mouth of the bag, insert a pneumatic drill with a well- sharp 2 –...
Page 228 XR250 Wheel REAR/SUSPENSION Arm Cushion: Inspection Inspect dust guards, sleeves, and needle bearings. Replace if they are scratched, scratched, or with abnormal or excessive wear and tear. NEEDLE BEARING Sleeves Seals Needles Note • careful not To release the bearing needles from the shock arm shock joint pivot.
Page 229 XR250 Wheel REAR/SUSPENSION Drive SHOCK ABSOBER ARM Apply multipurpose grease to new needle bearings. NEEDLE BEARINGS Press the Bearings Needles Within Arm Cushion Until What the Extremities External the Bearings Are Level With the Edges Internal Arm Cushion. Tools: Drive 07749-0010000 Accessory, 24x26 Mm 07746-0010700...
Page 230 XR250 Wheel REAR/SUSPENSION Install the Arm Cushion the Joint e Install Each Pin Each Nut Without Tighten Completely. Cushion TIGHTEN TO: Swing arm nut to the shock joint 44 N.m (4.4 kg.m) Install the shock (page 14-14). Cushion SHANK BOLT/NUT/CHASSIS BOLTS/SLEEVES/PLATE SWING ARM Disassembly...
Page 231 XR250 Wheel REAR/SUSPENSION CHAIN guide Check the slide and chain guide for wear or damage (page 3-12). UNASSEMBLE Remove the bolts and chain guide. Remove the screws, sleeve, and slide from the chain. BOLT/SLEEVE BEARINGS Remove the following components: – Tops –...
Page 232 XR250 Wheel REAR/SUSPENSION Press the Bearings Needles Within Arm Oscillating Until What the 8.0 – 8.5 Mm Extremities External the Bearings Are Level With the Edges Internal Arm of the. Tools: Drive 07749-0010000 Accessory, 24x26 mm 07746-0010700 Pilot, 20 mm 07746-0040400 NEEDLE BEARING...
Page 233 XR250 Wheel REAR/SUSPENSION Align Install the chain slide with its highlights in the swing arm holes. TRANSMISSION CHAIN SLIDE Clean and apply locking agent to screw threads. Install and tighten the screws and sleeve firmly. BOLT/SLEEVE SWING ARM BOLT/NUT Installation Apply a thin layer of grease to the sliding surface of the swing arm pivot bolt.
Page 234 XR250 Wheel REAR/SUSPENSION BOLTS/SLEEVES/PLATE Install the transmission chain and slide in the guide. Install and tighten the bolts and porch. Install the rear wheel (page 14-10). Install the transmission chain cover and tighten the bolts. GUIDE PLATE 14-22...
Page 235 XR250 Wheel REAR/SUSPENSION Adjustment the Saddle Height Removal Note • You Can adjust the Saddle height through the procedure below: • Positions Saddle height can be adjusted the High Bolts (HS type) Low (LS type) positions. PIVOT BOLT • there Are two types of Side support for High (HS type) and Low (LS type) adjustment positions, respectively.
Page 236 XR250 Wheel REAR/SUSPENSION 13. Install the Parts Removed. TIGHTEN TO: BOLT/NUT BETWEEN THE Cushion ARM AND THE Nut between the shock arm and shock stem 44 N.m (4.4 kg.m) swing ARM Nut between the shock arm and swing arm 78 N.m (7.8 kg.m) Shock lower fixing bolt 44 N.m (4.4 kg.m) After this operation, verify the following:...
Page 237 XR250 Wheel REAR/SUSPENSION NOTES 14-25...
Page 238 15. BRAKE SYSTEM XR250 Wheel REAR/SUSPENSION 15-4 Troubleshooting RESEARCH 15-7 BRAKE CLAMP REPLACING THE BRAKE/AIR PURGE FLUID SERVICE INFORMATION General Do not let the pads or brake disc come into contact with grease. brake Contaminated disc or brake pads reduce braking force. Discard contaminated pads and clean the disc with a high-quality degreaser.
Page 239 XR250 BRAKE SYSTEM 12 N.m (1.2 kg.m) 34 N.m (3.4 kg.m) 17 N.m (1.7 kg.m) 2 N.m (0.2 kg.m) 30 N.m (3.0 kg.m) 15-0...
