HONDA 250 MODEL XL250 OWNER’S MANUAL CONSUMER INFORMATION VEHICLE STOPPING DISTANCE This Ilgure lndiCaIeS braking perfoimanoe that can be met or exceeded by the vehlcies I0 which II applics‘ wilhout iocklng the wheeis under different c0n~ dlIlOlIs of loading, The irriormaimn presented represents results obtainable by skiiied drlvers under Controiled road and vehicle conditions, and the inIormatmn may no! he coirect under other condilmns. Descrlpiion of vehicles Io which Ihis table appiles: HONDA XL 250 Fully Operationai SCI’VICe Brake Load nghI Stopping Dis‘anca In Feet from 60 mph. ACCELERATION AND PASSING ABILITY This ligure indicates passing times and distances that can be met or exceeded by the vehicles to which it applies, In the situations diagrammed on the naxt page. The |ow»speed pass assumes an inllial speed M 20 MPH and a limiting speed of 35 MPH. The high-speed pass assumes an initial speed of 50 MPH and a limiting speed of 80 MPH. NOTICE The inlormalimi presented represents results obtainable by skilled drivers under controlled road and vehicle conditionsv and the infor- malinn may not be correct under other conditions. Descripiion of vehicles Io which this table applies: HONDA XL 250 SUMMARY TABLE: Low-speed pass ..... 347 Feet: A Seconds Highrspeed pass ..... 1360 Feel: 14.9 Seconds LDWVSPEEIJ INITIAL SPEED 3 ZDMPH LIMITING SPEED : 35M?" .4. HIGHr TOTAL PASSING DISTANCE, FEET TOTAL PASSING TIME‘ SECONDS ~=+ i ' Tons—1;“? 5074p] TRUCK SPEED INITIAL SPEED SDMPH LIMITING SPEED : anMPH TOTAL PASSING DISTANCE FEET TOTAL PASSING TIME, SECONDS PREFACE ' The XL-250 Motosport incorporates many special features for outstanding perform. ance under nfl-d1e.road conditions, oAdjustable front fork height and two position rear shock absorber mounts allow the rider to vary the ground clearance of the machine to suit riding conditioner oHeadlight and battery are easily re» moved to reduce weight. oOptional sprockets are available to provide the best ratios for optimum performance under any riding condi- tions. oRear shock absorbers have 5 settings for precise adjustment of the rear sus- pension. IPrimary kick starting enables the rider to restart quickly without first shifting to neutral. .Muffler incorporates a USDA approved spark arrester. This booklet is your guide to the basic operation and maintenance of your new Honda XL-250. Please take the time to read the Owner’s Manual carefully, then store it in the special compartment under the seat for future reference. As with any fine machine, proper care and maintenance are essential for Lrauble free operation and optimum performance. Your authorized Honda dealer will be glad to provide further information or assistance and is fully equipped to handle your future service needs. Thank you for selecting a Honda We wish you Many miles of continued riding pleasure in the years ahead. CONTENTS'IIIII SERIAL NUMBER LOCATION CONTROL LOCATION OPERATING INSTRUCTIONS Speedometer/Tachometer , Main Switch Emgrgency Swm: Headlight Control Switch Horn Button” Steering Lock . Rear Shock Absorbers ......... Seat Lock and Helmet Holder Document Compartment FUEL AND OIL Fuel Tank Fuel Valv ‘ Engine Oil Recommendation . Viscosity ....................... FEE-RIDING INSPECTION ‘ TIRE RECOMMENDATION 2 PRECAUTIONS BEFORE RIDING STARTING THE ENGINE Starting a Cold Engine I. Staining in Extremely Cold Weather 27 Starting a Warm Engine .. . 27 BREAK-IN PROCEDURE . . 27 RIDING THE MOTORCYCLE , . 28 PARKING I ................ TOOL KIT .................. MAINTENANCE SCHEDULE . MAINTENANCE OPERATIONS , Engine Oil Level“ Engine Oil Change, Oil Filter Maintenance . Spark Plug Replacement and Adjustment Contact Breaker Paint and lgn ion Timing Adjusu—nem Valve Tappet Adjusflnenl. V Cnm Chain Adjusunent. Air Cleaner Maimenance . Throttle Cable Adjustment Carburetor Adjustment ., Fuel Filter Maintenance Clutch Adjustment Drive Chain Maintenance Wheel Spoke Retigbtenlng Front Brake Adjustment Rear Brake Adjustment Front Suspension Inspection Front Fork on Change .. Rear Suspension Inspection . Rear Suspension Lubrication Front Wheel Removal Rear Wheel Removal. Banexy Maintenance Headlight Beam Adjustment Stoplight Switch Adjustment Headlight Replacement . Tail/Stoplight Bulb Replacement . . . SPECIFICATIONS .................... . 66 4 SERIAL NUMBER LOCATION ' The frame serinl numher @ is stamped on the lelr of rhe steering head. The engine serial number ® is located on top oi the upper crankcase left side. These numbers are required when registering 6) Frame serial number the motorcycles Refer to «he frame or engine serial number when ordering re. placement parts to ensure that you will obtain the correct pan—S {or your model series. @ Engine serial number CONTROL LOCATION G) High beam indicator light (3 Speedometer © Tachometex ® Choke knob ® Front brake lever Q5) Throttle grip 0) Emergency switch Headlight control switch @ Rear brake pedal @ Foot rest @ Kick starter pedal @ Clutch lever @ Hon: button @ Geax change pedal (9 Main awhch ® Gear change pedal @ Fuel valve (9 Kick sane: pedal (2) Rear bxake pedal OPERATING INSTRUCTIONSW Speedometer/Tachometer Speedometer and tachometer are mount. ed above the headlight case. Their rer spective functions are shown in the table on the next page. 10 (D @ g) @ (#3 @, Speedomexer 0dome|ex High beam Indicator ugm Neunal indicalor ngm achometer Tachamcmr red lune lripmem Tripmeler reset knoh Ref. No. Description F I: II c t i 0 II ® Speedometer Indicates driving speed. ® Odometer - Indicates total accumulated distance traveled. High beam indicator Light will be on when headlight is on high G) , light (red) beam. Neutral indicator Light will be on when the transmission is in light (green) neutral. @ Tachometer Indicates engine rpm. Do not allow indicated engine rpm to enter Tachometer red or exceed the red zone. Operation at exces- zone sive ipm will shorten engine life and may cause serious damage. (3 Tri mete! Indicates distance traveled. F (meter can be reset for each trip) Tripmeter reset knob ‘ Reset knob for‘ ‘uming” the trip meter. 