C M Y CM MY CY CMY K

SHOP MANUAL
XR250 TORNADO
SUPPLEMENT (2006)

00X65-KPS-001 Moto Honda da Amazônia Ltda.

TYPE CODE
• Throughout this manual, the following abbreviations are used to identify individual model.

CODE AREA TYPE

BR Brazil
2LA Latin America II
3LA Latin America III
A Few Words About Safety
Service information
The service and repair information contained in this manual is intended for use by qualified, professional technicians.
Attempting service or repairs without the proper training,tools, and equipment could cause injury to you or others. It could
also damage the vehicle or create an unsafe condition.

This manual describes the proper methods and procedures for performing service,maintenance,and repairs. Some proce-
dures require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement
part,service procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the
safe operation of the vehicle.

If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly rec-
ommended that you do not use replacement parts of inferior quality.

For Your Customer’s Safety

Proper service and maintenance are essential to the customer’s
safety and the reliability of the vehicle. Any error or oversight while WARNING
servicing a vehicle can result in faulty operation, damage to the
Improper service or repairs can create an unsafe
vehicle, or injury to others.
condition that can cause your customer or others
to be seriously hurt or killed.
For Your Safety
Because this manual is intended for the professional service techni- Follow the procedures and precautions in this
cian,we do not provide warnings about many basic shop safety manual and other service materials carefully.
practices (e.g,.Hot parts – wear gloves). If you have not received
shop safety training or do not feel confident about your knowledge
of safe servicing practice, we recommended that you do not attempt
to perform the procedures described in this manual.
WARNING
Failure to properly follow instructions and precau-
Some of the most important general service safety precautions are tions can cause you to be seriously hurt or killed.
given below. However, we cannot warn you of every conceivable
hazard that can arise in performing service and repair procedures. Follow the procedures and precautions in this
Only you can decide whether or not you should perform a given manual carefully.
task.

Important Safety Precautions

Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing
and using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the
skills required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer,drill,grind,pry or work
around pressurized air or liquids,and springs or other stored-energy components. If there is any doubt, put on eye protec-
tion.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause
severe burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or
a jack, make sure that it is always securely supported. Use jack stands.

Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise.
This will help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.
• Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of
the way.

Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful
when working around gasoline of batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never drain or store gasoline in an open container.
• Keep all cigarettes sparks and flames away from the battery and all fuel-related parts.
 24. XR250 HS/LS-6 ADDENDUM
INTRODUCTION
This addendum contains information for XR250 HS/LS-6.
Refer to XR250 HS/LS-1 SHOP MANUAL (No.62KPEAD1)
and XR250 HS/LS-3 SHOP MANUAL (62 KPEFM3) for ser-
vice procedures and data not included in this addendum.
Your safety, and the safety of others, is very important. To help
you make informed decisions we have provided safety mes-
sages and other information throughout this manual. Of
course, it is not practical or possible to warn you about all the
hazards associated with servicing this vehicle. You must use
your own good judgement.
You will find important safety information in a variety of forms
including:
• Safety Labels – on the vehicle
• Safety Messages – preceded by a safety alert symbol
and one of three signal words, DANGER, WARNING, or
CAUTION. These signal words mean:
You WILL be KILLED or SERIOUSLY HURT if
you don’t follow instructions.
You CAN be KILLED or SERIOUSLY HURT if
you don’t follow instructions.
You CAN be HURT if you don’t follow
instructions.
• Instructions – how to service this vehicle correctly and safe-
ly.
CONTENTS
MODEL IDENTIFICATION .............................................. 24-1
SPECIFICATIONS ............................................................ 24-2
TORQUE VALUES........................................................... 24-11
TOOLS............................................................................. 24-14
LUBRICATION & SEAL POINTS .................................... 24-15
CABLE & HARNESS ROUTING ..................................... 24-17
EMISSION CONTROL SYSTEMS .................................. 24-23
EMISSION CONTROL INFORMATION LABEL
(BR type only) ................................................................. 24-25
REAR COWL .................................................................. 24-26
NUMBER PLATE BRACKET .......................................... 24-26
SIDE SHROUDS ............................................................. 24-27
FRONT VISOR ................................................................ 24-27
EXHAUST SYSTEM REMOVAL/INSTALLATION ......... 24-28
MAINTENANCE SCHEDULE ......................................... 24-29
MAINTENANCE ............................................................. 24-30
PILOT SCREW ADJUSTMENT ..................................... 24-33
SECONDARY AIR SUPPLY SYSTEM ........................... 24-34
CYLINDER HEAD COVER .............................................. 24-36
REAR BRAKE DISASSEMBLY/ASSEMBLY .................. 24-38
WIRING DIAGRAM ........................................................ 24-39

As you read this manual, you will find information that is preced-
ed by a symbol. The purpose of this message is to help
prevent damage to your vehicle, other property, or the environ-
ment.

ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND

SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE
BASED ON THE LATEST PRODUCT INFORMATION AVAIL-
ABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda
Motor Co., Ltd. RESERVES THE RIGHT TO MAKE
CHANGES AT ANY TIME WITHOUT NOTICE AND WITH-
OUT INCURRING ANY OBLIGATION WHATEVER. NO
PART OF THIS PUBLICATION MAY BE REPRODUCED
WITHOUT WRITTEN PERMISSION. THIS MANUAL IS
WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC
KNOWLEDGE OF MAINTENANCE ON Honda MOTORCY-
CLES, MOTOR SCOOTERS OR ATVS.

Honda Motor Co., Ltd.

SERVICE PUBLICATION OFFICE

Date of Issue: September, 2005

© Honda Motor Co., Ltd.
 XR250 HS/LS-6 ADDENDUM

MODEL IDENTIFICATION

FRAME SERIAL NUMBER

ENGINE SERIAL NUMBER

The frame serial number is stamped on the right side of The engine serial number is stamped on the left side of
the steering head. the crankcase.

CARBURETOR IDENTIFICATION NUMBER

The carburetor identification number is stamped on the

left side of the carburetor body.

24-1
XR250 HS/LS-6 ADDENDUM

SPECIFICATIONS
GENERAL
ITEM SPECIFICATIONS
DIMENSIONS Overall length LS 2130 mm (83.9 in)
HS 2147 mm (84.5 in)
Overall width 845 mm (33.3 in)
Overall height LS 1166 mm (45.9 in)
HS 1203 mm (47.4 in)
Wheelbase LS 1416 mm (55.7 in)
HS 1427 mm (56.2 in)
Seat height LS 840 mm (33.1 in)
HS 880 mm (34.6 in)
Foot peg height LS 327 mm (12.9 in)
HS 366 mm (14.4 in)
Ground clearance LS 242 mm (9.5 in)
HS 281 mm (11.1 in)
Curb weight 143 kg (315 Ibs)
Maximum weight capacity 153 kg (337 Ibs)
FRAME Frame type Semi double cradle
Front suspension Telescopic fork
Front axle travel 220 mm (8.7 in)
Rear suspension Swingarm
Rear axle travel LS 224 mm (8.8 in)
HS 242 mm (9.5 in)
Front tire size 90/90M/C – 21 54S
Rear tire size 120/80M/C – 18 62S
Front tire brand METZELER
Rear tire brand METZELER
Front brake Hydraulic single disc
Rear brake Mechanical leading trailing
Caster angle LS 26° 9’
HS 25° 58’
Trail length LS 100 mm (3.9 in)
HS 98 mm (3.9 in)
Fuel tank capacity 11.5 liter (3.04 US gal, 2.53 lmp gal)
Fuel tank reserve capacity 3.7 liter (0.98 US gal, 0.81 lmp gal)
ENGINE Bore and stroke 73.0 x 59.5 mm (2.87 x 2.34 in)
Displacement 249.0 cm3 (15.19 cu in)
Compression ratio 9.3 : 1
Valve train Silent multi-link chain driven DOHC
Intake valve opens 10° BTDC At 1 mm (0.04 in) lift
closes 30° ABDC
Exhaust valve opens 40° BBDC
closes 0° ATDC
Lubrication system Forced pressure (wet sump)
Oil pump type Trochoid
Cooling system Air cooled
Air filtration Paper element
Cylinder arrangement Single cylinder 15° from vertical

