![Honda XR250R (2005) [10/300] General information](/img/pdf.png)
Honda XR250R (2005) [10/300] General information
![Honda XR250R (2005) [10/300] General information](/views2/1121068/page10/bga.png)
Содержание
- Cap 1 xr400 pdf 1
- Important safety notice 1
- Alternator 3
- Brake system 3
- Cc q q 3
- Clutch kickstarter gearshift linkage 3
- Crankcase crankshaft balancer цд 3
- Cylinder head valves 3
- Cylinder piston 3
- Electrical system 3
- Engine removal installation 3
- Frame body panels exhaust system 3
- Front wheel suspension steering 3
- Fuel system 3
- General information 3
- Howto use this manual contents 3
- Lubrication 3
- Maintenance 3
- Rear wheel suspension 3
- Transmission 3
- Troubleshooting 3
- Wiring diagrams 3
- Symbols 4
- Brake dust never use an air hose or dry brush to clean brake assem blies 5
- Brake fluid 5
- Carbon monoxide if the engine must be running to do some work make sure the area is well ventilated never run the engine in an enclosed area 5
- Caution 5
- Gasoline work in a well ventilated area keep cigarettes flames or sparks away from the work area or where gasoline is stored 5
- General information 5
- General safety 5
- General safety 1 1 torque values 1 14 5
- Hot components 5
- Model identification 1 3 lubrication seal points 1 19 5
- Run the engine in an open area or with an exhaust evac uation system in an enclosed area 5
- Service rules 1 2 tools 1 18 5
- Specifications 1 4 cable harness routing 1 21 5
- Spilling fluid on painted plastic or rubber parts will damage 5
- Them place a clean shop towel over these parts whenever the system is serviced keep out of reach of children 5
- Used engine oil 5
- General information 6
- Service rules 6
- General information 7
- Model identification 7
- General information 8
- Specifications 8
- General information 9
- General information 10
- R fuel system __________________ ___________ ___ ______________ v 10
- General information 11
- P cylinder head valves 11
- General information 12
- Clutch kickstarter gearshift linkage 13
- General information 13
- General information 14
- General information 15
- P front wheel suspension steering 15
- General information 16
- General information 17
- R electrical system 17
- General information 18
- I engine 18
- Torque values 18
- General information 19
- General information 20
- General information 21
- General information 22
- General information 23
- R frame 23
- General information 24
- Lubrication seal points 24
- Cable harness routing 25
- General information 25
- General information 27
- Cap 2 3 xr400 pdf 29
- Eneral 29
- Frame body panels exhaust system 29
- Front fender 2 2 under guard 2 3 29
- Service information 29
- Service information 2 1 seat 2 2 29
- Side cover 2 2 exhaust pipe muffler 2 3 29
- Torque values 29
- Troubleshooting 29
- Troubleshooting 2 1 rear fender mud guard 2 3 29
- Frame body panels exhaust system 30
- Front fender 30
- Installation 30
- Removal 30
- Removal installation 30
- Side cover 30
- Exhaust pipe muffler 31
- Frame body panels exhaust system 31
- Installation 31
- Rear fender mud guard 31
- Removal 31
- Removal installation 31
- Under guard 31
- Frame body panels exhaust system 32
- Frame body panels exhaust system 33
- Installation 33
- Air cleaner 3 6 35
- Brake light switch 3 17 35
- Clutch system 3 17 35
- Competition maintenance 35
- Cylinder compression 3 21 35
- Decompressor system 3 12 35
- Drive chain sprocket 3 13 35
- Engine oil 3 9 35
- Engine oil filter 3 11 35
- Fuel tank 3 5 35
- Headlight aim 3 17 35
- I engine idle speed 3 13 35
- Maintenance 35
- Maintenance schedule 3 3 brake system 3 15 35
- Nuts bolts fasteners 3 20 35
- Schedule 3 4 35
- Service information 35
