Thorough Illustrated Honda XR250R Repair Manual 1996-2004
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Models Covered & Key Technical Specifications
- XR250R (1996-2004)
- XR250R '96 (1996)
- XR250R '97 (1997)
- XR250R After '97 (1998-2004)
- XR250R California Type (1997-2004)
Professional Workshop Service Manual & Technical Specifications
1996-2004 Honda XR250R Motorcycle Service Manual
Unlock the professional-grade technical knowledge required to maintain and overhaul your legendary 249 cm³ air-cooled 4-stroke SOHC dirt bike with the authorized 1996-2004 Honda XR250R Service Manual. This comprehensive resource provides factory-certified procedures and precision specifications, making it the primary tool for dedicated owners and professional mechanics who demand technical accuracy for this legendary machine.
Model & Component Identification
This manual provides exact locations for critical identification numbers to ensure you utilize the correct data for your specific production year:
- Frame Serial Number: Stamped on the right side of the steering head.
- Engine Serial Number: Located on the lower left side of the crankcase.
- VIN (Vehicle Identification Number): Mounted on the left side of the steering head.
- Carburetor Identification: Stamped on the right side of the body (PDG1A for standard models; PDG1C for '97+ California types).
- Color Label: Attached to the left frame tube under the seat.
Specialized System Coverage & Technical Data
Every section of this manual is designed for high-precision workflow, covering everything from routine lubrication to advanced chassis geometry.
- Engine & Valvetrain: In-depth procedures for the 4-valve SOHC single-cylinder engine. Includes critical tolerances like the intake valve clearance (0.10 mm) and exhaust valve clearance (0.12 mm), plus cylinder compression benchmarks (92-107 psi with decompressor effected).
- Fuel System & Tuning: Complete disassembly and jetting guides for the 30mm piston-valve carburetor. Includes specialized altitude and temperature correction charts to maintain optimal performance in any environment.
- Transmission & Drive: Professional service for the 6-speed constant mesh transmission and multi-plate wet clutch. Includes detailed drive chain maintenance for the D.I.D. 520VC5 or RK 520MOZ9 series (standard 30-40 mm slack).
- Advanced Suspension: Master the 41mm telescopic front forks and the nitrogen gas-filled Pro-Link rear damper. Includes exact oil capacities (477 cm³ per fork leg) and nitrogen pressure specs (142 psi for the rear damper).
- Hydraulic Braking: Full service for front and rear hydraulic single-disc systems, including master cylinder I.D. limits (FR: 11.05 mm / RR: 14.06 mm) and bleed procedures using DOT 4 fluid.
- Electrical Diagnostics: Comprehensive troubleshooting for the CDI (Capacitive Discharge Ignition) system, alternator output (0.075 kW), and lighting circuits.
The Professional Maintenance Edge
This manual includes both a Regular Service Interval schedule and a specialized Competition Maintenance Schedule for high-performance racing conditions. It covers vital torque values for critical fasteners, such as:
- Clutch Center Lock Nut: 108 N-m (80 lbf-ft)
- Cylinder Head 10mm Bolts: 39 N-m (29 lbf-ft)
- Rear Axle Nut: 93 N-m (69 lbf-ft)
- Spoke Nipples: 3.8 N-m (2.7 lbf-ft)
By utilizing the official factory-authorized procedures, you ensure that every repair performed on your Honda XR250R meets the exact standards intended by the manufacturer, maximizing trail reliability and long-term durability.
Equip your workshop with the ultimate technical authority. Click 'Add to Cart' for the 1996-2004 Honda XR250R Service Manual!
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