24-2
 XR250 HS/LS-6 ADDENDUM

GENERAL (Cont’d)
ITEM SPECIFICATIONS
DRIVE TRAIN Clutch system Multi-plate, wet
Clutch operation system Mechanical type
Transmission Constant mesh, 6-speed
Primary reduction 3.100 (62/20)
Final reduction 2.923 (38/13)
Gear ratio 1st 2.769 (36/13)
2nd 1.777 (32/18)
3rd 1.333 (28/21)
4th 1.083 (26/24)
5th 0.923 (24/26)
6th 0.814 (22/27)
Gearshift pattern Left foot operated return system, 1-N-2-3-4-5-6
ELECTRICAL Ignition system DC - CDI
Starting system Electric starter motor
Charging system Triple phase output alternator
Regulator/rectifier SCR shorted/triple phase, full wave rectification
Lighting system Battery
CARBURETOR Carburetor type Piston valve type
Throttle bore 32 mm (1.3 in)

24-3
XR250 HS/LS-6 ADDENDUM

Unit: mm (in)
LUBRICATION SYSTEM
ITEM STANDARD SERVICE LIMIT
Engine oil capacity At draining 1.4 liter (1.5 US qt, 1.2 lmp qt)
At disassembly 1.8 liter (1.9 US qt, 1.6 lmp qt)
At filter change 1.5 liter (1.6 US qt, 1.3 lmp qt)
Recommended engine oil API service classification: SG or Higher
except oils labeled as energy conserv-
ing on the circular API service label
JASO T 903 standard: MA
Viscosity: SAE 10W-30
Suggested oil: Oil which Honda recom-
mends
Oil pump Tip clearance 0.15 (0.006) 0.20 (0.008)
Body clearance 0.15 – 0.21 (0.006 – 0.008) 0.25 (0.010)
Side clearance 0.02 – 0.08 (0.001 – 0.003) 0.12 (0.005)

FUEL SYSTEM
ITEM SPECIFICATIONS
Carburetor identification number BR type VEA1G
2LA type VEA1H
3LA type VEA1J
Main jet BR type # 135
2LA type # 135
3LA type # 138
Slow jet BR type # 45
2LA type # 45
3LA type # 45
Pilot screw opening See page 24-33
Float level 18.5 mm (0.73 in)
Idle speed 1,400 ± 100 min–1 (rpm)
Throttle grip free play 5 mm (3/16 in)
Pulse secondary air injection (PAIR)
control valve specified vacuum 49.3 kPa (370 mm Hg)

24-4
 XR250 HS/LS-6 ADDENDUM

Unit: mm (in)
CYLINDER HEAD/VALVE
ITEM STANDARD SERVICE LIMIT
Cylinder compression 1,128 kPa (11.5 kgf/cm ,
2

164 psi at 400 min–1 (rpm)

Cylinder head warpage 0.10 (0.004)
Camshaft Cam lobe height IN 37.00 – 37.24 (1.457 – 1.466) 36.94 (1.454)
EX 37.03 – 37.27 (1.458 – 1.467) 36.97 (1.456)
Runout 0.02 (0.0008) 0.10 (0.004)
Oil clearance 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004)
Valve and Valve clearance IN 0.12 (0.005)
valve guide EX 0.15 (0.006)
Valve stem O.D. IN 4.975 – 4.990 (0.1959 – 0.1965) 4.96 (0.195)
EX 4.955 – 4.970 (0.1951 – 0.1957) 4.94 (0.194)
Valve guide I.D. IN/EX 5.000 – 5.012 (0.1969 – 0.1973) 5.03 (0.198)
Stem-to-guide clearance IN 0.010 – 0.037 (0.0004 – 0.0015) 0.07 (0.003)
EX 0.030 – 0.057 (0.0012 – 0.0022) 0.09 (0.004)
Valve seat width IN/EX 1.0 – 1.2 (0.039 – 0.047) 2.0 (0.08)
Valve spring Free length Inner IN/EX 33.77 (1.330) 32.36 (1.274)
Outer IN/EX 36.64 (1.443) 34.84 (1.372)
Valve lifter Valve lifter O.D. IN/EX 25.978 – 25.993 (1.0228 – 1.0233) 25.97 (1.022)
Valve lifter bore I.D. IN/EX 26.010 – 26.026 (1.0240 – 1.0246) 26.06 (1.026)

24-5
XR250 HS/LS-6 ADDENDUM

Unit: mm (in)
CYLINDER/PISTON
ITEM STANDARD SERVICE LIMIT
Cylinder I.D. 73.000 – 73.010 (2.8740 – 2.8744) 73.11 (2.878)
Out of round 0.05 (0.002)
Taper 0.05 (0.002)
Warpage 0.05 (0.002)
Piston, Piston mark direction “IN” mark facing toward the intake side
piston ring Piston O.D. at 16 (0.6) from bottom 72.950 – 72.970 (2.8720 – 2.8728) 72.87 (2.869)
and piston pin
Piston pin hole I.D. 17.002 – 17.008 (0.6694 – 0.6696) 17.05 (0.671)
Piston pin O.D. 16.994 – 17.000 (0.6691 – 0.6693) 16.97 (0.668)
Connecting rod small end I.D. 17.016 – 17.034 (0.6699 – 0.6706) 17.06 (0.672)
Cylinder-to-piston clearance 0.030 – 0.060 (0.0012 – 0.0024) 0.23 (0.009)
Piston-to-piston pin clearance 0.002 – 0.014 (0.0001 – 0.0006) 0.07 (0.003)
Connecting rod-to-piston pin clearance 0.016 – 0.040 (0.0006 – 0.0016) 0.09 (0.004)
Piston ring-to-ring Top 0.015 – 0.05 (0.0006 – 0.002) 0.12 (0.005)
groove clearance Second 0.015 – 0.05 (0.0006 – 0.002) 0.12 (0.005)
Piston ring end gap Top 0.15 – 0.30 (0.006 – 0.012) 0.30 (0.012)
Second 0.30 – 0.45 (0.012 – 0.018) 0.45 (0.018)
Oil (side rail) 0.20 – 0.70 (0.008 – 0.028) 0.86 (0.034)
Piston ring mark direction Top/second “N” mark side facing up