- Service information 3 1 drive chain guide slider 3 15 35
- Side stand 3 18 35
- Spark arrester 3 19 35
- Spark plug 3 7 35
- Specification 35
- Steering head bearings 3 21 35
- Suspension 3 19 35
- Throttle operation 3 5 35
- Valve clearance 3 8 35
- Wheels tires 3 20 35
- Maintenance 36
- Torque values 36
- Maintenance schedule 37
- ___ _________________ maintenance 37
- Aaaaaaai 38
- Competition maintenance schedule 38
- Maintenance 38
- Fuel line 39
- Fuel tank 39
- Throttle operation 39
- Air cleaner 40
- Maintenance 40
- Inspection 41
- Maintenance 41
- Reusing a spark plug 41
- Spark plug 41
- Maintenance 42
- Replacing a spark plug 42
- Valve clearance 42
- Engine oil 43
- Inspection 43
- Maintenance 43
- Maintenance 44
- Oil change 44
- Oil drain bolt and smi 44
- Engine oil filter 45
- Maintenance 45
- Decompressor system 46
- Maintenance 46
- Drive chain sprocket 47
- Engine idle speed 47
- Maintenance 47
- Maintenance 48
- Ciain slider 49
- Dhive chain slider 49
- I rake system 49
- J iain guide slider 49
- Maintenance 49
- Rrake fluid 49
- Brake pad wear 50
- Maintenance 50
- Brake light switch 51
- Lutch system 51
- Maintenance 51
- R eadlightaim 51
- Rake pedal height 51
- Maintenance 52
- Side stand 52
- Maintenance 53
- Rear suspension 53
- Ront suspension 53
- Suspension 53
- Cleaning 54
- Maintenance 54
- Nuts bolts fasteners 54
- Wheels tires 54
- Cylinder compression 55
- Maintenance 55
- Steering head bearings 55
- Maintenance 56
- Cap 4 5 6 xr400 1di2 pdf 59
- General 59
- Lubrication 59
- Oil strainer screen cleaning 4 2 oil pipes 59
- Service information 59
- Service information 4 1 oil pump 59
- Specifications 59
- Torque values 59
- Troubleshooting 59
- Troubleshooting 4 1 oil pass pipe 59
- Lubrication 60
- Oil strainer screen cleaning 60
- Disassembly 61
- Lubrication 61
- Oil pump 61
- Removal 61
- Inspection 62
- Lubrication 62
- Lubrication 63
- Assembly 64
- Lubrication 64
- Lubrication 65
- Inspection 66
- Lubrication 66
- Oil pass pipe 66
- Removal 66
- Nstallation 67
- Oil pipes 67
- Removal 67
- Inspection 68
- Installation 68
- Lubrication 68
- Fuel system 71
- Service information 71
- Fuel system 72
- Specifications 72
- Torque values 72
- Troubleshooting 72
- Air cleaner housing removal installation 73
- Cap 4 5 6 xr400 2di2 pdf 73
- Fuel system 73
- Fuel tank removal installation 73
- Installation 73
- Note_________________________________ 73
- Removal 73
- Fuel system 74
- Installation 74
- Carburetor removal disassembly 75
- Removal 75
- Remove the carburetor to the left 75
- Turn the fuel valve off place a suitable gasolline container under the drain tube and loosen the drain screw to drain the fuel loosen the carburetor insulator clamp screw and connect ing tube clamp screw 75
- Disassembly 76
- Fuelsystem 76
- Assembly 78
- Carburetor assembly installation 78
- Fuel system 78
- Fuel system 79
- Fuel system 80
- Installation 80
- Fuel system 81
- Pilot screw adjustment 81
- Fuel system 82
- Engine removauinstallation 85
- Service information 85
- Drive sprocket removal 86
- Engine removal installation 86
- Engine removal 87
- Engine removal installation 87
- Engine removal installation 88
- Engine installation 89
- Engine removal installation 89
- Drive sprocket installation 90
- Engine removal installation 90
- Cylinder head valves 92
- 11 cylinder head cover removal 7 3 cylinder head assembly 7 14 93
- Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head 93
- Camshaft removal 7 5 cylinder head cover assembly 7 18 93
- Cap 7 8 xr400 1di2 pdf 93
- Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before 93
- Cylinder head cover cylinder head installation 7 15 93
- Cylinder head disassembly 7 8 installation 7 20 93
