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This motorcycle is designed and constructed as an operator only model. The seating configuration does not safely permit the carrying of a passenger. Do not exceed the vehicle capacity load. To comply with Local Laws Regulations it may be necessary to fit additional equipment.

Pay special attention to statements preceded by the Following words: Indicates a strong possibility of severe personal injury or loss of life if instructions are not followed. NOTE: Gives helpful information. This manual should be considered a permanent part of the vehicle and should remain with the vehicle when resold. Know these requirements before you ride. Always make a pre-ride inspection page warrant.

You may 8. If you are not familiar with the terrain, prevent an accident or equipment damage ride cautiously. Hidden rocks holes, or 2. Learn to ride in an uncongested off-road ravines could spell disaster.

Spark arresters and mufflers are required unfamiliar terrain. Don't modify your exhaust 3. Always obey local off-road riding laws and system.

Remember that excessive noise regulations. Obtain permission to ride on private image for motorcycling. Avoid posted areas and obey "no This motorcycle is not legally equipped trespassing" signs.

Remember 5. Ride with a friend on another motorcycle to walk an off-road motorcycle when so that you can assist each other in case of crossing public highways, roads or trouble. Familiarity with your motorcycle is critically important should a problem occur far from help. You should also wear a face shield or goggles as well as boots, gloves, and protective clothing. The exhaust system becomes very hot during operation, and it remains hot after operation.

Never touch any part of the hot exhaust system. Wear clothing that fully covers your legs. Do not wear loose clothing which could catch on the control levers, kickstarter, footpegs, drive chain, or wheels. Obey all federal, state and local equipment regulations. Addition of accessories or cargo can impair the motorcycle's stability and performance. To prevent an accident, use extreme care when adding and riding with cargo and accessories. These general guidelines may help you decide whether, or how to equip your motorcycle.

Luggage racks are for lightweight items. Bulky items may snag on a tree or other nearby objects causing loss of control. All cargo and accessories must be secure for stable handling. Recheck cargo security and accessory mounts frequently. Do not attach large or heavy items such as a sleeping bag or tent to the handlebars, front forks, or fender.

Unstable handling or slow steering response may result. Loading The vehicle capacity load is pounds. The combined weight of the rider, cargo, and all accessories must not exceed this limit. Keep cargo and accessory weight low and close to the centre of the motorcycle. Load weight equally on both sides to minimise imbalance. As weight is located father from the motorcycle's centre of gravity, handling is proportionally affected.

Accessories Genuine Honda accessories have been specifically designed for and tested on this motorcycle. Because the factory cannot test all other accessories, you are personally responsible for proper selection, installation, and use of non-Honda accessories. Always follow the guidelines under Loading, and these:. Carefully inspect the accessory to make sure it does not reduce ground clearance, or limit suspension travel, steering travel or control operation. Do not add electrical equipment that will exceed the motorcycle's electrical system capacity.

An electrical failure could cause a dangerous loss of lights or engine power at night, far from help. Their functions are described in the table on the following page. Function Shows riding speed. Shows mileage per trip or section of route. Verifies tripmeter reset knob position. Pull knob to OFF and turn to zero 0. Push knob to ON to begin counting. Use the chart below to determine the correct adjustment for you.

Condition The entire range of travel is too hard The entire range of travel is too soft bottoming. Initial travel is good, but the final stages of travel are too soft bottoming. The initial stages of travel are good but the final stages are hard The initial stages of travel are too soft, but the final stages are good The initial stages of travel are too hard, but the final stages are good Air pressure Lower Increase Oil volume Increase.

Air Pressure Adjustment Low air pressure settings provide a soft ride and are for light loads and smooth riding conditions. High air pressure settings provide a firm ride and are for heavy loads and rough riding conditions. For accurate pressure readings, check and adjust air pressure when the fork tubes are cold and with the front wheel off the ground.

Place a support under the engine to raise the front wheel off the ground. Remove the air valve caps 1 and check the air pressure with a pressure gauge. To decrease air pressure, depress the valve core. Some air will be lost when using pressure gauge.

Determine the amount of loss and compensate accordingly. Also, be sure that the air pressure in both fork tubes is equal. Oil Volume Adjustment: Low oil levels provide a soft ride and are for light loads and smooth riding conditions.

Height oil levels provide a firm ride and are for heavy loads and rough riding conditions. Remove the air valve caps and release all air pressure. Remove the fork cap bolts 2 and springs from the fork tubes. Install the air valve caps. Inspect the O-ring on the cap bolts and replace if they are damaged. The fork cap bolts are under extreme spring pressure. Use care when removing the cap bolts and wear eye and face protection.

Compress the forks all the way and measure the oil level 3 from the top of tubes. Standard oil level: mm 5. Add oil with a graduated beaker for accurate measurements. The recommended oil level range is mm 5. Do not use a level lower than the recommended minimum to prevent poor performance.

Be sure the oil level is the same in both fork tubes. Clean and dry the fork spring with a lint free cloth. Install the fork spring and fork cap bolt. Torque the fork cap bolt to Nm 1. Rebound damping: There are four detent rebound damping adjustment positions.

Turn the damping adjuster 1 at the lower end of the shock for rider weight and riding conditions. The adjuster is marked 2 for each adjustment position. NOTE: Be sure the damping adjuster is not between positions but is located in a detent. Compression damping: The compression damping adjuster has 16 positions or more. Turning the adjuster knob 3 one full turn clockwise advances the adjuster four positions.

To adjust the adjuster to the standard position, proceed as follows:. Turn the adjuster knob counter clockwise until it will no longer go. Check that the yellow dots 4 on the knob and reservoir are aligned. If they are not aligned, turn the knob clockwise until they are aligned.

The adjuster is set in the standard position when the knob is turned clockwise 12 positions 3 rotations from the above position. Spring preload: 1. Remove the left and right side covers. Remove the seat, exhaust muffler and air cleaner box.


Honda XR250R Service Manual



Honda XR250R Owner's Manual


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