Unit: mm (in)
CLUTCH/GEARSHIFT LINKAGE
ITEM STANDARD SERVICE LIMIT
Clutch Lever free play 10 – 20 (3/8 – 3/16)
Spring free length 35.6 (1.40) 44.7 (1.76)
Disc thickness 2.92 – 3.08 (0.115 – 0.121) 2.69 (0.106)
Plate warpage 0.30 (0.012)
Outer I.D. 25.000 – 25.021 (0.9843 – 0.9851) 25.04 (0.986)
Outer guide I.D. 19.990 – 20.010 (0.7870 – 0.7878) 22.05 (0.868)
O.D. 24.959 – 24.980 (0.9826 – 0.9835) 27.90 (1.098)
Mainshaft O.D. at clutch outer guide 19.959 – 19.980 (0.7858 – 0.7866) 21.91 (0.863)

24-6
 XR250 HS/LS-6 ADDENDUM

Unit: mm (in)
ALTERNATOR/STARTER CLUTCH
ITEM STANDARD SERVICE LIMIT
Starter driven gear boss O.D. 45.660 – 45.673 (1.7976 – 1.7981) 45.63 (1.796)

Unit: mm (in)
TRANSMISSION
ITEM STANDARD SERVICE LIMIT
Transmission Gear I.D. M5 20.000 – 20.021 (0.7874 – 0.7882) 20.08 (0.791)
M6 23.000 – 23.021 (0.9055 – 0.9063) 23.07 (0.908)
C1 23.000 – 23.021 (0.9055 – 0.9063) 23.07 (0.908)
C2 25.020 – 25.041 (0.9850 – 0.9858) 25.09 (0.988)
C3 25.000 – 25.021 (0.9843 – 0.9850) 25.07 (0.987)
C4 22.000 – 22.021 (0.8661 – 0.8670) 22.07 (0.869)
Gear bushing O.D. C1 22.959 – 22.980 (0.9040 – 0.9047) 22.90 (0.902)
C2 24.979 – 25.000 (0.9834 – 0.9842) 24.90 (0.980)
Gear bushing I.D. C1 18.000 – 18.018 (0.7087 – 0.7094) 18.08 (0.712)
C2 22.000 – 22.021 (0.8661 – 0.8670) 22.08 (0.869)
Collar O.D. C3 24.959 – 24.980 (0.9827 – 0.9835) 24.90 (0.980)
M6 22.959 – 22.980 (0.9040 – 0.9047) 22.92 (0.902)
Mainshaft O.D. at M5 19.959 – 19.980 (0.7858 – 0.7866) 19.91 (0.784)
Countershaft O.D. at C1 17.966 – 17.984 (0.7073 – 0.7080) 17.91 (0.705)
at C2, C4 21.959 – 21.980 (0.8645 – 0.8653) 21.91 (0.863)
Gear-to-bushing clearance 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004)
Gear-to-collar clearance 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004)
Gear bushing-to-shaft C1 0.016 – 0.052 (0.0006 – 0.0020) 0.10 (0.004)
clearance C2 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004)
Gear-to-mainshaft clearance at M5 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004)
Gear-to-countershaft
at C4 0.020 – 0.062 (0.0008 – 0.0024) 0.10 (0.004)
clearance
Shift fork, Shift fork I.D. 13.000 – 13.021 (0.5118 – 0.5126) 13.05 (0.514)
shift fork shaft Shift fork claw thickness L 4.90 – 5.00 (0.193 – 0.197) 4.5 (0.18)
and shift drum R,C 4.93 – 5.00 (0.194 – 0.197) 4.5 (0.18)
Shift fork shaft O.D. 12.966 – 12.984 (0.5105 – 0.5112) 12.90 (0.508)
Shift drum O.D. at right end 19.959 – 19.980 (0.7858 – 0.7866) 19.90 (0.783)
Shift drum journal I.D. (R.crankcase) 20.000 – 20.033 (0.7874 – 0.7887) 20.07 (0.790)

24-7
XR250 HS/LS-6 ADDENDUM

Unit: mm (in)
CRANKSHAFT/BALANCER
ITEM STANDARD SERVICE LIMIT
Connecting rod Big end side clearance 0.05 – 0.50 (0.002 – 0.020) 0.6 (0.02)
Big end radial clearance 0 – 0.008 (0 – 0.0003) 0.05 (0.002)
Crankshaft runout 0.02 (0.0008)

Unit: mm (in)
FRONT WHEEL/SUSPENSION/STEERING
ITEM STANDARD SERVICE LIMIT
Minimum tire tread depth – To the indicator
Cold tire pressure Driver only 150 kPa (1.50 kgf/cm , 21 psi)
2
–
Driver and passenger 150 kPa (1.50 kgf/cm2, 21 psi) –
Axle runout – 0.20 (0.008)
Wheel rim runout Radial – 1.0 (0.3)
Axial – 1.0 (0.3)
Fork Spring free length 535.8 (21.1) 482.2 (19.0)
Tube runout – 0.20 (0.008)
Recommended fluid Fork fluid –
Fluid level 128 (5.0) –
Fluid capacity 586 ± 2.5 cm3 (19.8 ± 0.08 US oz,
–
20.6 ± 0.09 lmp oz)
Steering head bearing pre-load 7.8 – 12.7 N (0.8 – 1.3 kgf) –

Unit: mm (in)
REAR WHEEL/BRAKE/SUSPENSION
ITEM STANDARD SERVICE LIMIT
Minimum tire tread depth – To the indicator
Cold tire pressure Driver only 150 kPa (1.50 kgf/cm , 21 psi)
2
–
Driver and passenger 200 kPa (2.00 kgf/cm , 28 psi)
2
–
Axle runout – 0.20 (0.008)
Wheel rim runout Radial – 1.0 (0.3)
Axial – 1.0 (0.3)
Drive chain Size/link 520/104 –
Slack 20 – 30 (13/16 – 1 3/16) –
Brake Brake pedal free play 20 – 30 (13/16 – 1 3/16) –
Brake drum I.D. 130 (5.1) 131 (5.2)
Lining thickness – To the indicator

24-8
 XR250 HS/LS-6 ADDENDUM

Unit: mm (in)
HYDRAULIC BRAKE
ITEM STANDARD SERVICE LIMIT
Specified brake fluid DOT3 or DOT4 –
Brake pad wear indicator – To groove
Brake disc thickness 3.5 (0.14) 3.0 (0.12)
Brake disc runout – 0.1 (0.004)
Master cylinder I.D. 12.700 –12.743 (0.5000 – 0.5017) 12.755 (0.5022)
Master piston O.D. 12.657 –12.684 (0.4983 – 0.4994) 12.645 (0.4978)
Caliper cylinder I.D. 27.000 –27.050 (1.0630 – 1.0650) 27.060 (1.0654)
Caliper piston O.D. 26.918 –26.968 (1.0598 – 1.0617) 26.91 (1.059)

BATTERY/CHARGING SYSTM
ITEM SPECIFICATIONS
Battery Capacity 12 V – 6 Ah
Current leakage 0.1 mA max
Voltage (20°C/68°F) Fully charged Above 12.8 V
Needs charging Below 12.3 V
Charging current Normal 0.6 A/5 – 10 h
Quick 3.0 A/ 1 h max
Alternator Capacity 204 W/ 5,000 min–1 (rpm)
Charging coil resistance (20°C/68°F) 0.1 – 1.0 Ω