- Cylinder head removal 7 7 cylinder head cover 93
- Cylinder head valves 93
- Disassembly 7 3 camshaft installation 7 16 93
- Engine installed in the frame 93
- General 93
- Inspection 93
- Service information 93
- Specifications 93
- This section covers maintenance of the cylinder head valves and camshaft these services can be done with the 93
- Troubleshooting 93
- Unit mm in 93
- Valve guide replacement 93
- Valve seat inspection and refacing 93
- When disassembling mark and store the disassembled parts to ensure that they are reinstalled in their original loca 93
- Cylinder head valves 94
- Torque values 94
- Troubleshooting 94
- Cylinder head cover disassembly 95
- Cylinder head cover removal 95
- Cylinder head valves 95
- Cylinder head valves 96
- Cylinder head valves 97
- F camshah removal 97
- Inspection 97
- Rocker arm and sub rocker arm 97
- Rocker arm shaft and sub rocker arm shaft inspection 97
- Camshaft inspection 98
- Cylinder head valves 98
- Cylinder head removal 99
- Cylinder head valves 99
- Cylinder head disassembly 100
- Cylinder head valves 100
- Cylinder 101
- Cylinder head inspection 101
- Valve inspection 101
- Valve spring inspection 101
- Cylinder head valves 102
- Valve guide inspection 102
- Valve guide replacement 102
- Cylinder head valves 103
- Inspection 103
- Valve seat inspection and refacing 103
- Cylinder head valves 104
- Cylinder head valves 105
- Cylinder head assembly 106
- Cylinder head valves 106
- Cylinder head installation 107
- Cylinder head valves 107
- Camshaft installation 108
- Cap 7 8 xr400 2di2 pdf 108
- Cylinder head valves 108
- Cylinder head cover assembly 110
- Cylinder head valves 110
- Cylinder head valves 111
- Cylinder head cover installation 112
- Cylinder head valves 112
- Cylinder head valves 113
- Cylinder piston 115
- Cylinder removal 8 3 cylinder installation 8 7 115
- General 115
- Service information 115
- Service information 8 1 piston removal 8 4 115
- Specifications 115
- Troubleshooting 8 2 piston installation 8 6 115
- Cylinder piston 116
- Torque values 116
- Troubleshooting 116
- Cylinder inspection 117
- Cylinder removal 117
- Cylinder piston 118
- Piston piston ring inspection 118
- Piston removal 118
- Connecting rod small end inspection 119
- Cylinder piston 119
- Cylinder piston 120
- Piston installation 120
- Piston ring installation 120
- Cylinder installation 121
- Cylinder piston 121
- Cylinder piston 122
- Cap 9 10 11 xr400 1di2 pdf 125
- Clutch installation 9 10 127
- Clutch kickstarter gearshift linkage 127
- Clutch removal 9 5 gearshift cam 9 16 127
- General 127
- Installation 127
- Installation 9 14 127
- Kickstarter assembly 127
- Primary drive gear 9 8 right crankcase cover 127
- Right crankcase cover removal 9 3 127
- Service information 127
- Service information 9 1 kickstarter removal 127
- Specifications 127
- Troubleshooting 9 2 disassembly 9 12 127
- Clutch kickstarter gearshift linkage 128
- Torque values 128
- Troubleshooting 128
- Clutch kickstarter gearshift linkage 129
- Right crankcase cover removal 129
- Clutch kickstarter gearshift linkage 130
- Right crankcase cover inspection 130
- Clutch kickstarter gearshift linkage 131
- Clutch removal 131
- Clutch inspection 132
- Clutch kickstarter gearshift linkage 132
- Clutch kickstarter gearshift linkage 133
- Clutch kickstarter gearshift linkage 134
- Primary drive gear 134
- Removal 134
- Clutch kickstarter gearshift linkage 135
- Installation 135
- Clutch installation 136
- Clutch kickstarter gearshift linkage 136
- Clutch kickstarter gearshift linkage 137
- Clutch kickstarter gearshift linkage 138
- Kickstarter removal disassembly 138
- Clutch kickstarter gearshift linkage 139