11 Main Switch The main switch (D is located on the left side below the front end of the fuel tank. Functions of the respective switch positions are shown in the than below ® Mam switch Key Position Function OFF All electrical circmts are open engine can not he started Electrical Circuits are closed: engine ; can be started, headlight and tail/ stoplight can be operated, neutral indicator light is on when the trans mission is in neutral ON (red dot) 12 Key Removal Key can be removed Key cannot be re- moved. Emergency Switch The three position emergency switch (D is located on top of the right bundle grip switch housing. In the “ON” position (center) the ignition circuit is complete and the engine operates. In the “OFF" position (either side of center) the igni- tion circuit is open and the engine will not operate. This switch is intended primarily as a safety or emergency switch and normally remains in the “ON" position, The igni- tion will not operate unless the main switch is also in the "ON“ position. Headlight Control Switch The headlight control switch ® is located on the right handle grip switch housing, It can be operated without taking the hand off the handle grip The red dot is the “OFF" position (headlight and tailv light off) “L” is the low beam position (low beam light and taillight on). “"H is the high beam position (high beam light and taillight on). The headlight will only operate when the main switch is in the “ON” position. © Emergency switch ® Headlight control switch 13 Bum Button The horn button 6) is located on the left handle grip switch housing. Press this button to operate the horn. ’@ no?“ bug; 14- Steering Lock The steering lock (D is located on the steering stem directly below the headlight case. Turn the handle her all the way to the steering stop. either to the left or right, insert the key into the lock, turn the key counterclockwise 60" and press in, turn the key hack to the original position and remove the key, This locks the steering to prevent theft. (D Sleering lock Rut Shock Absmber The rear shock absorber ® has five set- tings for different riding conditions. Posi- rion (1.11) is standard setting. Adjustment is performed by using the pin wrench ® contained in the tool kit, Turning the adjuster G) in direction ® softens the rear suspension, turning it in direction (:9 stiHeus the rear suspension (D Rear shock absorber (3 Pin wrench @ Adwster Seat Lock and Helmet Holder The seat lock ® is located on the lower right side of the seat, Insert the main switch key and turn it counterclockwise 90" to unlock and raise the seat. The helmet holder (2 is located under the seat, Hang the helmet on the hook and lock the seat. '1) Suit lock (Z7 llelmcr holder 15 Document Compartment The document compartment (D is located under the seat. Put this owner's manual and other docu. meme in vinyl sack and place them in the document companmenr. When washing your motorcycle, be carer {ul no! to direct a blast of water at the bottom of Lhe seat. (D Documenl companmem 16 FUEL AND OIL Fuel Tank Fuel tank capacity is 2.1 U.S.gal. (8!) including 0.5 U3. gal. (2 2 > in the reserve supply. Use of low-lead gasoline with a 91 octane raring or higher is recommended. If such gasoline is not available, you may use a leaded regular grnde gasoline. When refueling, take care to exclude din, water, or other contaminates from the fuel tank. WARNING: Gasoline is finmmable, and explosive under certain conditions. Always stop the engine and do not smoke or allow open flames or sparks near the motorcycle when refueling. Fuel Val\e The fuel valve (D is mounted under the left side of the luel tank. “S" position: When the fuel valve is turned to the “S" position, luel cannot flow from the fuel tank to the carburetor. Set the valve in this position whenever thc motorcycle is not in use. «1) Fuel valve “0N" pusitiou: When the fuel valve is turned to the “ON" position, fuel will flow from the main fuel supply to the carburetor. Set the valve in this position when the engine is to be operated from the main luel supply, “R" position: When the fuel valve is turned to the “R" position, fuel will flow from the reserve fuel supply to the carburetor. The fuel valve should be set in this posi- tion only alter the main fuel supply has been consumed. The reserve luel supply is 0.5 US. gal. (2 Z ), When it becomes necessary to switch to the resene luel supply, this serves as a wnrmng ro the rider that it is time to refill the fuel tank 17 Engine Oil Recommendation Use only high detergent, premium quality motor oil certified to meet or exceed US automobile manufacturer’s requirements for Service Classification SE. Motor oils intended for Service SE will show this designation on the container. The regular use of special oil additives is unnecessary and will only increase oper- ating expenses. Engine oil should be changed at the in- tervals prescribed in the maintenance schedule on page 32. NOTE: Engine oil is a major factor infecting the performance and service life of the engine. Non-detergent and low quality oils are specifically not recommended. 18 Viscosity Viscosity selection should be based on the average atmospheric temperature in your riding area. Change to the proper viscosity oil whenever the average atmos- pheric temperature changes substantially Recommended oil viscosity : General, all temperatures SAE row-40 Temperatures above 59"F SAE 20W-50 Alternate: Above 5901; l SAE 30 or 30w 327m 59"} SAE 30 or zow’ 330w Err SAE Iow' " PRE-RIDING INSPECTION ' At the start of each riding day, perierm a general inspection to be certain the motorcycle is in good, safe operating condition. This inspection will require only a few minutes and can save you much time and expense in the long run. Check the following items and adjust or service if necessary. Refer to the appro- printe section of the Owner’s Manual for detailed maintenance instructions. 1. ENGINE OIL LEVELiMeasure oil level and add oil it necessary (page 34). 2. FUEL—Check fuel level and fill tank if low (page 16). 