24-9
XR250 HS/LS-6 ADDENDUM

IGNITION SYSTEM
ITEM SPECIFICATIONS
Spark plug NGK
Standard CR8EH-9S
For extended high speed riding CR9EH-9S
Spark plug gap 0.8 – 0.9 mm (0.031 – 0.035 in)
Ignition coil primary peak voltage 100 V minimum
Ignition pulse generator peak voltage 0.7 V minimum
Ignition timing (“F” mark) 8° BTDC at idle

Unit: mm (in)
ELECTRIC SYSTEM
ITEM STANDARD SERVICE LIMIT
Starter motor brush length 12.5 (0.49) 8.5 (0.3)

LIGHT/METER/SWITCHES
ITEM SPECIFICATIONS
Bulbs Headlight (high/low beam) 12 V – 35/35 W
Tail/brake light 12 V – 5/21 W
Front turn signal light 12 V – 10 W x 2
Rear turn signal light 12 V – 10 W x 2
Instrument light LED
Turn signal indicator LED
High beam indicator LED
Neutral indicator LED
Side stand indicator LED
Fuse Main fuse 20 A
Sub fuse 10 A x 3, 15 A x 1

24-10
 XR250 HS/LS-6 ADDENDUM

TORQUE VALUES
STANDARD
TORQUE TORQUE
FASTENER TYPE FASTENER TYPE
N·m (kgf·m, lbf·ft) N·m (kgf·m, lbf·ft)
5 mm bolt and nut 5.2 (0.5, 3.8) 5 mm screw 4.2 (0.4, 3.1)
6 mm bolt and nut 10 (1.0, 7) 6 mm screw 9 (0.9, 6.6)
(Include SH flange bolt) 6 mm flange bolt and nut 12 (1.2, 9)
8 mm bolt and nut 22 (2.2, 16) (Include NSHF)
10 mm bolt and nut 34 (3.5, 25) 8 mm flange bolt and nut 27 (2.8, 20)
12 mm bolt and nut 54 (5.5, 40) 10 mm flange bolt and nut 39 (4.0, 29)
• Torque specifications listed below are for important fasteners.
• Others should be tightened to standard torque values listed above.

NOTE:
1. Apply locking agent to the threads.
2. Stake.
3. Apply oil to the threads and seating surface.
4. U-nut.
5. ALOC bolt.
6. Apply grease.

ENGINE
THREAD TORQUE
ITEM Q’TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
MAINTENANCE:
Spark plug 1 10 16 (1.6, 9)
Crankshaft hole cap 1 30 8 (0.8, 5.9) NOTE 6
Timing hole cap 1 14 10 (1.0, 7) NOTE 6
Engine oil drain bolt 1 12 30 (3.1, 22)
FUEL SYSTEM:
PAIR check valve cover bolt 2 5 5.2 (0.5, 3.8)
CYLINDER HEAD/VALVE:
Cylinder head cover bolt 3 6 12 (1.2, 9)
Camshaft holder bolt 8 6 12 (1.2, 9) NOTE 3
Cylinder head nut 4 10 45 (4.6, 33) NOTE 3
Oil path pipe upper joint bolt 1 7 12 (1.2, 9)
CLUTCH/GEARSHIFT LINKAGE:
Clutch center lock nut 1 16 108 (11.0, 80) NOTE 2, 3
Primary drive gear nut 1 16 108 (11.0, 80) NOTE 3
Shift drum stopper arm bolt 1 6 12 (1.2, 9)
ALTERNATOR/STARTER CLUTCH:
Flywheel bolt 1 12 103 (10.5, 76) NOTE 3
Starter clutch bolt 6 6 16 (1.6, 12) NOTE 1
Ignition pulse generator mounting bolt 2 5 5.2 (0.5, 3.8)
Starter mounting bolt 3 6 10 (1.0, 7)
Starter cord clamp bolt 1 6 10 (1.0, 7)
TRANSMISSION:
Mainshaft bearing setting plate bolt 2 6 12 (1.2, 9)
Shift return spring pin 1 8 24 (2.4, 18)
Oil path pipe lower joint bolt 2 8 12 (1.2, 9)
OTHER FASTENERS:
Gearshift pedal pinch bolt 1 6 12 (1.2, 9)
Neutral switch wire terminal nut 1 4 1.5 (0.2, 1.1)
Neutral switch body 1 10 12 (1.2, 9)
Drive sprocket setting plate bolt 2 6 10 (1.0, 7)
Oil pump relief valve cap 1 14 19 (1.9, 14)

24-11
XR250 HS/LS-6 ADDENDUM

FRAME
THREAD TORQUE
ITEM Q’TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
FRAME/BODY PANELS/EXHAUST SYSTEM:
Muffler band bolt 1 8 20 (2.0, 15)
Exhaust pipe joint nut 2 8 18 (1.8, 13)
Muffler mounting bolt (front) 1 8 26 (2.7, 19)
Muffler mounting nut (rear) 1 8 26 (2.7, 19)
Exhaust pipe protector 2 6 14 (1.4, 10)
Fuel cock 1 18 27 (2.8, 20)
ENGINE REMOVAL/INSTALLATION:
Front engine mounting bolt/nut 1 10 49 (5.0, 36)
Front engine hanger bracket bolt/nut 2 8 26 (2.7, 19)
Front upper engine mounting bolt/nut 1 10 49 (5.0, 36)
Front upper engine hanger bracket bolt/nut 2 8 26 (2.7, 19)
Front lower engine mounting bolt/nut 1 10 49 (5.0, 36)
Rear lower engine mounting bolt/nut 1 10 49 (5.0, 36)
Rear upper engine mounting bolt/nut 1 10 49 (5.0, 36)
Rear upper engine hanger bracket bolt/nut 2 8 26 (2.7, 19)
Upper engine mounting bolt/nut 1 10 49 (5.0, 36)
Upper engine hanger bracket bolt/nut 2 8 26 (2.7, 19)
FRONT WHEEL/SUSPENSION/STEERING:
Fork cap 2 37 22 (2.2, 16)
Fork socket bolt 2 8 20 (2.0, 15) NOTE 1
Handlebar holder bolt 4 8 24 (2.4, 17)
Steering stem nut 1 24 103 (10.5, 76)
Steering stem adjusting nut 1 26 See page 13-31
Fork top bridge pinch bolt 4 8 21 (2.1, 15)
Fork bottom bridge pinch bolt 4 8 32 (3.3, 24)
Front brake hose guide bolt 2 6 12 (1.2, 9)
Front axle bolt 1 12 59 (6.0, 44)
Front axle holder nut 4 6 12 (1.2, 9) NOTE 4
Front brake disc bolt 4 6 20 (2.0, 15) NOTE 5
Front wheel hub cover bolt 4 4 0.74 (0.08, 0.5)
Spoke 36 BC 3.2 3.7 (0.4, 2.7)
Clutch lever pivot nut 1 6 5.9 (0.6, 4.4)
REAR WHEEL/BRAKE/SUSPENSION:
Rear axle nut 1 16 88 (9.0, 65) NOTE 4
Driven sprocket nut 6 8 32 (3.3, 24) NOTE 4
Rear brake arm nut 1 6 9.8 (1.0, 7) NOTE 4
Shock absorber upper mounting nut 1 10 54 (5.5, 40) NOTE 4
Shock absorber lower mounting bolt 1 10 44 (4.5, 32) NOTE 4
Swingarm pivot bolt/nut 1 14 88 (9.0, 65) NOTE 4
Cushion arm-to-cushion connecting rod nut 1 10 44 (4.5, 32) NOTE 4
Cushion arm-to-swingarm nut 1 12 78 (8.0, 58) NOTE 4
Cushion connecting rod-to-frame nut 1 10 44 (4.5, 32) NOTE 4
Spoke 36 BC 3.2 3.7 (0.4, 2.7)
Chain slider 1 5 4.2 (0.4, 3)