- Kickstarter inspection 139
- Clutch kickstarter gearshift linkage 140
- Kickstarter assembly installation 140
- Clutch kickstarter gearshift linkage 141
- Clutch kickstarter gearshift linkage 142
- Gearshift cam 142
- Removal 142
- Clutch kickstarter gearshift linkage 143
- Installation 143
- Right crankcase cover installation 143
- Clutch kickstarter gearshift linkage 144
- Cap 9 10 11 xr400 2di2 pdf 145
- Alternator 147
- Flywheel removal 10 3 147
- General 147
- Left crankcase cover installation 10 4 147
- Left crankcase cover removal 10 2 147
- Service information 147
- Service information 10 1 flywheel installation 10 3 147
- Torque values 147
- Alternator 148
- Enerator 148
- Left crankcase cover removal 148
- Remova 148
- Alternator 149
- Flywheel installation 149
- Flywheel removal 149
- Alternator 150
- Left crankcase cover installation 150
- Alternator 151
- 3 balancer crankshaft installation 11 9 153
- Balancer crankshaft 153
- Crankcase crankshaft balancer 153
- Crankcase separation 153
- General 153
- Removal 11 4 crankcase assembly 11 11 153
- Service information 153
- Service information 11 1 crankcase bearing 153
- Specifications 153
- Torque values 153
- Troubleshooting 11 2 replacement 11 6 153
- Crankcase crankshaft balancer 154
- Troubleshooting 154
- Crankcase separation 155
- Balancer gear inspection 157
- Crankcase crankshaft balancer 157
- Crankshaft bearing transmission bear ing inspection 157
- Crankcase bearing replacement 158
- Crankcase crankshaft balancer 158
- Crankshaft bearing replacement 158
- Transmission bearing replacement 158
- Crankcase crankshaft balancer 159
- Crankcase crankshaft balancer 160
- Balancer crankshaft installation 161
- Crankcase crankshaft balancer 161
- Crankcase crankshaft balancer 162
- Crankcase assembly 163
- Crankcase crankshaft balancer 163
- Crankcase crankshaft balancfr 164
- Cap 12 13 xr400 1di2 pdf 167
- General 167
- Installation 12 6 167
- Service information 167
- Service information 12 1 transmission inspection 12 3 167
- Specifications 167
- Transmission 167
- Transmission removal disassembly 12 3 167
- Troubleshooting 12 2 transmission assembly 167
- Transmission_________ 168
- Troubleshooting 168
- Transmission 169
- Transmission inspection 169
- Transmission removal disassembly 169
- Transmission 170
- Gearshift spindle inspection 171
- Transmission 171
- Transmission ___________________ 172
- Transmission assembly installation 172
- Transmission 173
- Transmission 174
- Front wheel suspension steering 178
- Front wh eel s uspensio n steeri ng 179
- Front wheel 13 3 steering 13 20 179
- General 179
- Service information 179
- Service information 13 1 fork 13 7 179
- Specifications 179
- Torque values 179
- Troubleshooting 13 2 speedometer 13 19 179
- Front wheel suspension steering 180
- Troubleshooting 180
- Front wheel 181
- Front wheel suspension steering 181
- Inspection 181
- Removal 181
- Disassembly 182
- Front wheel suspension steering 182
- Assembly 183
- Front wheel suspension steering 183
- Front wheel suspension steering 184
- Front wheel suspension steering 185
- Installation 185
- Removal 185
- Disassembly 186
- Front wheel suspension steering 186
- Cap 12 13 xr400 2di2 pdf 187
- Front wheel suspension steering 187
- Front wheel suspension steering 188
- Caution 189
- J lp fork 189
- Front wheel suspension steering 190
- Inspection 190
- Front wheel suspension steering 191
- Assembly 192
- Front wheel suspension steering 192
- Front wheel suspension steering 193
- Front wheel suspension steering 194
- Front wheel suspension steering 195
- Front wheel suspension steering 196
- Front wheel suspension steering 197
- Installation 197
- Removal 197
- Speedometer 197