3. BRAKES—Check operation of front and rear brakes. Adjust free play if necessary (page 54~56), 4. TIRE AIR PRESSURE—Check with a tire air pressure gauge: normal inflation pressure for both front and rear tires is 21 psi (page 20). . DRIVE CHAIN—Check condition of chain and measure chain slack. Adjust if drive chnin slack is incorrect. Lu; bricate if drive chain appeals dry, Replace if drive chain is badly worn or damaged (page 49~53). . THROTTLEicheck throttle Opera- tion in all steering positions Adjust it free play is incorrect. Replace er correct cable routing if throttle does not operate freely in all steering posi» tious (psge 44~45). . LIGHTING EQUIPMENTrCheck headlight and tail/stoplight. Replace any bulb which falls to light (page 63~65)r 19 TIRE RECOMMENDATION ooflthe-rond tires are standard on this model. Select the right tires in accordance with the following specifica- lions: Bridge- Front: TRAIL WING 5A The slone leer: TRAIL WING 5A Brand NM Emm- N'HozB' , 7‘ ear NT—ipr , , Tire size fig: 275?; Tire inflation Front: 21 psi (1.5 kg/cm‘) pressure (cold) Rear: 21 psi (1.5 tying Vehicle load 2201bs (100 kg) limit 701mm." only When riding at any speed higher than 60 mph, use the tires specified below: Bridger Frum: TRAIL WING stone Rear The Brand . F ron! Nuto Re 20 .0ver or under inflation of the tires causes abnormal tread wear or other defects which may result in serious accidents. Riding with under inflated tires will cause the tires to slip out of place in the rims, damaging the inner» tube valves. When running with a low air pressure below 14 psi (lkg/ cm‘), be sure to install rim locks (option) on the rear wheel. 0me time to time check tire pressure and correct it, if necessary. .Replace the tires when the center block height of the tread is less than 015 in. (4 mm), PRECAUTIONS BEFORE RIDING‘ Observe the following precautions: .When crossing a stream or when riding in a deep puddle, have the ends of the breather pipe and the carburetor flow pipe raised up to the level of seat At the end of riding, water should be drained from the carburetor float chamber. ITake care not to block air cleaner suction port in tool tray with a tool bag or rags, this will result in poor engine performance. Optional alterations for oflrthe-road use Consult your Honda dealer for recom- mended adjustmenrs and optional altera- tions best suited to your riding conditions. OIncreasiug minimum ground clearance i. Loosen the three front fork attach- ing bolts ® and lower the front rork pipe @ until its upper surface becomes flush with the fork top bridge ©. 2. Reughten the front fork attaching bolts firmlyi (5 Front iork attaching bolts (2) From fork pipe @ Fork lop bridge © Alignment mark 21 3. Remove the attaching bolt © at top of the each rear shock absorber, and rebolt the absorber through hole A. Tighten the bolt firmily. NOTE: When returning the front fork legs to the normal position, align the alignment marks ® (page 21) even with the upper surface of the fork top bridger (5) Anaching bolt 22 o Removing headlight l. Raise the trout side of the fuel tank, and disconnect the wire leads at the lead coupler (D and attach the rubber cap ® tn the coupler. . Disconnect the wire leads running to the instruments, . Remove one headlight bracket attach- iug bolt @ and two nuts (4) Reinstall the two nuts if not removing the speedometer and tachometer. (a) Atmclring hull ( ® Lead Coupler :3 Rubber cap (4) Nuts lRemoving battery L Raise the seat and remove the moi (ray 2. Loosen the battery holding band. 3 Disconnect are battery cable connec- tor ® and remove «he battery. <9 Battery cable connecmr .Replncing final drive and driven sprockets: When replacing the drive sprocket and the driven sprocket» ihe drive chain and the rear brake anchor arm (page 24) ® and the rear axle ® (page 25) should be installed in the combination Shown on the table belo No of No, of No. of Brake dm-e dmm lime anchor ‘eprockeiapi‘uelwl elm“ & axle |eell1 reeih links pnsmon Siamlmi 15 43 as A 51 100 0pm“ I *5 (opiion) (npinn) . l4 Oplion [1 mm“) 93 A 14 51 100 0"“0” 1" (oplmn) (option) (rum; NOTE: To increase the clearance be- tween the rear wheel and rear fender, move the rear brake anchor arm and 23 the rear axle to position B by using the following combinations: m drive driven drive anchor & rprueirez spreekei chain axle teeth ‘ reerh link: i posirirm 48 100 ‘ B 48 Inn B a; Real brake anchor um 24 1. Take off the drive chain clip and master link, and remove the drive chain from the sprockets . Remove the crankcase rear left cover and the two 5 mm bolts ®, so that the drive sprocket @ can be removed. ® 6 mm bolrs @ Drive spraeker 3. Remove the rear- wheel from the frame according to instructions on page (SO-61. Straighten the tab of the lock nut washers Q5) and unscrew the six lock nuts © securing the driven sprocket © and remove the driven sprocket. 4. The drive 5 rocket and driven sprocket shoul be installed in the reverse order of 1. to 3. Make sure that each ml) of the lock washers is bent toward nut head after tightening. (9 Lock uul .Isliers (5) ank “ms @ Driven spruckel 5 Rear axle ® sition varies with the number of £2 drive chain links. Install rear axle in position A when using a 987 or loo-link chain. Install it in position B when extending wheelbase and using a 1007link chain. NOTE: If it becomes necessary to move the rear axle farther back than the applicable position indicated in the tables on pages 23 and 24, then the drive chain is excmaively worn and should be replaced. ® Rear axle 25 STARTING THE ENGINE Starting a Cold Engine 1. Turn the fuel valve to the “ON" posir lion (page 17). 