24-12
 XR250 HS/LS-6 ADDENDUM

FRAME
THREAD TORQUE
ITEM Q’TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
HYDRAULIC BRAKE:
Front brake hose oil bolt 2 10 34 (3.5, 25)
Front master cylinder holder bolt 2 6 12 (1.2, 9)
Front master cylinder cover screw 2 4 1.5 (0.2, 1.1)
Front brake light switch screw 1 4 1.2 (0.1, 0.9)
Brake lever pivot nut 1 6 5.9 (0.6, 4.4)
Brake lever pivot bolt 1 6 1.0 (0.1, 0.7)
Front brake caliper upper mounting bolt 1 8 30 (3.1, 22) NOTE 5
Front brake caliper lower mounting bolt 1 8 30 (3.1, 22) NOTE 5
Front caliper pin bolt (main) 1 8 22 (2.2, 16)
Front caliper pin bolt (sub) 1 8 12.3 (1.3, 9)
Front caliper pad pin 1 10 17.2 (1.8, 13)
Front caliper pad pin plug 1 10 2.5 (0.3, 1.8)
Bleed valve 1 8 5.4 (0.6, 4.0)
OTHER FASTENERS:
Side stand pivot bolt 1 10 10 (1.0, 7)
Side stand lock nut 1 10 39 (4.0, 29) NOTE 4
Side stand switch bolt 1 6 10 (1.0, 7)
Front step bracket bolt 2 12 84 (8.6, 62)
Turn signal light mounting bolt 4 4 0.9 (0.1, 0.7)

24-13
XR250 HS/LS-6 ADDENDUM

TOOLS

DESCRIPTION TOOL NUMBER REMARKS REF.SEC.

Attachment, 24 x 26 mm 07746-0010700 14
Attachment, 32 x 35 mm 07746-0010100 13
Attachment, 37 x 40 mm 07746-0010200 12, 14
Attachment, 42 x 47 mm 07746-0010300 11, 14
Attachment, 45 x 50 mm 07946-6920100 13
Attachment, 52 x 55 mm 07746-0010400 11
Attachment, 72 x 75 mm 07746-0010600 12
Bearing remover head, 15 mm 07746-0050400 13
Bearing remover head, 17 mm 07746-0050500 14
Bearing remover shaft 07746-0050100 13, 14
Bearing remover shaft set, 12 mm 07936-1660101 12
Bearing remover head, 15 mm 07936-KC10200 11
Bearing remover shaft 07746-KC10100 11
Bearing remover shaft set 20 mm 07936-3710600 14
Bearing remover handle 07936-3710100 14
Bearing remover weight 07741-0010201 11, 12, 14
Carburetor float level gauge 07401-0010000 5
Clutch center holder 07JMB-MN50301 9
Clutch center holder 07724-0050002 9
Crankshaft assembly collar 07965-VM00100 12, 24
Crankshaft assembly shaft 07965-VM00200 12, 24
Driver 07749-0010000 11, 12, 13, 14
Driver shaft 07953-MJ10200 13
Attachment 07953-MJ10100 13
Drive chain tool set 07HMH-MR10103 3
Flywheel holder 07725-0040000 10
Flywheel puller 07733-0020001 10
Flywheel puller bar 07716-0020500 10
Fork seal driver body 07947-KA50100 13
Fork seal driver attachment 07947-KF00100 13
Peak voltage adaptor 07HGJ-0020100 17
Pilot, 12 mm 07746-0040200 12
Pilot, 15 mm 07746-0040300 13
Pilot, 17 mm 07746-0040400 11, 14
Pilot, 20 mm 07746-0040500 11, 14
Pilot, 22 mm 07746-0041000 11
Pilot, 28 mm 07746-0041100 12
Tappet hole protector 24 x 25.5 07HMG-MR70002 7
Steering stem driver 07946-4300101 13
Snap ring pliers 07914-SA50001 15
Spoke wrench C, 5.8 mm x 6.1 mm 07701-0020300 13, 14
Steering stem lock nut wrench 07916-KA50100 13
Steering stem socket wrench 07716-0020400 13
Threaded adaptor 07965-VM00300 12, 24
Universal bearing puller 07631-0010000 12
Valve guide driver 07942-MA60000 7
Valve guide reamer 07984-MA60001 7
Valve spring compressor 07757-0010000 7
Valve spring compressor attachment 07959-KM30101 7
Valve seat cutter
Seat cutter, 27.5 mm (45° IN) 07780-0010200 7
Seat cutter, 24 mm (45° EX) 07780-0010600 7
Flat cutter, 27 mm (32° IN) 07780-0013300 7
Flat cutter, 24 mm (32° EX) 07780-0012500 7
Interior cutter, 37.5 mm (60° IN) 07780-0014100 7
Interior cutter, 26 mm (60° EX) 07780-0014500 7
Cutter holder, 4.5 mm 07781-0010600 7
Pilot screw wrench 07908-4730002 23, 24

24-14
 XR250 HS/LS-6 ADDENDUM

LUBRICATION & SEAL POINTS

ENGINE
LOCATION MATERIAL REMARKS
Camshaft journals and cam lobes Molybdenum oil solution
Valve lifter outer slipper surfaces (a mixture of 1/2 engine
Valve stem (valve guide sliding surface and stem end) oil and 1/2 molybdenum
Clutch outer guide inner and outer surfaces disulfide grease)
Piston pin outer surface
Connecting rod small end inner surface
Transmission gear rotating surfaces
Transmission gear shift fork grooves
Crankshaft rolling contact area (needle bearing)
Cam chain Engine oil
Cylinder head nut threads and seating surfaces
Piston outer surface and piston pin hole
Piston rings
Cylinder bore
Clutch arm spindle
Clutch lifter pin
Clutch disc lining
Clutch center lock nut threads and seating surface
Primary drive gear nut threads and seating surface
Flywheel bolt threads and seating surface
Transmission gear teeth
Shift fork shaft
Shift drum grooves
Each bearing rotating area
Each O-ring whole surface
Crankshaft side of big end outer surface
Camshaft holder bolt threads
Each oil seal lip Multi-purpose grease
Gearshift cam plate bolt threads Locking agent
Alternator wire clamp bolt threads (inside left crankcase cover)
Ignition pulse generator bolt threads
Breather plate/mainshaft bearing set plate bolt threads
Cam chain tensioner guide/mainshaft bearing stopper bolt threads Coating width:
Starter clutch bolt threads 6.5 mm (0.26 in)
from tip
Alternator/ignition pulse generator wire grommet seating surface Liquid sealant
Cylinder head surface
Applied Portion