Page 240 XR250 Brake System TIGHTENING TORQUE VALUES Front brake bolt 34 N.m (3.4 kg.m) Front Master Cylinder Bracket Bolt12 N.m (1.2 kg.m) Front master cylinder cap screw2 N.m (0.2 kg.m) Front Brake Light Switch Screw 1 N.m (0.1 kg.m) Brake lever pivot nut6 N.m (0.6 kg.m) Brake lever pivot bolt6 N.m (0.6 kg.m) Front Brake Clamp Top Mount Bolt30 N.m (3.0 kg.m) ALOC Bolt Front Brake Caliper Bottom Mount Bolt 30 N.m (3.0 kg.m)ALOC...
Page 241 XR250 Brake System REPLACING THE BRAKE FLUID/AIR PURGE Note • After opening the hydraulic brake system, or if the brake Is Soft the system must be purged. available • When using a commercially purging system, follow the manufacturer's instructions. foreign •...
Page 242 XR250 Brake System TOP LEVEL FILLING/PURGING THE BRAKE FLUID Ⅰ Do not mix different types of fluid, they may not be compatible with each other. Fill the master cylinder with DOT 4 brake fluid up to the top- level mark. Connect a commercially available purge system to the purge valve.
Page 243 XR250 Brake System TOP LEVEL 2. Release the brake lever slowly until the purge valve closes. 3. Repeat steps 1 and 2 until there are no more bubbles in the purge hose. After fully purging, tighten the purge valve to the specified torque. TIGHTEN TO: 5 N.m (0.5 kg.m) Fill the fluid tank to the top-level molten mark with DOT 4 brake fluid.
Page 244 XR250 Brake System PAD PIN Remove the pin from the PADS. Remove the brake pads. PAD-PIN BRAKE PADS Push the brake pads against the spring of the pads, then install the pad pin cap. Tighten the pin of the pickups to the specified torque. TIGHTEN TO: 17 N.m(1.7 kg.m) Install and tighten the brake pad pin plug.
Page 245 XR250 Brake System BRAKE DISC BRAKE DISC INSPECTION Visually inspect the brake disc for damage or cracks. Measure the thickness of the brake disc with a micrometer. Replace the brake disc if the lower reading is less than the service limit.
Page 246 XR250 Brake System INTERRUPTOR BOLT Remove the screw and the front brake light switch. Remove the master cylinder guard, and the master Cylinder. Note Be careful not to damage the protector. Guard PRESSURE RING Remove the pressure ring using the special tool. Tool: Pressure ring pliers 07914-SA50001...
Page 247 XR250 Brake System Inspection Check the master cylinder and piston for scratches, scratches or other damage. Measure the inner diameter of the master Cylinder. Measure the Diameter External Piston Master. ASSEMBLE Screws FIXING PLATE Diaphragm Screw Lever Screw GOMA PROTECTOR FRONT BRAKE LIGHT SWITCH 15-9...
Page 248: 07914-Sa50001
XR250 Brake System Cylinder Master PISTON Bath the master piston and piston retainers with clean brake fluid. Install the spring and master piston inside the master Cylinder. Install the washer and pressure ring. Ⅰ of the Do not let the lips piston retainer turn outwards.
Page 249 XR250 Brake System INTERRUPTOR BOLT screw Install and tighten the front brake light switch firmly. Apply silicone-based grease to the sliding surface of the pivot bolt. Install the brake lever and pivot bolt. Install and tighten the pivot nut to the specified torque. TIGHTEN TO: Pivot Bolt6 N.m(0.6 kg.m) Pivot Nut6 N.m(0.6 kg.m)
Page 250 XR250 Brake System BRAKE CALIPER Bolts Disassembly Drain the fluid from the hydraulic brake system (page 15-3). Remove the brake pads (page 15-5). Remove the banjo bolt, O-rings and eyege from the brake hose connection. the clamp Remove the mounting bolts from and then remove and bracket as being the clamp...
Page 251 XR250 Brake System If necessary, gently apply compressed air through the fluid inlet of the clamp to remove the pistons. Place a rag under the clamp to cushion the piston drop when it is expelled. Use short air jets. Do not Place the air nozzle Too close To the fluid inlet or the pistons may be forced Out so hard that they Can cause injury.