2. Insert the key into the main switch and turn to the ”ON” position. At this time observe the neutral indicator light on the left side of the tachometer. The light will be lit when the transmise slon is in the neutral posltlnn (page 10). . Pull the choke knob out to the full closed position (/9. to Choke knob 26 . Twist the throttle grip inward slightly (do not twist it too much, but approx. % turn.) and operate the kick starter with the right foot, starting from the top of the stroke and following through to the bottom with a rapid and continuous kick. Operate several times until engine starts. The engine can be kick-started with the clutch lever pulled in regardless of the gear selected, If the engine [ails to start alter several repeated attempts, it may hme become flooded with excess fuel, To deflood the engine, turn off the main switch and push the choke knob in to the full open position, twist the throttle grip inward {ully and crank the engine using the kick starter pedal, This is then followed by turning the main switch to the “ON" position and following the starting procedure out lined in steps 1 through 4, however, at this time the use of the choke is not necessary 5, After starting, warm up the engine at approximately 1,500 rpm until the engine properly responds to the throtr tle with the choke fully open (pushed in). Starting in Extremely Cold Weather Prime the engine before starting by crank iug several times with the kick starter pedali The main switch should be “OFF". the choke fully closed (pulled out) and the throttle opened. Follow by the starting procedure for a cold engine Starting a Warm Engine When the engine is to be re-started while still warm, proceed as [or cold engine starting however, do not use the choke. BREAK-IN PROCEDURE During the first 600 miles (1,000km), operate your new XL 250 so the engine neither pulls laboriously nor exceeds 80% of the maximum rpm in the respective genrr Avoid full throttle operation, and select your genr changes to spare the engine undue stress. Careful breakrin procedure during the initial mileage will measurably extend the service life of the engine 27 RIDING THE MOTORCYCLE 1. After the engine has been warmed up, the motorcycle is ready for riding. 2 While the engine is idling, pull in the clutch lever and depress the gear Change pedal to shift into low (1 st) gearr 3. Slowly release the clutch lever and at the snrne Lime gradually increase engine speed by twisting the throttle grip inward, coordination of the throttle and clutch lever will assure a smooth positive start. 4, When the motorcycle attaiusn moder- ate speed, close the throttle, pull in the clutch lever and shift to 2nd gear by raising the gear change pedal. 5. This sequence is repented to progres. sively shift to 3rd, 4th and 5th (top) gear, 6. When decelerating the motorcycle, coordination of the throttle and the 28 sliilting pattern front and rear brakes is important. 1) The smooth grenlunl applientinn ol both the front and rear brakes to- gether with the required throttle coordination will, under most con» ditions, assure good control and stability during deceleration, As the motorcycle speed is reduced, it is common practice to shift the Lmnsmission progressively into the gear appropriate tor the speed of the motorcycle. This assures maxi» mum control through better brak- ing effectiveness end better accel- station when necessary. For maximum deceleration and stopping, close the throttle, apply both the front and rear brakes simultaneously, and as the motor- cycle comes to a stop, disengage the clutch. This maneuver requires smooth coordination of the con» trols. Both front and rear brakes should be applied equally. Independent use of only the front or rear brake reduces stopping performance. Ex- cessive brake application may cause either wheel to lock, reduc. ing control of the motorcycle. Avoid locking the wheels. If ex, cessive brake application causes either wheel to lock, reduce applied pressure on the brake pedal or lever. WARNING: The exhaust pipe and muflier become very hot during opera- tion. Wear clothing which will com- pletely cover the legs while riding, and avoid any contact with unshielded por- tion: of the exhaust system. 29 PARKING "m When parking the motorcycle, turn the main switch to the “OFF” position and remove the key. Also, the steering should be locked and the fuel valxe turned to the “s" position 30 TOOL KIT- The tool kit G) is mounted under the seat. Minor adjustment and parts re- placement can be performed with the tools contained in the kit Adjustments or repalrs which cannot be performed with these tools should be referred to your Honda dealer, (9 Tool hh I Listed below are the items included in the tool kit. - 10x12 mm open end wrench v 14x17 mm open end wrench . Pliers - No. 2 screw driver ~ No, 2 cross point screw driver -No. 3 cross point screw driver .Sci-ew driver grip - Screw driver handle . 25 mm wrench and handle lever . Spark plug wrench - Pin wrench . Tool bng 0 Items provided with the motorcycle in a separate package - A can of mucheup paint - Spare battery fuse MAINTENANCE SCHEDULE" "“ The mileage intervals shown in the maintenance schedule are intended as a guide for establishing regular mainte- nance and lubrication periods for your Honda. Sustained severe or high speed operation under adverse conditions may necessitate more frequent servicing. To determine specific recommendations for conditions under which you use your motorcycle, consult your authorized Honda dealer. If your Honda XLVZSO is ever overturned or involved in a collision, have your Honda dealer care- fully inspect the major components, eg. frame, suspension and steering pens, for misalignment or damage to insure fur. ther safe operation. 31 Months or Miles, whichever angurs first First ‘ 3;; Third fi‘gered‘" P . . peat Every age Sauce RequIred mlj J 712 73 Reference M11: zoo 3,000 6,000 3.000 on Km W 5,000 10,003 Tami Ifioo Engine OiLchange 7 7 7 7 o 7Evu71.noflues7u,sgxfl 147‘ OIITr-IlmTcleanT ' 7o 7 I707 7 as 7spark PITg c can and adJusl or xepITce 7 I Q o ‘Conkact Breaker PoIms7 check or service 9 o Q J , L ,0 ‘70 Q *Cam Chain7zdju 7 7O 70 Q 7AI: CIeaT can andi 7 77 ‘7 O 7 Q replace 77 7 7 7 7 ThnTuIc Operation? checIT O O O ‘Carburézor7 check or adjusI Q o 0 us] VaTIve Straine can 7 I7 07‘ O 70 Fuel Tank Tnd Fuel LIneT7 checIT 7 7 7 o 7 07 7Q CITmch7check or adjust O O I O O Items marked " should be serviced by an authonzed Honda deqler, unless Ihe uwnerhzs proper mols and Is mechanically proficient All oIher maintenance Items are simple In perform and may be servIced by any owner 32 Month: or Miles, whichevex occurs first . See . Thereafrer Service Required Fm" D“ 1:53! Raw“ Every Raff: LEE-1Q 7 —7 s 127 57 12 ° " Mile 200 3,0007 6,000 3.000 1 6,000 Km 300 5,000 10,000 5,000 ‘ 10.000 Dr]3’;fni‘iffigpil’ge°ckets’adlu5‘ “d 0 Every 500 miles (800 km) 49 JFrunfrncTRerr Brakeradlust ’ 7 'o o 7 O 0’ l 7 '54 From