Description
This Clymer Honda XL XR250 1978-2000 XL XR350R 1983-1985 XR 200R 1984-1985 XR250L 1991-1996 Repair Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 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) motorcycles.
1978 1979
1980 1981 1982 1983 1984 1985 1986 1987 1988 1989
1990 1991 1992 1993 1994 1995 1996 1997 1998 1999
2000
Features 536 illustrated pages.
QUICK REFERNECE DATA
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-checks / Service intervals / Tires and wheels / Battery (XL series) / Periodic lubrication / Periodic maintenance / Tune-up
CHAPTER FOUR / 1978-1983 250 CC ENGINE
Engine principles / Engine cooling / Servicing engine in frame / Engine removal/installation / Cylinder head cover / Cylinder head / Valve and valve components / Camshaft / Camshaft chain and dampers / Cylinder / Piston, piston pin and piston rings / Ignition advance mechanism / Oil pump and oil filter screen / Kickstarter / Crankcase (XL250S and XR250) / Crankcase (1982-1983 XL250R and 1981-1982 XR250R) / Crankshaft and connecting rod / Balancer system / Break-in procedure
CHAPTER FIVE / 200 TRU 350 CC RFVC ENGINES
Engine principles / Engine cooling / Servicing engine in frame / Engine removal/installation / Cylinder head cover and camshaft / Camshaft chain tensioner / Cylinder head / Valves and valve components / Cylinder / Piston, piston pin and piston rings / Primary drive gear (200-250 CC) / Primary drive gear (1985 XR350R / Primary drive gear (XL350R and 1983-1984 XR350R) / Oil pump (1984-1985 XR200R and 1984-on R250R) / Oil pump (1983 XR350R) / Oil pump (all other models) / Oil lines (dry-sump models) / Oil cooler system (1986-on XR250R) / Camshaft chain / Crankcase and crankshaft / Balancer system / Kickstarter / Break-in procedure
CHAPTER SIX / CLUTCH AND TRANSMISSION
Clutch / Clutch (XR200R, 1984-on XR250R, XL350R, XR350R) / Clutch cable replacement / External shift mechanism (all RFVC engine models) / External shift mechanism (all except RFVC engine models) / Transmissions / 5-speed transmission (XL250S, 1979-1980 XR250) / 6-speed transmission (1982-1983 XL250R, XR250R, XR200R, 1984-on XL250R, 1984-on XR250R) / 6-speed transmission and internal shift mechanism (XL350R and XR350R) / Internal shift mechanism (XL250S, XR250, 1982-1983 XL250R, 1981-1982 XR250R) / Internal shift mechanism (all other models)
CHAPTER SEVEN / FUEL AND EXHAUST SYSTEMS
Carburetor operation / Carburetor service / Throttle cable replacement / Choke cable replacement / Fuel tank (metal) / Fuel tank (plastic) / Fuel filter / Gasoline/alcohol blend test / Evaporative emission control system (1984-on California XL series only) / Air filter case / Exhaust system
CHAPTER EIGHT / ELECTRICAL SYSTEM
Charging system (XL series models) / Alternator rotor / Alternator stator / Voltage regulator/rectifier (XL series models) / AC regulator kit installation (1985 XR250R) / Capacitor discharge ignition / Mechanical ignition advance mechanism (XL250S, XR250, 1981-1982 XR250R) / Starting difficulties (1984 XL250R) / Pulse generator / Ignition coil / Lighting system / Switches / Electrical components / Fuse (XL series models)
CHAPTER NINE / FRONT SUSPENSION
Front wheel (drum brake) / Front wheel (disc brake) / Wheel inspection (all models) / Front hub / Wheels / Tire changing / Tire repairs / Handlebar / Steering head and stem (loose ball bearings) / Steering head and stem (roller bearings) / Steering head bearings races / Front fork
CHAPTER TEN / REAR SUSPENSION
Rear wheel (dual shock) / Rear wheel (pro-link) / Rear wheel inspection (all models) / Rear hub (XL250S, XL250R, XR250, 1981-1982 XR250R, XL350R) / Swing arm (dual shock) / Swing arm (Pro-Link) / Dual shock absorbers / Pro-Link suspension system / Shock absorber (Pro-Link) / Pro-Link pivot arm assembly (1982-1983 XL250R, XL250R, 1981-1982 XR250R) / Pro-Link pivot arm assembly (1984-1985 XR200R, 1984-on XR250R) / Pro-Link pivot arm assembly (1984-on XL250R, XL350R, XR350R)
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)
SUPPLEMENT / 1990 AND LATER SERVICE INFORMATION
Emergency troubleshooting / Engine starting / Routine checks / Battery (XR250L) / Periodic lubrication / Periodic maintenance / Tune-up / Engine removal/installation / Oil cooler system (XR250R) / Balancer system (XR250L) / Carburetor service / Fuel tank (metal) / Evaporative emission control system (California models) / Charging system (XR250L) / Alternator stator / Ignition system / Switches / Steering stem and head (XR250L) / Front forks (XR250R) / Fork service (XR250L) / Rear wheel / Rear hub / Swing arm and shock linkage / Shock absorber (Pro Link) / Front brake pad replacement / Front caliper / Rear brake pad replacement / Rear caliper / Rear master cylinder / Rear brake hose replacement / Rear brake disc
INDEX
WIRING DIAGRAMS