Page 252 XR250 Brake System ASSEMBLE PROTECTOR OF THE CLAMP PAD SPRING PIN S CLAMP SUPPORT PISTON SEALING RING Overall PISTON SUPPORT PIN PROTECTOR BODY OF THE CLAMP PISTON PAD PIN PLUG BRAKE PASTILLAS PAD SPRING PAD PIN Install New Overalls New Rings Sealed the pistons in the slots sealing on the clamp.
Page 253 XR250 Brake System Support Support Install the retainer on the clamp hole. Install the guard. BODY OF THE CLAMP Inspect the rubber protectors on the clamp and hole and replace them with new ones if they are hard or damaged. Install the bracket pin guard on the clamp body.
Page 254 16. BATTERY/CHARGING SYSTEM XR250 Brake System SERVICE INFORMATION GENERAL INSTRUCTIONS explosive • the battery produces Gases. Keep it away from sparks, flames and lit cigarettes. Provide adequate ventilation when recharging or using the battery in To closed premises. acid cause •...
Page 255 BATTERY/ XR250 CHARGING SYSTEM LOAD SYSTEM DIAGRAM Alternator Y: Yellow G: Green A: Red W: White 16-0...
Page 256 XR250 BATTERY/CHARGING SYSTEM • Supplying a new battery with electrolyte will produce a certain voltage. However, for the battery to peak performance, it must always be charged. In addition, battery life increases when an initial charge is applied to it. •...
Page 257 XR250 BATTERY/CHARGING SYSTEM TROUBLESHOOTING Damaged or un-charged battery Remove the battery (page 16-4). Verify Wrong Check the battery conditions, using the • Battery With defect. recommended tester. Correct Install the battery (page 16-4). Check the battery current leak (Current Leak Wrong Test: page 16-6).
Page 258 XR250 BATTERY/CHARGING SYSTEM NEGATIVE TERMINAL (–) POSITIVE TERMINAL (+) Battery Disassembly Note • Always disconnect the Power switch, before removing or installing the battery. • Release the negative Cable (–) first, and then release the positive (+) Cable from the battery. Remove the left side cover (page 2-2).
Page 259 XR250 BATTERY/CHARGING SYSTEM Battery STRESS INSPECTION Measure battery voltage, using a commercially available digital multitester. Voltage (at 20oC): Fully charged Superior at 12.8 V Load need Inferior at 12.3 V Tool: Commercially available digital multitester BATTERY CHARGE • the battery produces explosive gases. Keep it away from sparks, flames and lit cigarettes.
Page 260 XR250 BATTERY/CHARGING SYSTEM INSPECTION OF THE LOADING SYSTEM Note When • Page inspecting the loading system, Check the components and lines of the system step by step, according fault investigation to the presented page 16-3. • If the measured circuit capacity exceeds the measuring capacity of the multitester, the multitester may be Damaged.
Page 261 XR250 BATTERY/CHARGING SYSTEM Operate the motor and heat it until it reaches its normal operating temperature. Stop the motor and connect the multitester between the of the battery. positive (+) and negative (–) terminals Note Make sure the battery is in good condition before performing this test.
Page 262 XR250 BATTERY/CHARGING SYSTEM 3P CONNECTEDR Charging circuit Note You do not need to remove the stator coil for this test performed. Measure the resistance between the 3P switch terminals. Connection: Yellow & Yellow Padron: 0.1 – 1.0 (20o) If the coil resistance is outside the specifications, replace the stator (page 10-3).
Page 263 XR250 BATTERY/CHARGING SYSTEM NOTAS 16-9...
Page 264 17. IGNITION SYSTEM XR250 BATTERY/CHARGING SYSTEM SYSTEM DIAGRAM FAULT INVESTIGATION SERVICE INFORMATION INSPECTION OF THE IGNITION SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • When performing services on the ignition system, always follow the procedures scribed in "Fault Investigation" (page 17-3), in the sequence presented. •...
Page 265 XR250 IGNITION SYSTEM SYSTEM DIAGRAM IGNITION COIL POWER CONTROL MODULE IGNITION (ICM) SPARK PLUG Bl: Black Y: Yellow G: Green A: Red W: White Bu: Blue Lg: Light green 17-0...