and Rear Brake sllneseclreelr or O ‘ o _ replace 7 7 7 7 77 77 7 7 7 From and Rear Brake Linlgge—check o o o 77 _ Wheel Rims and Spokurcheck o o o o 54 TireSrcheck or replace ' o o o 7 7 7 'From Fork Oilrchange o o 57 Steering Head BearingSrcheck Dr adjusti 7 7o 7 l707 7 7 77 Side Sland SpringSrcl-leck o o o 53 RE“ 7Fotk7 Bilshingrgnase o o o 59 ;‘Ballery Eleczrelyle Levelrcheck "7 and repl7e3|i7sh ll neuisary 7 7 7 O O O O 6‘ *Lights, Horn, Speedomeler and 63 Tachometerrcheck [or operation or adjusl O O O m MAINTENANCE OPERATIONS Engine Oil Level Check engine oil level at the start of each day the motorcycle is to be operated, The oil filler cap © is located on the right crankcase Cover and contains a dipstick (or measuring oil level Oil level must be maintained between the upper ® and @ Upper level mark 6) Oil filler cap ® aner level mark 34 lower ® oil level marks on the dipstick. Oil level must be checked with the motor- cycle stnnding upright on level ground and the oil filler cap touching the surface of the filler orifice but not screwed in. Engine Oil Change Engine oil should be changed in accord ance with the maintenance schedule on page 32. Use only motor oil of the grade and viscosity recommended on page 13' When changing oil, drain the used oil from the crankcase while the engine is warm. This will ensure complete and rapid dxaining. Remove the oil filler cap © from the right crankcase cover. 2, Place a drip pan underxhe engine to catch the oil, and then remove the drain plug @ with a 17 mm wrench. 3. After the oil stops draining from the crankcase, Operate the kick starter several times to drain any oil which may be left in the engine. @ Drain plug 4. When the oil has been comyletely drained, reinstall the drain plug male ing sure that the sealing washer used on the plug is in good condition. 5. Fill the crankcase through the oil filler orifice with approximately 1.6 US qt. (1.5! ) of recommended grade nill Make sure that the oil level is between the upper ® and lower @ level marks (page 34) NOTE: When operating the motorcy- cle under unusually dusty conditions, it is recommended that the oil changes he performed at more frequent intervals than that specified in the maintenance schedule. .75 Oil Filter Maintenance To clean the oil filter, proceed as follows: 1. Remove the oil filter cap (D, 2. Remove the spring @ and oil filter screen ®, and wash them with solvent. 3. Reinstall the screen, spring, and cap as illustrated below. NOTE : Unless the motorcycle is tilted more than 25 degrees to the left side, crankcase oil will drain through the oil filter opening when the cap is removed. To avoid oil spillage, it is best to clean the oil filter after draining the crank- case, during periodic oil changes (9 on me, can 36 "@ Spring (2) Oil hl|errsereen Spark Plug Replacement and Adjustment The standard spark plug [or this model is NGK USES-L. For most riding conditions this spark plug heat range number is satisfactory. How. ever. if the motorcycle is going to be operated for extended periods al high speeds or near maximum power in hot c imates. the s ark plug should be changed to a an der heat range number, such as the NGK DSES ar its equivalent. Be sure L0 clean mud and sand from around the spark plug heiore removing it. The use of the optional plug Cap is recommended if the motorcycle is subject to irequem. ofLLheeroad riding. 1. Detach the high tension cord cap and remove the spark plug with the spark plug Wrench provided in the tool kit, 2. Inspect the electrodes and center porcelain oi the spark plug for denos. its, eroded electrodes, or carbon [cul- ing. If the spark plug deposits are heavy, or the electrodes appear to be eroded excessively, replace the spark plug with a new one. If the spark plug is carbon or wet fouled, the plug can sometimes be cleaned with a stiff wire such as a pin. 3, Adjust the spark plug gap (9 to 0.024— 0.023 in. (new mm). The gap can be measured with a feeler gauge. The adjustment is made by bending the side (grounded) electrode @, @r (9;. dilli (9 Spark plug gap @ side electrode 37 Belore installing the spark plug, clenn any oil or dirt from the spark plug seat in the cylinder head. Install the spark plug by hand until finger tight. Then use the spark plug wrench to tighten the plug an addition 1/2 to 3/4 turn or until the sealing gasket is com- passed 58 Contact Breaker Point Gap and Ignition Timing Adjustment Adjustment of the point gap and ignition timing should be made at one time To adjust, proceed as follows: Contact Breaker Point Gap: 1. Place a block under the engine and stand the motorcycle upright. Res move the generator cover and the point cover. 2. Wipe the Contact breaker point snr. lnces with clean rag if dirty. 3, Turn the generator rotor counter- clockwise by using a 17mm box wrench and check the point gnp when it is at its maximum The curreut gap is 001270.016 in. (0370.4 null). To ad- just the point gap, loosen the contact breaker plate locking screws (2) (page 39) and move the contact breaker point plate (D to obtain the correct gapr Tighten the locking screws when the correct gap is obtained. Recheck the gap after tightening the locking screws, to Contact breaker point (3 Contact breaker pinto lacking screws @ Paint Cam @ Contact breaker point plate Ignition Timing‘ Adjust the ignition timing upon complet- ing the adjustment of the contact breaker point gap. 1. Turn the generator rotor © counter- clockwise and align the “F” mark with the index mark ®. The ignition timing is correct if the contact breaker points © start opening at this mo- ’mcntr @ Generator rotor q; index mark @ “F” mark @ Advance marks 39 2‘ If ignition timing is incorrect loosen the two base late locking screws and turn the Ease plate qy‘ slowly in either direction. Turning it clockwise will advance timing, and vice versn, Use of a strobnsecpic liming light is recommended to obtain accumle sett- ing. After adjustment, make sure that the “F” mark is aligned with index mark at an idle speed at 1200 rpm, and also that index mark stays within advance marks (page 39) at 4,000 1' m or above Base plate locking screws @ Base plale 40 Valve Tappet Adjustment Excessive valve tappet clearance will cause tappet noise, and little or no clearance will cause valve damage and loss of power, Therefore, valve tappel clearance should be maintained properly, 1. Raise the seat and remove the fuel tank 2. Remove the intake and exhaust tnppet covers. 