Description
This 246 page, 1985-1986 Honda ATC250R Service Manual is a reproduction (by Honda) of the original out of print manual. This manual includes detailed service information, step-by-step repair instruction and maintenance specifications for Honda ATC250R ATVs.
This manual is arranged into 16 sections. Sections 1 and 2 apply to the whole ATC while sections 3 through 15 describe parts of the ATC, grouped according to location. When using this manual you will find the section you want and then turn to the table of contents on page 1 of that section. Most sections start with an assembly or system illustration, general instructions, specifications, torque values, tools and troubleshooting for the section. The subsequent pages give detailed procedures. If you don’t know the source of a problem, section 16 contains Troubleshooting information.
Some troubleshooting help you will find is how to deal with:
Clogged fuel line or fuel filler
Carburetor flooding
Faulty CDI unit
Faulty Alternator
Faulty pulse generator
Piston rings stuck
Compression leak
Faulty or clogged reed valve
Worn cylinder and piston rings
Blown cylinder head gasket
Excessively open bystarter (choke)
Starter valve stuck opened
Air leaking past intake pipe
Improper Ignition liming (CDI unit or pulse generator faulty)
The sections in this manual are organized as follows:
General Information
Maintenance
Fuel System
Engine Removal / Installation
Cylinder Head / Cylinder / Piston
Alternator
Clutch / Gearshift Linkage / Kick
Starter
Transmission / Crankshaft / Balancer
Cooling System
Front Wheel / Suspension / Steering
Rear Wheel / Drive Mechanism
Rear Suspension
Hydraulic Disc Brakes
Rear Fender / Seat / Exhaust
System
Electrical System
Troubleshooting
You will find the following torque values for the engine:
Cylinder head nut
Cylinder base nut
Clutch center lock nut
Primary drive gear bolt
Shift drum center pin
Transmission oil drain bolt
Countershaft bearing holder screw
Shift drum stopper arm bolt
Alternator rotor bolt
Drive sprocket bolt
Water pump impeller nut
Spark plug
Transmission oil check bolt
Cylinder coolant drain bolt
Water pump cover coolant drain bolt
Cylinder stud bolt
Gearshift pedal bolt
This manual also include torque values for the chassis:
Steering stem nut
Steering bearing adjustment nut
Steering bearing adjustment nut
Front fork top pinch bolt
Front fork bottom pinch bolt
Front axle
Front axle holder nut
Rear axle nut (outer)
(inner)
Rear wheel hub nut (with washer) ’85:
Rear wheel hub nut (flange nut type)
AFTER MID ’85:
Wheel nut (wheel-to-hub)
Front disc nut
Front brake caliper mounting bolt
Brake hose bolt
Bleed valve
Front master cylinder holder screw
Rear disc bolt
Rear master cylinder mounting bolt
Pad pin bolt
Rear caliper bracket bolt
Rear brake caliper mounting bolt
Parking brake attaching bolt