Page 266 XR250 Ignition System Specifications Item Specifications Spark plug Range CR8EH-9 (NGK) Opening the spark plug electros 0.8 - 0.9 mm Ignition coil peak voltage 100 V minimum Ignition pulse generator peak voltage 0.7 V minimum Mark "F" of the ignition point 8th APMS (idling) TIGHTENING TORQUE VALUES Timing hole cover6 N.m (0.6 kg.m)Apply grease to the thread...
Page 267 XR250 Ignition System TROUBLSHOOTING • Before diagnosing system failures, inspect the following: – Spark plug defect – Inadequate connection of the noise-suppressing layer or spark plug – Water penetration into the noise suppressor layer (secondary winding current leakage of the ignition coil) –...
Page 268 XR250 Ignition System 1. Incorrect connections of the peak voltage adapter. the initial voltage is normal, but no peak 2. Multitester impedance too low: less than 10 M /Vcc voltage occurs during motor operation. 3. Defect in the power switch or emergency switch. 4.
Page 269 XR250 Ignition System Inspection Ignition System MULTITESTER Digital Note in the • If there Are Sparks Spark Plug Check all connections for loose or loose or inadequate contacts, before measuring peak voltage. commercially • Use To available, recommended Digital multitester with To minimum impedance of 10 M /Vcc. •...
Page 270 XR250 Ignition System With the Curl Primary the Coil On Connected Connect the Adapter IGNITION the Tension beak o the Tips Test Testator Imrie To Earth In the PEAK VOLTAGE terminal of the Curl Primary the Coil On. ADAPTER Note Do not disconnect primary winding cables from the ignition coil.
Page 271 XR250 Ignition System 8P CONNECTEDR IGNITION PULSE GENERATOR PEAK VOLTAGE INSPECTION Note Check the compression on the cylinder and make sure that the Spark Plug Is installed correctly. Release the 8P switch from the Power Control Module (ICM). Connect the peak voltage adapter or test tips of the Imrie tester to the terminals.
Page 272 XR250 Ignition System Coil DISASSEMBLY/INSTALLATION IGNITION Remove the fuel tank (page 2-3). Release the noise-suppressing layer from the spark plug. Disconnect the ignition coil cables. Remove the two bolts, the washers, the ground terminal and the ignition coil. Install the parts in the reverse out Disassembly. Note Install the spark plug cable correctly.
Page 273 XR250 Ignition System the Point On Is Right Yes the Brand "F" In the Rotor Generator Impulses On it is Ranks With the Notch Reference In the Lid the Housing Engine Agreement With the Illustration. Bathe A New Ring O-rings With Oil Engine e Install In the Lid Hole Sync Hole Timing.
Page 274 XR250 Ignition System NOTES 17-10...
Page 275 ELECTRIC START SYSTEM SYSTEM DIAGRAM 18-9 SERVICE INFORMATION INVESTIGATION OF START-UP CLUTCH DIODE ENGINE FAILURES SERVICE INFORMATION GENERAL INSTRUCTIONS Ⅰ the engine can Before Performing services on the starter, turn Off the ignition switch . The In Otherwise, be operated suddenly, causing serious injury.
Page 276 XR250 STARTINGP SYSTEM SYSTEM DIAGRAM STARTER ENGINE START-UP MAIN SWITCH START-UP MAGNETIC SWITCH IGNITION SWITCH REAR LIGHT, INSTRUMENT BOX, 15 A BlBl/BrBl FUSMAINVE PARA THE REGULATOR SOPORTE LATERAL / RECTIFIER 10A INDICATOR BATER 12V - 6AH Í Picked up Down Y/Bl SWITCH STARTING...
Page 278 XR250 ELECTRIC START SYSTEM TROUBLESHOOTING the starter does not turn. • Check if the main fuse (10 A) is burned. á battery • Make sure the is fully charged in good condition. cable Inspect the battery fora interrupted Abnormal • Contact Inappropriate Cable the Batery To. circuit or improper contact.
Page 279 XR250 Electric Start System Comes from page 18-2 Abnormal start Measure the tension magnetic • Switch On d e f e c t iv e . switch (page 18-10). • Fuse burnt. • Faulty emergency switch. • Faulty start switch. Normal •...