3 Remove the generator cover. "T" mark ® Inde; mnrk 4. While slowly rotating the generator rotor counterclockwise watch the in- take valve tappet. When this tappet goes down all the way and then starts to lift, you must then watch for the alignment of the index mark (D and ”'1‘" mark (2). In this position, the piston will he at TlD.C. (top dead center) of the Com- pression stroke and the intake and up haust valves should be fully closed. 5. Check the clearance of both values by inserting the fecler gauge ® between the valve stem and the tappet adjust ing screw @. If the clearance is cor- rect there will be slight drag or resis- tance as the gauge is inserted. The standard tappet clearance is: In 0.002in. (0.06 mm) Ex 0.003 in (008 mm) Adjust tappet clearance by loosening the lock nuts © and turning the tappet adjust- ing screws («3) Tighten the lock nuts after adjusting the tappets. NOTE : Make sure that the adjustment has not heen disturbed while tightening the lock nut. © Feeler gauge @ Tappetadyusting screws (5) Lock nuts 41 Cam Chain Adjustment When cam chain is noisy, adjust its ten. sion in the following manner: L Stop the engine. 2. Remove the generator cover. 3. Align the “T" mark G) with the index mark ® when the piston is at top dead center on the compression stroke See valve tappet adjustment (page 40~ 41), @ “T 1* mark 42 ® Index mark 4. Loosen the cam chain adjuster lock nut ©. 5. Hold the generator rotor and loosen the cam chain adjuster @. Tension is automatically applied to the cum chain. 6. Tighten the cam chain adjuster and the lock nut. ® Cam chain adjuster lock nut g) Cam chain adjuster Air Cleaner Maintenance The alt cleaner element must be cleaned 3, Wash the air cleaner element in clean and oiled at least once every 3000 miles. stoddard solvent and a110W to dry If your motorcycle is operated in dusty areas more frequent servicing will be ‘hmwghly‘ required. Your Honda dealer can help 4' 5°“ “.‘f a“ “13“” 3'3“?“ ”1 d“: you to determine the correct service ine gear 0' (15 80~$ 90) Hun ‘ sxturate . terval for your particular riding condl- then squeeze out excess oxl» Reinstall Lhe air cleaner element. Reinstall the air cleaner cover » Va tions. 1. Remove the air cleaner cover G). 2, Remove the air cleaner element (i). 919 . l . cu Alr cleaner elemem a) Alr cleaner cover 9 Alr Cleaner element munching bull :2 Air cleaner cover attaching nui (5; Air cleaner band screw 43 WARNING : Gasoline or low flash point solvents are highly flammable and must not be used to clean the air cleaner elements. Throttle Cable Adjustment ’l‘wo control cables connect the throttle grip to a throttle crank on the carburetor operating har. One cahle opens the throt- tle valve, while the other cable ensures positive closure. Standard throttle grip tree play is approximately 10715° ol grip rotation. This play can be adjusted at the grip play upper adjuster (D and also with the grip play lower adjuster Q), 44 (3 Lock nut (0 Grip play upper ntljusler Major free play adjustments are made with the lower adjuster (3) (such as after replacing a throttle cable or removing the carburetor). Minor free play adjustments are made with the upper adjuster (D. Tn adjust free play, loosen the lock nut and turn the adjuster When performing the adjustment, both the opening and closing sides of the adjusters should be adjusted by equal amounts. Tighten the @ Grip play lower adjusler 14> Throttle crank (5‘) Lock nut lock nut after adjustment Check for smooth rotation and snap back tension of the throttle grip from the full open to the full closed positions with the steering to the full right and left as well as straight ahead. inspect the condition at the throttle cable housings and the cables for kinks, chafing and improper muting, Carburetor Adjustment The carburetor should be adjusted only after the engine has attained operating temperature. 1. Adjust the idle speed screw (D until the engine idles at approximately 1200 R? I Turn the idle speed screw cloc vuse to increase idle speed or counterclockwise to decrease idle speed. . Turn the air screw (2) cloclese until you hear the engine miss or d 45 in speed, then counterclockwise until the engine again misses or decreases in speed. Set the air screw exactly between these two extreme positions, Usually the correct setting (between extremes of rich and lean) will be found to be Hie—1V3 turns open from a fully closed position, 3, If idle speed changes after adjusting fuel mixture, readjust the idle speed screw 46 Fuel Filter Maintenance The fuel filter is incorporated in the fuel valve (D which is mounted on the bottom of the fuel tank at the left side. Accum~ ulation of dirt in the filter will restrict the flow of the fuel and cause the carburetor to malluuction, therefore, the fuel filter should be serviced periodically, 1. Turn the [uel valve © tn the “5" position a) Fuel valve 2. Unscrew the fuel filter cap @. Wipe all sediment from the inside of the can 3. Remove the “O" ring seal ® and the filter screen ®l Clean the filter screen. 4‘ Reinstall the filter screen, “0" ring, and Cap. 5. Turn the fuel valve to the “ON” posi tion and Check for leakage at the filter 06 © @ (9‘ ® Fuel filler cap @ Filter screen (:9 "o" ring seal Clutch Adjustment The clutch should be adjusted so that pulling in the clutch lever will completely disengage the transmission, If the clutch does not cornpletely disengage, the engine will stall when shifting into gear or else the motorcycle will have the tendency to creep even with the clutch lever disenr gaged. If the clutch does not iully engages the clutch will slip and the motorcycle will not accelerate in response to the accelerr ation of the engine In nrdcr (or the full engine output [0 be delivered to the rear wheels it is necessary to haxe the clutch properly adjusted, The normal clutch lever free play is 0.4—0.8in. (10720 mm) at the lever end before the clutch starts to disengage To adjust, perform the following steps. 