24-15
XR250 HS/LS-6 ADDENDUM

FRAME
LOCATION MATERIAL REMARKS

Steering head bearings Multi-purpose grease

Steering thread seal lips
Shock link needle bearings
Shock link dust seal lips
Swingarm pivot bearings
Swingarm pivot seal lips
Rear brake cam
Rear brake anchor pin sliding surface
Speedometer gear box inside
Wheels dust seal lips
Rear brake cam dust seal lips
Clutch lever pivot sliding surface
Side stand pivot sliding surface
Rear brake pedal pivot sliding surface
Throttle pipe flange groove and sliding surface
Throttle cable slider sliding area
Brake master cylinder cups DOT 3 or 4 brake fluid
Brake lever pivot sliding surface Silicone grease
Brake caliper pin sliding surface
Brake lever push rod contact surface
Brake master cylinder piston sliding surface
Brake caliper piston sliding surface
Driven sprocket bolt threads Engine oil
Fork oil seal lips Fork fluid
Handlebar grip rubber inside surface Honda bond A or
equivalent

24-16
 XR250 HS/LS-6 ADDENDUM

CABLE & HARNESS ROUTING

FRONT BRAKE HOSE

THROTTLE CABLES
CLUTCH CABLE

RIGHT FRONT TURN

SIGNAL LIGHT WIRE LEFT FRONT TURN
SIGNAL LIGHT WIRE

HEADLIGHT 3P
CONNECTOR

SPEEDOMETER
CABLE

24-17
XR250 HS/LS-6 ADDENDUM

FRONT BRAKE HOSE

AIR SUPPLY HOSE

SPEEDOMETER CABLE

THROTTLE CABLES

STARTER
MOTOR
CABLE

STARTER MOTOR CLUTCH CABLE

GROUND CABLE

24-18
 XR250 HS/LS-6 ADDENDUM

FRONT BRAKE HOSE

REGULATOR/RECTIFIER

IGNITION COIL
GROUND WIRE

SPARK PLUG WIRE

HORN WIRE

MAIN WIRE HARNESS

24-19
XR250 HS/LS-6 ADDENDUM

AIR SUCTION HOSE

VACUUM TUBE

THROTTLE CABLES

CLUTCH CABLE

REAR BRAKE LIGHT CRANKCASE CARBURETOR DRAIN TUBE

SWITCH WIRE BREATHER DRAIN TUBE

24-20
 XR250 HS/LS-6 ADDENDUM

MAIN WIRE HARNESS

NEUTRAL DIODE

IGNITION CONTROL
MODULE (ICM)
AIR VENT TUBE

GROUND CABLE STARTER RELAY SWITCH WIRE

FUEL HOSE

CARBURETOR
DRAIN TUBE

THROTTLE STOP SCREW

CONTROL KNOB SIDE STAND
SWITCH WIRE
BATTERY NEGATIVE (–) BATTERY POSITIVE (+)
TERMINAL TERMINAL

ALTERNATOR/IGNITION PULSE GENERATOR/ BATTERY

NEUTRAL SWITCH WIRE

24-21
XR250 HS/LS-6 ADDENDUM

RIGHT REAR TURN SIGNAL LIGHT WIRE

MAIN WIRE HARNESS

LEFT REAR TURN SIGNAL LIGHT WIRE

24-22
 XR250 HS/LS-6 ADDENDUM

EMISSION CONTROL SYSTEMS

This motorcycle complies with the requirements of the Air Pollution Control Program for Motorcycles and Similar Vehicles-
PROMOT (Resolution no. 297 dated 02/26/2002 of CONAMA - Environmental National Council).

POLLUTANT EMISSIONS
The combustion process produces carbon monoxide, oxides of nitrogen and hydrocarbons among other elements. Control of
hydrocarbon and oxides of nitrogen is very important because, under certain conditions, they react to form photochemical
smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic.

Moto Honda da Amazonia Ltda. utilizes lean carburetor settings and other systems to reduce carbon monoxide and hydro-
carbons.

EXHAUST EMISSION CONTROL SYSTEM

The exhaust emission control system is composed of a lean carburetor setting, and no adjustments should be made except
idle speed adjustment with the throttle stop screw. The exhaust emission control system is separate from the crankcase emis-
sion control systems.

CRANKCASE EMISSION CONTROL SYSTEM

The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere.
Blow-by gas is returned to the combustion chamber through the air cleaner and carburetor.

CARBURETOR AIR CLEANER

HOUSING

FRESH AIR

BLOW-BY GAS

24-23
XR250 HS/LS-6 ADDENDUM

EXHAUST EMISSION CONTROL SYSTEM (SECONDARY AIR SUPPLY SYSTEM)

The exhaust emission control system is composed of a lean carburetor setting, and no adjustments should be made except
idle speed adjustment with the throttle stop screw. The exhaust emission control system is separate from the crankcase emis-
sion control system.

The exhaust emission control system consists of a secondary air supply system which introduces filtered air into the exhaust
gases in the exhaust port. Fresh air is drawn into the exhaust port by the function of the PAIR (Pulse Secondary Air Injection)
control valve.

This charge of fresh air promotes burning of the unburned exhaust gases and changes a considerable amount of hydrocar-
bons and carbon monoxide into relatively harmless carbon dioxide and water vapor.

The reed valve prevents reverse air flow through the system.The PAIR control valve reacts to high intake manifold vacuum and
will cut off the supply of fresh air during engine deceleration, thereby preventing afterburn in the exhaust system.

No adjustments to the secondary air supply system should be made, although periodic inspection of the components is rec-
ommended.

PAIR CONTROL VALVE

PAIR CHECK VALVE

AIR CLEANER HOUSING

EXHAUST PORT
FRESH AIR

EXHAUST GAS

NEGATIVE PRESSURE

OXIDATION CATALYTIC CONVERTER

This motorcycle is equipped with an oxidation catalytic converter.

The oxidation catalytic converter is in the exhaust system. Through chemical reactions, it converts HC and CO in the engine’s
exhaust to carbon dioxide (CO2) and water vapor.

24-24
 XR250 HS/LS-6 ADDENDUM

NOISE EMISSION CONTROL SYSTEM

TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Local law prohibits the following acts or the causing there
of; (1) The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of
any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or deliv-
ery to the ultimate purchaser or while it is in use; (2) the use of the vehicle after such device or element of design has been
removed or rendered inoperative by any person.

AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW:
1. Removal of, or puncturing of the muffler, baffles, header pipes or any other component which conducts exhaust gases.
2. Removal of, or puncturing of any part of the intake system.
3. Lack of proper maintenance.
4. Replacing any moving parts of the vehicle, of parts of the exhaust or intake system, with parts other then those specified
by the manufacturer.

EMISSION CONTROL INFORMATION EMISSION CONTROL INFORMATION LABEL

LABEL (BR type only)

The Vehicle Emission Control Information Label is attached on the left
side of swingarm.

In order to ensure that the motorcycle complies with the regal require-
ments, check if CO and HC emissions are within the recommended lev-
els at idle speed (Resolution no. 297/02, article 16 of CONAMA) (page 24-
31).

24-25
XR250 HS/LS-6 ADDENDUM

REAR COWL SCREWS

REMOVAL/INSTALLATION
Remove the seat and side covers (page 2-2).