Page 280 XR250 ELECTRIC START SYSTEM Engine Starter TERMINAL NUT/CABLE Disassembly Before performing services on the starter, turn off the ignition the engine can switch. Otherwise, be operated suddenly, causing serious injury. Clamp Remove the muffler(page 2-5). STARTER ENGINE Remove the terminal nut and the starter cable. the starter motor and the Remove the two locking bolts from ground wire.
Page 281 XR250 Electric Start System ARMATURE CASE Remove the back cover, socks, and o-ring. Remove the Induced the Housing Engine Start. Note Write Down the number of shims and their respective positions. O-RING SHIMS BACK COVER BEARING Inspect the bearing and the checkpoint of oil in the front door, with regard to wear or damage FRONT oil seal...
Page 282 XR250 ELECTRIC START SYSTEM Check for continuity between each collector bar and the induced shaft. there must be no continuity. Check for continuity between each insulated brush and the starter cable terminal. there must be continuity. Washer Brushes Remove the following components: –...
Page 283 XR250 Electric Start System ASSEMBLE Washer O-Ring BACK COVER shims Spring Brush carrier O-RING Induced Shims Terminal FRONT COVER STARTER ENGINE O-Ring HOUSING Shims LOCK WASHER NEEDLE BEARING DUST GUARD O-RING BRUSH CARRIER Install the brushes in the brush hole. Brush Washer BRUSH CARRIER...
Page 284 XR250 ELECTRIC START SYSTEM CASE OF MOTOR ARMATURE ALIGN Keep brushes pressed inside the brush hole. Next, install the induced one in the starter housing, through the brush hole. When installing the induced in the starter motor housing firmly in out to prevent loose, housing from attracting.
Page 285 XR250 Electric Start System STARTER ENGINE Installation Install the starter motor into the engine housing. Install the clamp and connect the ground cable and tighten the starter motor lock bolts firmly. Install the starter cable and tighten the terminal nut firmly. Firmly install the rubber guard over the starter terminal.
Page 286 XR250 ELECTRIC START SYSTEM 4P CONNECTEDR Voltage breaker magnetic start Plug the connector 4P breaker magnetic start. Place the transmission in neutral. Measure the voltage between the terminal of the cable yellow/red (+), in the connector 4P breaker magnetic to start, and the earth ( ).
Page 287 XR250 Electric Start System Inspection Diode Verify the continuity between the Diode terminals. If there is continuity, a small or resistance value will be record. Normal address: there must be continuity. Reverse direction: there should be no continuity. In case there is continuity only in one direction, this indicates that the Diode is normal.
Page 288 LIGHTS/INDICATORS/SWITCHES LOCATION OF SYSTEMS SERVICE INFORMATION BRAKE LIGHT SWITCH 19-8 TROUBLESHOOTING Clutch Switch, Neutral 19-9 REPLACEMENT OF LAMPS Panel INSTRUMENT SPEED SENSOR SERVICE INFORMATION GENERAL INSTRUCTIONS the halogenic lamp of the headlight becomes too hot while the headlight is on and remains warm for some time, after the headlight is deactivated.
Page 289 XR250 Electric Start System LIGHTS/INDICATORS/SWITCHES IGNITION SWITCH SWITCHES ON THE RIGHT Side OF THE HANDLEBARS REAR BRAKE LIGHT SWITCH BRAKE LIGHT SWITCH SWITCHES ON THE LEFT Side OF THE HANDLEBARS Clutch Switch SWITCH SIDESTAND SWITCH 18-10...
Page 290 XR250 LIGHTS/INDICATORS/INTERRUPTORES Specifications Item Specifications Lights Lighthouse High 12 V - 35 W 12 V - 35 W Rear light/brake light 12 V - 5/21 W Front steering flasher 12 V – 15 W x 2 Rear steering flasher 12 V – 15 W x 2 Light of instruments Flashing indicator High headlight indicator...
Page 291 XR250 LIGHTS/INDICATORS/INTERRUPTORES the instrument panel doesn't work Check the auxiliary fuse (15 A) and the Burnt fuse clock/hodometer fuse (10 A) in the fuse box. • Replace the Fuse. Normal Remove the 16P connector from the instrument panel and measure the voltage between connector Green Black/Brown cable...
Page 292 XR250 LIGHTS/INDICATORS/INTERRUPTORES Headlamp Replacement Retainer Light housing • the halogenic lamp of the headlight becomes too hot while the Connector headlight is on and remains warm for some time, after the headlight is deactivated. • Make sure the Lamp You cooled down before Performing services.
