MOTORCYCLE SERVICE MANUAL

MODELS COVERED:

XR200R* (1984-1985)
XL250S (1978-1981)
XL250R (1982-1987)
XR250 (1979-1980)
XR250R (1981-1982, 1984-2000)
XR250L (1991-1996)
XL350R (1984-1985)
XR350R (1983-1985)

This Honda Motorcycle Manual is 536 pages.

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Notes, cautions and warnings / Torque specifications / Safety first / Special tips / Expendable supplies / Parts replacement / Serial numbers / Basic hand tools / Special tools / Tune-up and troubleshooting tools / Mechanic's tips / Off the Road rules / Safety

CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Emergency troubleshooting / Engine starting / Engine performance / Engine noises / Excessive vibration / Front suspension and steering / Brake problems

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Routine checks / pre-check pre-ride inspection / Service intervals maintenance schedule / Tires and wheels / Battery (XL series) / Periodic lubrication / Engine oil change / Oil filter replacement / Fork oil change / Swing arm lubrication / Pro-link suspension lubrication / Periodic maintenance / Drive chain adjustment / Clutch adjustment / Starter decompressor adjustment / Air filter replacement / Fuel shut off filter and valve replacement / Fuel strainer cleaning / Crankcase breather / Spark arrestor cleaning / Tune-up / Valve clearance adjustment / Compression test / Carburetor idle speed adjustment / Carburetor idle mix adjustment / Specifications

CHAPTER FOUR AND FIVE/ ENGINE
Removal installation / Cylinder head cover / Cylinder head / Valve and components / Camshaft / Camshaft chain and dampers / Cylinder / Piston, pin and rings / Ignition advance mechanism / Primary drive gear / Oil pump and oil filter screen / Oil lines and cooler / Kickstarter / Crankcase / Crankshaft and connecting rod / Balancer system / Break-in / specifications

CHAPTER SIX / CLUTCH AND TRANSMISSION
Clutch cable / External shift mechanism / 5-speed transmission / 6-speed transmission / Internal shift mechanism / specifications

CHAPTER SEVEN / FUEL AND EXHAUST SYSTEMS
Carburetor / Throttle cable / Choke cable / Fuel tank / Fuel filter / Gasoline alcohol blend test / Evaporative emission control system / Air filter / Exhaust system / specifications

CHAPTER EIGHT / ELECTRICAL SYSTEM
Charging system / Alternator rotor / Alternator stator / Voltage regulator rectifier / AC regulator kit installation (1985 XR250R) / Capacitor discharge ignition / Mechanical ignition advance mechanism / Starting difficulties / Pulse generator / Ignition coil / Lighting system / Switches / specifications

CHAPTER NINE / FRONT SUSPENSION
Front wheel / Wheel inspection / Front hub / Handlebar / Steering head and stem / Steering head bearings races / Front fork / specifications

CHAPTER TEN / REAR SUSPENSION
Rear wheel / Inspection / Rear hub / Swing arm / Dual shock absorbers / Pro-Link suspension system / Shock absorber / Pro-Link pivot arm assembly / specifications

CHAPTER ELEVEN / BRAKES
Drum brakes / Front drum brake / Front disc brake / Front brake pad replacement / Front master cylinder / Front caliper / Front brake hose replacement / Front brake disc / Bleeding the system / Rear drum brake / Brake cable (drum brake models) / specifications

SUPPLEMENT / 1990 AND LATER SERVICE INFORMATION

WIRING DIAGRAMS