Remove the following:

– Bolts REAR
– Screws COWL
– Rear cowl

Installation is in the reverse order of removal. BOLT

BOLTS

NUMBER PLATE BRACKET 3P CONNECTOR

REMOVAL NUMBER
PLATE
Remove the following: BRACKET
– Seat and side covers (page 2-2)
– Rear cowl (page 24-26)

Disconnect the tail/brake light 3P connector and rear

turn signal wire connectors.
BOLTS/COLLARS/
Remove the following:
RUBBERS
– Bolts
– Collars
TURN SIGNAL WIRE CONNECTORS
– Rubbers
– Number plate bracket

DISASSEMBLY
Remove the screws, collars and tail/brake light.
Remove the bolts, collars, rubbers and turn signal TAIL/BRAKE LIGHT
lights.
Remove the screws and turn signal light brackets.

Assemble and install the removed parts in the reverse

COLLARS
order of disassembly and removal.

SCREWS

SCREWS

RUBBER
TURN SIGNAL
LIGHT BRACKET
COLLAR

BOLT

24-26
 XR250 HS/LS-6 ADDENDUM

SIDE SHROUDS
REMOVAL/INSTALLATION
SCREWS
LEFT SHROUD BOLT
Remove the following:
– Screw
– Bolt, collar and washer
– Left shroud

RIGHT SHROUD
Remove the following:
– Screw
– Bolt, collar and rubber
– Right shroud

Installation is in the reverse order of removal.

WASHER COLLAR

RUBBER
COLLAR
BOLT

FRONT VISOR
FRONT VISOR/
REMOVAL HEADLIGHT
CASE SPEED SENSOR
Remove the bolts.
Disconnect the headlight 3P connector.
Disconnect the speedometer cable. SETTING PLATE
Remove the clip, setting plate and vehicle speed sen-
sor.
Remove the front visor and headlight case.

CLIP 3P CONNECTOR
BOLTS
SPEEDOMETER CABLE

24-27
XR250 HS/LS-6 ADDENDUM

DISASSEMBLY
FRONT VISOR SCREWS
Remove the following:
– Headlight aim adjusting screw, washer, spring, nut
– Screws and headlight HEADLIGHT CASE
– Screws, and then separate the front visor and head–
light case

Assemble and install the removed parts in the reverse HEADLIGHT

order of disassembly removal.

NOTE:
After installation, adjust the headlight aim (page 3-20).

SCREWS
SPRING

WASHER
NUT
ADJUSTING
SCREW

EXHAUST SYSTEM REMOVAL/INSTALLATION

26 N·m (2.7 kgf·m,19 lbf·ft)

26 N·m (2.7 kgf·m,

19 lbf·ft)

18 N·m (1.8 kgf·m,

20 N·m (2.0 kgf·m, 15 lbt·ft) 13 lbf·ft)

14 N·m (1.4 kgf·m, 10 lbt·ft)

24-28
 XR250 HS/LS-6 ADDENDUM

MAINTENANCE SCHEDULE

NOTE: 1. Service more frequently when ridden in unusually wet or dusty areas.
2. Service more frequently when riding in rain or at full throttle.
3. Change every year or at each odometer interval, whichever comes first.
4. Check the oil level daily before riding the motorcycle and add the recommended oil, if necessary.
5. Service more frequently when riding OFF-ROAD.
6. Replace every 2 years, or at indicated odometer interval, whichever comes first. Replacement requires mechanical skill.

24-29
XR250 HS/LS-6 ADDENDUM

MAINTENANCE
FRAME FIN
AIR CLEANER
REMOVAL/INSTALLATION

Remove the air cleaner element assembly (page 3-6).

Remove the air cleaner element A and B.

Install the air Install the air cleaner element B to the setting frame.
cleaner element B
under the setting
frame fin.
Align the setting Install the air cleaner element A to the setting frame.
frame fin with the
valley of the air Install the air cleaner element assembly to the air
cleaner element
cleaner case (page 3-6).
A.

SEETING
FRAME
ELEMENT B

ELEMENT A

CLEANING AIR CLEANER ELEMENT A

Clean the air cleaner element A and element B using

compressed air from the carburetor side, or replace
it if necessary.

Replace the elements accordance with the mainte-

nance schedule (page 24-29). CARBURETOR
SIDE
NOTE:
Don’t apply air filter oil to air cleaner element B or
cause premature air cleaner element wear perfor-
mance problems.

24-30
 XR250 HS/LS-6 ADDENDUM

EXHAUST SYSTEM (BR type only) CO/HC MEASUREMENT TOOL PROBE

EXHAUST EMISSION MEASUREMENT AT IDLE

Check the following items before inspection:

– Spark plug condition
– Air cleaner element condition
– Crankcase emission control system
– Ignition timing
60 cm
1. Place the motorcycle on its side stand. (23.6 in)
2. Connect an appropriate pipe or hose (heat-resis-
tant, chemical-resistant) to the muffler so that the
probe can be inserted by more than 60 cm (23.6 in).
Reference engine 3. Warm up the engine to operating temperature.
oil temperature: Stop and go driving for 10 minutes is sufficient.
60°C 4. Adjust the engine idle speed, if necessary.

IDLE SPEED: 1400 ± 100 min–1 (rpm)

5. Insert the probe into the muffler and measure the

carbon monoxide (CO, %) and hydrocarbon (HC,
ppm) concentration.

CO measurement at idle: Below 0.6 ± 0.2 %

HC measurement at idle: Below 250 ppm

If the CO and/or HC concentration is exist, adjust the

pilot screw (page 24-33).

24-31
XR250 HS/LS-6 ADDENDUM

SECONDARY AIR SUPPLY SYSTEM PAIR CHECK VALVE

• This model is equipped built-in secondary air sup-
ply system. The secondary air supply system is
located on the cylinder head cover.
• The secondary air supply system introduces filtered
air into exhaust gases in the exhaust port.
The fresh air is drawn into the exhaust port when-
ever there is negative pressure pulse in the exhaust CYLINDER
system. This charged fresh air promotes burning of HEAD COVER
the unburned exhaust gases and changes a consid-
erable amount of hydrocarbons and carbon monox-
ide into relatively harmless carbon dioxide and
water.

EXHAUST PORT

If the hoses show Check the air supply hose between the PAIR control AIR SUCTION HOSE PAIR CONTROL VALVE
any signs of heat valve and cylinder head cover for deterioration, dam-
damage, inspect age or loose connections. Make sure that the hose is
the PAIR check not cracked.
valve in the PAIR
check valve cover
for damage
Check the air suction hose between the air duct and
(page 24-35). PAIR control valve for deterioration, damage or loose
connections.
Make sure that the hose is not kinked, pinched or
cracked.

Check the PAIR control valve vacuum tube between

the carburetor and PAIR control valve for deteriora-
tion, damage or loose connections. VACUUM TUBE AIR SUPPLY HOSE
Make sure that the tube is not kinked, pinched or
cracked.

24-32
 XR250 HS/LS-6 ADDENDUM

PILOT SCREW ADJUSTMENT PILOT SCREW

IDLE DROP PROCEDURE

NOTE:
• The pilot screw is correctly adjusted at the factory.
As the adjustment of the pilot screw is very critical
for the emission of CO and HC gases, such an
adjustment shall be carried out very carefully.
• The pilot screw is factory pre-set. Adjustment is not
necessary unless the carburetor is overhauled or a
new pilot screw is installed.
• Use a tachometer with graduations of 50 min–1 PILOT SCREW WRENCH
(rpm) or smaller that will accurately indicate a
50 min–1 (rpm) change.