Page 293 XR250 LIGHTS/INDICATORS/INTERRUPTORES INSTRUMENT BOX DISASSEMBLY/INSTALLATION Remove the headlight housing(page 2-5). Remove the clamp. Disconnect the speedometer cable. SPEEDOMETER CABLE INSTRUMENT PANEL Disconnect the 16P switch from the instrument panel. Remove nuts, washers, and instrument panel from the hole. the Installation it is Performed In the out Reverse To Disassembly.
Page 294 XR250 LIGHTS/INDICATORS/INTERRUPTORES Remove the Connector 16p Box Instruments Check Yes there's Continuity Between the Connector Cable Green From the Side Wiring the Earth. Disconnect the positive (+) cable from the battery and initialize the instrument panel again. Wait a few seconds, connect the positive (+) cable of the battery and check the operation of the instrument panel.
Page 295 XR250 LIGHTS/INDICATORS/INTERRUPTORES Connectors IGNITION SWITCH Inspection Remove the front headlight housing (page 2-5). Release the power switch switches. Check for continuity between the power switch terminals, in all positions. Continuity should obey the color co shown in the table below: IGNITION SWITCH Activated IGNITION SWITCH...
Page 296 XR250 LIGHTS/INDICATORS/INTERRUPTORES Switches Side Left Handlebar Release the 9P switch from the switches on the left side of the handlebars. LIGHTING SWITCH Bl/Br R/Bl • Side 9P SWITCH OF THE LEFT THE HANDLEBAR FARO SWITCH SWITCHES ON THE LEFT SIDE OF H (High) THE HANDLEBARS L (Low)
Page 297 XR250 LIGHTS/INDICATORS/INTERRUPTORES CLUTCH INTERRUPTOR Release the 2 P switch of the clutch switch and check for continuity between the switch terminals. there should be continuity when the clutch lever is operated and there should be no continuity when the clutch lever is released. Switch Clutch NEULTRAL SWITCH Remove the transmission pinion cover (page 6-3).
Page 298 XR250 LIGHTS/INDICATORS/INTERRUPTORES 3P SIDE BRACKET SWITCH SWITCH DISASSEMBLY/INSTALLATION Release the 3P switch from the side bracket switch. Remove the bolt and switch from the side bracket. Install the side bracket switch, aligning the following: – the switch pin with the bracket hole –...
Page 299 XR250 LIGHTS/INDICATORS/INTERRUPTORES • In case the light turns on: Check for continuity between the Relay Connector Grey Cable Terminal and chassis ground. – If there is continuity, inspect for: – Inadequate connections – Faulty flasher relay. 16P CONNECTEDR – If there is no continuity, check if the Gray cable circuit is interrupted.
Page 300 XR250 LIGHTS/INDICATORS/INTERRUPTORES NOTES 19-11...
Page 301 20. ELECTRICAL DIAGRAM LIGHTS/INDICATORS/INTERRUPTORES START-UP RELAY LIGHT PANEL OF INSTRUMENTS SWITCH SWITCH SWITCH OF THE ENGINE, STARTER IGNITION SWITCH Indicator Support FROM THE FRONT PRINCIP FUSEAT 20A REAR theTERAL BRAKE BRAKE INDICATOR IDNDICATOR OF THE INDICATOR OF THE LIGHTING the Instruments L FARo High Point ad Intermittent SPEED SENSOR Battery RELE L...
Page 302 NOTES 21-14...
Page 303 21. TROUBLESHOOTING XR250 Diagram theÉCTRICO THE ENGINE DOES NOT START/ Poor DIRECTABILITY 21-4 THE ENGINE HAS NO Power LOW PERFORMANCE At LOW ROTATIONS OR IDLING ENGINE DOES NOT START/START DIFFICULT Probable causes Fuel doesn't go all the way the carburetor 1.
Page 304 21-16...
Page 305 XR250 TROUBLESHOOTIN 21-4...
Page 306 21-18...

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Summary of Contents for Honda TORNADO XR 250

Page 18: Table Of Contents

Page 163: Pilot, 15 Mm

Page 170: Pilot, 28 Mm

Page 178: 07953-Mj10200

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