- Front wheel suspension steering 198
- Handlebar removal 198
- Intallation 198
- Steering 198
- Front wheel suspension steering 199
- Handlebar installation 199
- Front wheel suspension steering 200
- Front wheel suspension steering 201
- Steering stem removal 201
- Front wheel suspens1on steering 202
- Steering stem bearing replacement 202
- Front wheel suspension steering 203
- Steering stem installation 203
- Front wheel suspension steering 204
- Rear wheel suspension 206
- Cap 14 xr400 1di2 pdf 207
- Item standard service limit 207
- Rear wheel suspension 207
- Service information 207
- Rear wheel suspension 208
- Torque values 208
- Troubleshooting 208
- Caution 209
- Rear wheel 209
- Rear wheel suspension 209
- Removal 209
- Disassembly 210
- Inspection 210
- Rear whee1 suspensi0n______________ 210
- Rear wheel suspension 211
- Assembly 212
- Rear wheel suspension 212
- Rear wheel suspension 213
- Installation 214
- Rear wheel suspension 214
- Rear wheel suspension 215
- Removal 215
- Shock absorber 215
- Bladder replacement 216
- Caution 216
- Disassembly 216
- Rear wheel suspension 216
- Rear wheel suspension 217
- Rear wheel suspension 218
- Damper disassembly 219
- Rear wheel suspension 219
- Piston ring replacement 220
- Rear wheel suspension 220
- Caution__________________ ______ ____ 221
- Damper 221
- Rear wheel suspension 221
- Rod disassembly 221
- Damper rod inspection 222
- Rear wheel suspens10n 222
- Rod guide case inspection 222
- Caution 223
- Damper assembly 223
- Rear wheel suspension 223
- Rear wheel suspension 224
- Cap 14 xr400 2di2 pdf 225
- Rear wheel suspension 225
- Rear wheel suspension 226
- Rear wheel suspension 227
- Rear wheel suspension 228
- Hmf ks60100 229
- Rear wheel suspension 229
- Installation 230
- Rear wheel suspension 230
- Removal 230
- Shock linkage 230
- Disassembly 231
- Inspection 231
- Rear wheel suspension 231
- Needle bearing replacement 232
- Rear wheel suspension 232
- Assembly 233
- Rear wheel suspension 233
- Spherical bearing replacement 233
- Installation 234
- Rear wheel suspension 234
- Removal 234
- Swingarm 234
- Disassembly 235
- Inspection 236
- Rear wheel suspension 236
- Rear wheel suspension 237
- Installation 239
- Rear wheel suspension 239
- Rear wheel suspension 240
- Brake system 242
- Brake system 243
- Cap 15 xr400 pdf 243
- Service information 243
- Brake system 244
- Torque values 244
- Troubleshooting 244
- Brake fluid replacement 245
- Brake fluid replacement air bleeding 245
- Brake system 245
- Air bleeding 246
- Brake system 246
- Brake pad replacement 247
- Brake system 247
- Brake system 248
- Brake disc inspection 249
- Brake system 249
- Caution 249
- Front brake caliper 249
- Removal 249
- Brake system 250
- Disassembly 250
- Brake system 251
- Inspection 251
- Assembly 252
- Brake system 252
- Brake sytem 253
- Installation 253
- Brake system 254
- Front master cylinder 254
- Removal 254
- Disassembly 255
- Inspection 255
- Tool snap ring pliers 07914 3230001 255
- Assembly 256
- Brake system 256
- Brake system 257
- Installation 257
- Tool snap ring pliers 07914 3230001 257
- Torque 9 n m 0 kgf m 6 ibf ft 257
- Brake system__________ 258
- Disassembly 258
- Rear brake caliper 258
- Removal 258
- Torque 34 nm 3 kgf m 25 ibf ft 258
- Brake system 259
- Brake system 260
- Service limit 26 9 mm 1 59 in 260
- Service limit 27 6 mm 1 65 in 260
- Brake system 261
- Brake system 262
- Installation 262
- Brake system 263
- Disassembly 263
- Rear master cylinder 263
- Removal 263
- Inspection 264
- Brake system 265
- Service limit 13 5 mm 0 49 in 265
- Service limit 14 6 mm 0 54 in 265
- 3230001 266
- Each part is ree 266
- Brake lever 267
- Brake system 267
- Installation 267
- Removal 267
