Honda XR250L, XR250R, XR400R Repair Manual 1986-2004

This Haynes 2219 repair manual covers the following Honda dirt bikes:

• 1991-1996 Honda XR250L
• 1986-2004 Honda XR250R
• 1996-2004 Honda XR400R

With a Haynes manual in your toolbox, you will be able to confidently tackle most any repair, service or maintenance task on your Honda XR250L/R or XR400R. This DIY manual includes step-by-step procedures complimented by detailed photography, troubleshooting techniques and specifications. Rest assured, with the help of this expert manual you will succeed and save dollars too.

Book Excerpt: 1986-2004 Honda XR250L, XR250R, XR400R Repair Manual TUNE-UP AND ROUTINE MAINTENANCE

FRONT FORK OIL CHANGE
(Refer to illustration 27.6)

1. Although fork oil changes are not a regularly scheduled maintenance procedure, the oil should be changed if it becomes contaminated. The following steps apply to models equipped with fork drain screws. If you're working on a bike that doesn't have a drain screw, you'll need to disassemble the forks part-way to drain the oil (see Chapter 5).
2. Support the motorcycle securely upright.
3. Remove the handlebars (see Chapter 5).
4. Remove the fork cap bolts.
5. Wrap a rag around the top of the fork to catch dripping oil, and then lift out the fork spring from each fork.
6. Place a pan under the fork drain bolt and remove the drain bolt and gasket (see illustration). WARNING: Do not allow the fork oil to drip onto the tire or brake disc. If it does, wash it off with soap and water before riding the motorcycle.
7. After most of the oil has drained, slowly compress and release the forks to pump out the rest of the oil. An assistant may be needed to do this.
8. Check the drain bolt gasket for damage and replace it if necessary. Clean the threads of the drain bolt with solvent and let it dry, then reinstall the bolt and gasket, tightening it securely.
9. Pour the type and amount of fork oil listed in the Chapter 5 Specifications into the fork tube through the opening at the top. Slowly pump the forks a few times to purge air from the upper and lower chambers.

IGNITION AND ELECTRICAL SYSTEMS

ENGINE STARTS BUT MISFIRES

11. If the engine starts but misfires, make the following checks before deciding that the ignition system is at fault.
12. The ignition system must be able to produce a spark across a seven millimeter (1/4-inch) gap (minimum). A simple test fixture (see illustration) can be constructed to make sure the minimum spark gap can be jumped. Make sure the fixture electrodes are positioned seven millimeters apart.
13. Connect the spark plug wire to the protruding test fixture electrode, and then attach the fixture's alligator clip to a good engine ground.
14. Crank the engine over with the kill switch in the Run position and see if well-defined, blue sparks occur between the test fixture electrodes. If the minimum spark gap test is positive, the ignition coil is functioning properly. If the spark will not jump the gap, or if it weak (orange colored) refer to Steps 5 through 10 of this Section and perform the component checks described.

Subject: 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004 Honda XR250L, XR250R, XR400R service, maintenance, repair. ISBN-10: 1620920964 | ISBN-13: 9781620920961 | Haynes 2219