![Honda XR250R (2005) [201/300] Front wheel suspension steering](/img/pdf.png)
Honda XR250R (2005) [201/300] Front wheel suspension steering
![Honda XR250R (2005) [201/300] Front wheel suspension steering](/views2/1121068/page201/bgc9.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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FRONT WHEEL SUSPENSION STEERING Install the clutch lever bracket and holder with the punch mark on the holder up and the end of the holder aligned with the punch mark on the handlebar Install the left handlebar switch NOTE Tighten the upper bolt first then the lower bolt Align the split line of the engine stop switch with the punch mark on the handlebar Install and tighten the screw with the black cord Install the wire bands page 1 21 Adjust the decompressor cable free play page 3 12 Adjust the throttle cable free play page 3 5 STEERING STEM REMOVAL Remove the following Front wheel page 13 3 Front brake caliper page 15 7 Headlight case page 16 10 Speedometer page 13 19 Handlebar page 13 20 Bolts washers Front fender Steering stem nut Washer Fork page 13 7 Top bridge 13 23