Product Details

Clymer repair manuals are written specifically for the do-it-yourselfer.

For routine maintenance or more extensive repairs involving engine and transmission disassembly, it has all the information you need.

Step-by-step procedures, detailed photography and extensive use of exploded views based on the complete disassembly of the machine.

Clymer shop manuals are perfect for everyone, from the first-time user to the seasoned professional.

CHAPTER ONE / GENERAL INFORMATION

CHAPTER TWO / TROUBLESHOOTING

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP

CHAPTER FOUR AND FIVE/ ENGINE

Removal installation / Cylinder head cover / Cylinder head / Valve and components / Camshaft / Camshaft chain and dampers / Cylinder / Piston, pin and rings / Ignition advance mechanism / Primary drive gear / Oil pump and oil filter screen / Oil lines and cooler / Kick starter / Crankcase / Crankshaft and connecting rod / Balancer system / Break-in

CHAPTER SIX / CLUTCH AND TRANSMISSION

Clutch cable / External shift mechanism / 5-speed transmission / 6-speed transmission / Internal shift mechanism

CHAPTER SEVEN / FUEL AND EXHAUST SYSTEMS

Carburetor / Throttle cable / Choke cable / Fuel tank / Fuel filter / Gasoline alcohol blend test / Evaporative emission control system / Air filter / Exhaust system

CHAPTER EIGHT / ELECTRICAL SYSTEM

Charging system / Alternator rotor / Alternator stator / Voltage regulator rectifier / AC regulator kit installation (1985 XR250R) / Capacitor discharge ignition / Mechanical ignition advance mechanism / Starting difficulties / Pulse generator / Ignition coil / Lighting system / Switches

CHAPTER NINE / FRONT SUSPENSION

Front wheel / Wheel inspection / Front hub / Handlebar / Steering head and stem / Steering head bearings races / Front fork

CHAPTER TEN / REAR SUSPENSION

Rear wheel / Inspection / Rear hub / Swing arm / Dual shock absorbers / Pro-Link suspension system / Shock absorber / Pro-Link pivot arm assembly

CHAPTER ELEVEN / BRAKES

Drum brakes / Front drum brake / Front disc brake / Front brake pad replacement / Front master cylinder / Front caliper / Front brake hose replacement / Front brake disc / Bleeding the system / Rear drum brake / Brake cable (drum brake models)

SUPPLEMENT / 1990 AND LATER SERVICE INFORMATION

WIRING DIAGRAMS

NOTE: This manual is not exclusive to the model specified in this listing and contains information on a variety of makes and models. See Clymer manual M318 for 1981-1983 and 1986-2003 XR200R models.