47 1. Remove the clutch adjuster rubber cap (D. 2. Loosen the clurch adjuster lock nut ®, and turn the clutch adjuster @ clock- wise until it stops Then turn it coune terclockwise 1/2~1 turn. and lock it in place by tightening the lock nutr After adjustment, install the rubber Cap with its arrow mark aligned with the do: on the crankcase. (0 Clutch adjuster rubber mp @ Cluich mum, lotk nul @ Clutch adjusler 4B 3. Clutch lever free play can be adjusted at either end of the clurch cable. Major adjustmenis (such as after replacing the clutch cable) should be made at the lower adjuster ©. Minor adjust- ments should he made at the upper adjuster @. The ndjusLment procedure is similar for using either the upper or lower adjuster. @ Lock nut @ Clutch cahleloweradjusler @ Lock nut ® 01inch cable upper adjusler Loosen the lock nut (© lower or upper), turn the adjuster (© lower or (7) upper) to provide the correct clutch lever free play, then retighten the adjuster. Turning the adjuster in direction (A; will decrease tree play and vice versa. After the adjustment has been made, check to see that the clutch is not slipping or that the clutch is properly disengaging according to the following procedure. After the engine starts, pull in the clutch lever and shift into gear, and make sure that the engine does not stall, nor the motorcycle start to creep Gradually release the clutch lever and open the throttle, the motorcycle should start smoothly and accelerate gradually. Drive Chain Maintenance Proper tensioning and lubrication will help to extend the service life of the drive chain and ensure smooth power transmission to the rear wheel. Under severe usage, or when the motorcycle is ridden in unusually dusty areas, more frequent maintenance is necessary. Tension Adjustment: 1. Place the motorcycle on a support block to raise the rear wheel of! the ground. Shift the transmission into neutral 2 Check vertical movement of the lower length of the drive chain at a point midway between the sprockets Move the chain up and down with your fingers and observe the amount of slack. Drive chain tension should be adjusted to allow approximately 3/“ vertical mmement at this point. Rotate the rear wheel and check drive chain tension throughout its length. 49 U) 50 Drive chain tension should remain constant as the wheel is rotated. If the chain is found to be slack in one segment of its length and taut in another. this indicates that some oi the links are either worn or kinked and binding. Kinking and binding can frequently be eliminated by lu- brication. Drive (‘Il'dlll 3. If the drive chain is found to require adjustment,the procedure is as follows: 3. Remove the rear axle nut cotter pin (2 and loosen the rear axle nut ©. b. Loosen the lock nuts Q) and turn the adjusting bolts @ to increase or decrease chain tension. Align the chain adjuster index marks ® Cotter pin 6) Rear aVlc uul @ Lnek nul @ Adjusting boil [5) index mark fl) Reference marks ® Chain proreclor to the reference marks (3 on both sides of the rear fork. c. Tighten the rear axle nut and secure the nut with the cotter pin (replace the cotter pin if it has become broken or damaged). And then tighten the lock nuts G). d. Recheck drive chain tension. Rear brake pedal free travel is af- fected when repositioning the rear wheel to adjust drive chain tension. Check rear brake pedal free travel and adjust ax necessary (page 56). (a CAUTION: Check alignment of the chain protector (ID. If the chain pro— tector should become bent, it may rub against the drive chain and cause rapid wear. NOTE: If correct drive chain adjust- ment requires the rear axle to be moved back further than the applicable posi- tions indicated in the tlbles on page: 23 and 24, then the drive chain is ex- cessively Worn and should be replaced. For example, if the table specifies ule position A for your sprocket and drive chain combination, then the chin should be considered excessively worn ® Rear axle 51 when it becomes necessary to move the rear axle to position B. Similarly, if the table specifies axle position B, then the chain should be considered excessively worn when it becomes necessary to move the rear axle to positinn C. 52 Lubrication : Lubricnce the drive chain every 500miles. Commercially prepared drive chain lubri- cams may be purchased at most motor- cycle shops and should be used in prefer ence to motor oil or other lubricants. Saturate each chain joint so that the lubricant will penetrate the space between adjacent surfaces of link plates mid rollers. Removal and Cleaning: When the drive chain becomes extremely dirty, it should he removed and cleaned prior to lubrication. 1. Carefully remove the master link re- taining clip with pliers. Do not bend or twist the clip. Remove Lhe master link, Remme the drive chain from the motorcycle. 2. Clean the drive chain in solvent and allow to dry. Inspect the drive chain for possible wear or damage. Replace any chain that has damaged rollers, loose fitting links, or otherwise appears 4. uuserviceable. Inspect the sprocket teeth for possible wear or damage. Replace if necessary. Never use a new drive chain on badly worn sprockets Both chain and sproc- kets must he in good condition, or the new replacement chain or sprocket will wear rapidly. Lubricate the drive chain. Pass the chain over the sprockets and join the ends of the chain with the master link. For ease of assembly, hold the chain ends against adjacent rear sprocket teeth while inserting the master link. Install the master link retaining clip @ so that the closed end of the clip will face the direction of forward wheel rotation. The master link is the most critical part affecting the security of the drive chain. Master links are reusable, if they remain in excellent condition. but it is recommended that a new master link retaining clip he installed Whene‘er the drive chain is teas» sembled 6. Adjust the drive chain to the proper tension, lollowing the instructions on page 49~5l @ Remining clip 53 Wheel Spoke Retighening Retighten the wheel spokes after the first 600miles (1,000 Km) and everv 3.000 miles (5,000 Km) thereafter, Torque specification: 20~45 kg. mm. 54 Front Brake Adjustment Free play, measured at the tip of the front brake lever ®, should be maintained at 0,871.2 in. (20730 null). Free play is the distance the brake lever moves before the brake starts to engage. Major adjustmems should he made using the adjuster located at the front wheel. 