Honda XR200R, XL250, XR250, XL350 & XR350 1978 - 2000

Clymer Owners Service & Repair Manual

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Front Cover
Stock image only. Actual cover art may differ.
Honda XR200R, XL250, XR250, XL350 & XR350 1978 - 2000 Clymer Owners Service & Repair Manual Covers the following Models:
● Honda XR200R, 1984-1985*
● Honda XL250S, 1978-1981
● Honda XL250R, 1982-1987
● Honda XR250, 1979-1980
● Honda XR250R, 1981-1982, 1984-2000
● Honda XR250L, 1991-1996
● Honda XL350R, 1984-1985
● Honda XR350R, 1983-1985

Note: Covers 200CC through 350cc RFVC (Radial Four Valve Combustion) engines

*XR200R from 1981 - 1983 and 1986 - 1987 are covered in Clymer manual CM318-4

Contents:
QUICK REFERENCE DATA

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

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

LUBRICATION, MAINTENANCE AND TUNE-UP
Routine checks / pre-check pre-ride inspection / Service intervals maintenance schedule / Tyres 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

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

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

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

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

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

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

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

Clymer motorcycle repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.

General information on Repair Manuals

Please note that workshop manuals are usually written for models sold in a specific country. Differences in specification can exist between models sold in different countries and items such as engines can vary. Please check that the manual will cover your model before purchase and if you are unsure please contact us first.

Publisher
Clymer Publications
ISBN
0892878215
ISBN-13
9780892878215
Format
Paperback, 536 pages
Published
June 2002

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