- Brake system 268
- Installation 268
- Brake system 269
- Installation 269
- Electrical system 270
- Cap 16 17 18 xr400 pdf 271
- Electrical system 271
- Service information 271
- Electrical 272
- Nations 272
- Special 272
- Specifications 272
- System 272
- Torque values 272
- _____ ___________ it 272
- __________ specific 272
- Electrical system 273
- Ignition system 273
- Light does not come on when engine is running 273
- No spark at plug 273
- Troubleshooting 273
- Unusual condition probable cause check in numerical order 273
- _____ i 273
- Ac regulator connectors 274
- Ac regulator groundline 274
- Alternator 274
- Voltage too low 274
- Ignition system inspection 275
- Commercially available digital multimeter impedance 10 mq dcv minimum 276
- Connection black red terminal body ground 276
- Connection black yellow terminal body ground 276
- Electrical system 276
- Exciter coil peak voltage 276
- He kicks 276
- Hgj 0020100 with 276
- N 07hgj 0020100 with commercially available digital multimeter impedance 10 mq dcv minimum 276
- Peak voltage 100 v minimum 276
- Tool imrie diagnostic tester model 625 or ci 276
- Tool imrie diagnostic tester model 625 or peak voltage adaptor 276
- Commercially available digital multimeter impedance 10 mft dcv minimum 277
- Connection blue yellow terminal green white terminal 277
- Eak voltage 0 v minimum 277
- Electrical system 277
- Ignition pulse generator peak voltage 277
- Tool imrie diagnostic tester model 625 or peak voltage adaptor 07hgj 0020100 with 277
- Electrical system 278
- Ignition coil removal installation 278
- Ignition timing 278
- Ac regulator 279
- Alternator 279
- J i i i 279
- Installation 280
- Regulated voltage inspection 280
- Electrical system 281
- Regulated voltage 14 15 v at 5 000 min 281
- Regulated voltage too high 281
- Standard 0 1 q 20 c 68 f 281
- Standard continuity 281
- Standard no continuity 281
- Voltage not raised to regulated voltage 281
- Wire harness inspection 281
- Electrical system 282
- Headlight 282
- Removal bulb replacement 282
- Bulb replacement 285
- Electrical system 285
- License light 285
- Removal 285
- Speedometer 285
- Dk type 286
- Electrical system 286
- Handlebar switches 286
- Horn switch engine stop switch 286
- Lighting dimmer switch ed type 286
- U type 286
- Electrical system 287
- Front brake lightswitch 287
- Inspection 287
- Rear brake lightswitch 287
- Electrical system 288
- Performance test 288
- Turn signal relay 288
- Engine does not to start or is hard to start 293
- Probable cause 293
- Troubleshooting 293
- Engine lacks power 294
- Probable cause 294
- Troubleshooting 294
- Poor performance at low and idle speed 295
- Probable cause 295
- Poor handling 296
- Poor performance at high speed 296
- Probable cause 296
- Troubleshooting 296
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GENERAL INFORMATION Unit mrr ir ITEM Engine oil capacity SERVICE LIMIT at draining 1 3 liter 1 37 US qt 1 14 Imp qt at disassembly 1 7 liter 1 79 US qt 1 50 Imp qt at oil filter change Recommended engine oil Oil pump rotor STANDARD 1 4 liter 1 47 US qt 1 23 Imp qt API Service Classification SF or SG Viscosity SAE 10W 40 or 20W 50 Tip clearance 0 15 0 006 0 20 0 008 Body clearance 0 15 0 22 0 006 0 009 0 25 0 010 End clearance 0 02 0 09 0 001 0 004 0 12 0 005 r FUEL SYSTEM __________________ ___________ ___ ______________ v ITEM Carburetor identification number Main jet blow jet Jet needle clip position Pilot screw initial opening Float level Idle speed Ihrottle grip free play SPECIFICATIONS ED DK types PDG1A U type ___________ PDG1B ED DK types 132 U type 75 45 3rd groove from top 1 3 4 turns out 12 5 mm 0 49 in 1 300 100 mim rom 2 6 mm 1 12 1 4 in _