Thorough Illustrated Honda XR250R Repair Manual 1996-2004
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Sample pages from the Thorough Illustrated Honda XR250R Repair Manual 1996-2004 manual
Purchase Information
1996-2004 Honda XR250R Service Manual - Technical Specifications
- Document Number / Seller:
- 27844 / Walter Lee
- File Size:
- 59.22 MB
- File Type:
- Language:
- English
- Pages:
- 277
- Printable:
- Yes
- Estimated Download Time:
- 1.21 Minutes
- Delivery Format:
- Digital (PDF) - Instant Access
- Category:
- Motorcycle
- Brand:
- Honda
- Reviewed and Approved:
- Dec 26, 2025
Honda Models and Parts Covered in this Motorcycle Manual
- XR250R (1996-2004)
- XR250R '96 (1996)
- XR250R '97 (1997)
- XR250R After '97 (1998-2004)
- XR250R California Type (1997-2004)
Complete Manual Information
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!
Download Instructions for Honda Motorcycle Manual
Frequently Asked Questions - Honda Motorcycle Manual
What does this Honda manual cover?
This comprehensive service manual covers detailed repair procedures, maintenance schedules, troubleshooting guides, and technical specifications for Thorough Illustrated Honda XR250R Repair Manual 1996-2004. It includes information for the following models: - XR250R (1996-2004) - XR250R '96 (1996) - XR250R '97 (1997) - XR250R After '97 (1998-2004) - XR250R California Type (1997-2004).
Is this manual suitable for beginners?
Yes, this Honda manual is designed for both professional technicians and DIY enthusiasts. It includes step-by-step procedures with clear illustrations and safety guidelines for Motorcycle maintenance and repair.
What file format will I receive?
You will receive this manual as a PDF file (59.22 MB), which is compatible with all devices. The manual is fully searchable and printable for your convenience.
How quickly can I access the manual after purchase?
You'll receive instant access to your Honda Motorcycle manual immediately after payment completion. The download link is valid for 3 days, with lifetime re-download guarantee.
Are engine specifications included?
This motorcycle service manual includes detailed engine specifications, valve clearances, torque settings, and performance data specific to your Honda model.
Can I print specific sections of the manual?
Absolutely! This digital manual allows you to print any section you need, from individual pages to complete chapters, making it perfect for workshop use.
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