Damage to the 1. Turn the pilot screw with the pilot screw wrench
pilot screw seat clockwise until it seats lightly, then back it out to
will occur if the the specification given. This is an initial setting
pilot screw is prior to the final pilot screw adjustment.
tightened against
the seat.
TOOL: Pilot screw wrench 07908 – 4730002

INITIAL OPENING:
BR TYPE: TBD
2LA TYPE: TBD
3LA TYPE: TBD

Reference engine 2. Warm up the engine to operating temperature. THROTTLE STOP CONTROL KNOB
oil temperature: Stop and go riding for 10 minutes is sufficient.
60°C 3. Stop the engine and connect a tachometer according
to the tachometer manufacturer’s instructions.
4. Disconnect the PAIR control valve vacuum tube VACUUM PUMP
from the PAIR control valve, then install the pulg
to the vacuum tube and connect the vacuum VACUUM TUBE
pump to the PAIR control valve.
5. Apply specified vacuum to the PAIR control valve PLUG
vacuum tube more than 49.3 kPa (370 mm Hg).
6. Start the engine and adjust the idle speed with
the throttle stop control knob.

IDLE SPEED: 1,400 ± 100 min–1 (rpm)

7. Turn the pilot screw in or out slowly to obtain the

highest engine speed.
8. Lightly open the throttle 2 or 3 times, then adjust
the idle speed with the throttle stop control knob.
9. Turn the pilot screw in until the engine speed
drops by 50 min–1 (rpm).
10. Turn the pilot screw with the pilot screw wrench
counter clockwise to the final opening from the
position obtained step 9.

TOOL: Pilot screw wrench 07908 – 4730002

FINAL OPENING:
BR TYPE: 1/2 turns out
2LA TYPE: TBD
3LA TYPE: TBD

24-33
XR250 HS/LS-6 ADDENDUM

11. Disconnect the vacuum pump from the PAIR con-

trol valve then remove the plug from the PAIR
control valve vacuum tube and connect the PAIR
control valve vacuum tube to the PAIR control
valve.
12. Readjust the idle speed with the throttle stop con-
trol knob.
13. Recheck the exhaust emission measurement at
idle (page 24-31) (BR type only).

If the CO and/or HC concentration is exist, inspect

the secondary air supply system (page 24-34) (BR
type only).

SECONDARY AIR SUPPLY SYSTEM AIR SUCTION HOSE

SYSTEM INSPECTION
Start the engine and warm it up to normal operating
temperature, then stop the engine.

Disconnect the air suction hose from air cleaner case.

Check that the secondary air intake port and air suc-
tion hose are clean and free of carbon deposits.
Check the pulse secondary air injection (PAIR) check
valve if the port is carbon fouled. AIR INTAKE PORT

Disconnect the PAIR control valve vacuum tube from

the PAIR control valve and install the plug to the vac- PAIR CONTROL VALVE VACUUM PUMP
uum tube.
Connect a vacuum pump to the PAIR control valve.
VACUUM TUBE
Start the engine and open the throttle slightly to be AIR SUPPLY
certain that air is sucked in through the air suction HOSE
hose.
If the air is not drawn in, check the air suction and air
supply hoses for clogging.

With the engine running, gradually apply vacuum to

the PAIR control valve vacuum tube.
Check that the air suction hose stops drawing air, and
that the vacuum does not bleed.

SPECIFIED VACUUM: 49.3 kPa (370 mm Hg)

If the air is drawn in, or if the specified vacuum is not

maintained, install a new PAIR control valve (page 24-
35). AIR SUCTION
HOSE

PLUG

24-34
 XR250 HS/LS-6 ADDENDUM

PAIR CHECK VALVE VALVE PLATE

BOLTS
REMOVAL

Remove the following:

– Side shrouds (page 24-27)
– Fuel tank (page 2-3)

Remove the bolts and pulse secondary air injection

(PAIR) check valve cover from the cylinder head cover.
Remove the PAIR check valve and valve plate.

VALVE COVER PAIR CHECK VALVE

INSPECTION
REED
Check the reed for damage or fatigue.

Replace the PAIR check valve if the rubber seat is

cracked, deteriorated or damaged, or if there is clear-
ance between the reed and rubber seat.

RUBBER SEAT

INSTALLATION VALVE PLATE

BOLTS
Install the valve plate, PAIR check valve and cover.

Install and tighten the bolts to the specified torque.

TORQUE: 5.2 N·m (0.5 kgf·m, 3.8 lbf·ft)

PAIR CHECK VALVE VALVE COVER

PAIR CONTROL VALVE AIR SUCTION HOSE BOLT

REMOVAL/INSTALLATION
PAIR CONTROL
Remove the following: VALVE
– Side shrouds (page 24-27)
– Fuel tank (page 2-3)

Disconnect the air supply hose, vacuum tube and air

suction hose from the PAIR control valve.
Remove the bolt and PAIR control valve.

Installation is in the reverse order of removal.

VACUUM TUBE AIR SUPPLY HOSE

24-35
XR250 HS/LS-6 ADDENDUM

CYLINDER HEAD COVER AIR SUPPLY

HOSE
REMOVAL
Remove the following:
– Side shrouds (page 24-27)
– Fuel tank (page 2-3)
– Spark plug cap (page 3-7)

Disconnect the air supply hose.

Remove the cylinder head cover bolts, rubber seals
and cylinder head cover.
HEAD COVER RUBBER SEALS/BOLTS

Remove the rubber packing.

RUBBER PACKING DOWEL PIN
Remove the dowel pin and O-ring.

O-RING

INSTALLATION
Clean the mating surface of the cylinder head and
head cover.

Apply sealant to the cylinder head semi-circular

cutouts as shown.

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 XR250 HS/LS-6 ADDENDUM

Install the new rubber packing to the cylinder head

RUBBER PACKING DOWEL PIN
cover.
Install the dowel pin on the cylinder head.
Apply engine oil to a new O-ring and install it onto the
dowel pin.
Install the cylinder head cover.
O-RING

CYLINDER
HEAD COVER

Install new rubber seals onto the cylinder head cover

with its “UP” marks facing up.

RUBBER SEAL

Install and tighten the cylinder head cover bolts to the AIR SUPPLY PLUG CAP
specified torque. HOSE

TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)

Connect the air supply hose.

Connect the spark plug cap.

Install the fuel tank (page 2-3).

Install the side shrouds (page 24-27).

HEAD COVER BOLTS

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XR250 HS/LS-6 ADDENDUM

REAR BRAKE DISASSEMBLY/ASSEMBLY

BRAKE CAM

INDICATOR
PLATE

SPRINGS

PLATE

9.8 N·m (1.0 kgf·m, 7 lbf·ft)

BRAKE
SHOES

BRAKE ARM

BRAKE ARM COVER BRAKE PANEL

24-38
 XR250 HS/LS-6 ADDENDUM

WIRING DIAGRAM

24-39
 K

C M Y CM MY CY CMY

MANUAL DE TALLER
CRF230F

00X62-KPE-003

Moto Honda da Amazônia Ltda.