1, Loosen the lock nut C2) and then turn the front brake adjusting nut @. @ Front brake lever Turning the nut in the direction (29 will decrease the brake lever free play and turning the nut in the direction (3 will increase the play ® Lock nut @ Front brake adjusting mii 2, Minor adjustments can be mad: with the front brake cable adjuster on the front brake leverv Remove the dust cover @, loosen the lock nut (5) and turn the front brake cable adjuster 0, Turning the ad- 'usler in direction Q) will decrease the rake lever free play and tuming the adjuster in direction ® will increase the play. (A) Dust cover 5) Lock nut From brake cable adjuslel’ 55 Rear Brake Adjustment Rear brake pedal free play, measured at the tip of the rear brake pedal ®, should be maintained at 0.8712 in. (20730 InIII). Free play is the distance the brake pedal moves before the brake starts to engage. @ Rear brake pedal 56 1. Adjust the static position of the brake pedal to suit the rider by adjusting the pedal stopper bolt ®. 2. Adjust the pedal free play by turning the rear brake adjusting nut @. Turnr ing the adjusting nut in direction @ will decrease the brake pedal fxee play and turning the nut in direction ® will increase the play. n, " 1®yx V® Rear brak;2djv;ting nu| ;@ Pedal stopper ho]! @ Lock nu! Front Suspension Inspection Check from fork action by locking the front brake and pumping the forks up and down several times. The suspension should function smoothly. with no oil leakage from the fork legs. Damaged, binding, or leaking {rant forks should be repaired before the motorcycle is operatedr Check security of all iron: forks and handlebar mouuting bolts illustrated below. Front Fork Oil Change Oil in boxh from fork legs should be changed at least once a year. 1. Remove drain plugs ® from each fork leg and pump Lhe forks several times to ensure Complete draining. 2, Reinstall drain plugs and block up the from of Lhe motorcycle. 3. Remove the handlebars and the oil filler plugs a). (p on filler plugs @ Drain plug 57 4. Refill each fork leg with 4.902. (14500) of premium quality automatic trans- mission fluid (ATP). 5. Install filler plugs, handlebars, and remove block from under motorcycle. 58 Rear Suspension Inspection Check the rear suspension periodically by careful visual examination. Note the following items. 1. Rear fork bushingvthis can be checked by pushing hard against the side of the rear wheel while the motor- cycle is on a suppon block and feeling for looseness of the fork bushings. Check side stand spring for damage. Check all suspension componenm at- tachment points for security of their respective fasteners. 9”?” NOTE 2 If any of the above components appear damaged or worn, consult your Honda dealer for further inspection. Rear Suspension Lubrication There are grease fittings at each end at the rear fork pivot. The rear fork pivot should be lubricated evcry 3000 miles (5000 km) with multipurpose grease, type NLGI No. ” @ Grease nipples Front Wheel Removal To remove the front wheel, proceed as follows: 1. Place a wood block under the engine and raise the front wheel off the ground. 2‘ Remove the cone! pin (i) and dis- connected the front brake cable (2 from the brake arm. 3. Remove the speedometer cable set screw and disconnect the Speeder meter cable (3) (page 60). 4, Remove the front axle holder nuts ® (lour on each side), and remove the front axle holders (one on each side)‘ (D Cotter pan (2 Front brake cable q) Front axle holder nuts © From axle holder 59 and rlren the lronl wheel cnn be removed. 5. To install me lrom wheel, follow the reverse of removal procedure outlined in steps 1 through 4. NOTE : When installing the from. ule holders, make sure the “F” mark in forward. l 7 © speedomerer cable @ From axle holder nuts @ From axle holder @ Speedometer cable ser screw 60 Rear Wheel Removal To remove the rear wheel, proceed as follows: 1. Place a wood block under are engine and raise the rear wheel off die ground. . Remove the rearbrake adjustingnut®. . Remove the brake panel stopperaxm atmohing bolt @. (0 Rear brake adjusling n'ul ® Brake panel stopper nrm anachlng bolt @ Rear axle 4. Remove the cutter pin (3) from rear axle nut. 5. Remove the rear axle nut G), and pull out the rear axle ©, and then the rear wheel can he removed. 6‘ To install the rear wheel, follow the reverse of removal procedure outlined in steps 1 through 5, @ Cotter pin 9 Rear axle nul But‘el‘y Maintenance Battery Electrolyte Replenishment: The battery is mounted under the seat, and is accessible by releasing the seat lock and raising the seat. Remuve the tool tray and battery holding hand. Raise the battery slightly to check the hatlery electrolyte. The electrolyte level must be maintained between the upper © and lower level (a; battery. marks on the side of the (D Bullery (2) Filler Bap: ® Upperilzvel mark 8) Luwer level mark 61 If the electrolyte level is found to be low, remove the battery filler caps and care fully add distilled water until the electro lyte level in each cell is between the upper and lower level marks. Use a small syrirrg or plastic funnel to add water. Only distilled water should he added, to avoid contaminating the electrolyte. Battery Removal and Installation: The battery should be removed for pro- longed storage, or for recharging ii electrolyte specific gravity falls below 1.200. Refer to page 23 for this pro- cedure. CAUTION: When installing the bat— tery, be careful not to bend or twist the vent tube. 62 Battery Charging: During the use of the motorcycle, should battery electrolyte specific gravity reading (measured with a hydrometer) drop below 1,200 @ 68”F (20°C), the battery should be charged at a rate not to exceed 0.6 amps until the specific gravity reading is between 1 260 and 1.280 @ GSVF (20°C). Frequent discharging or a partially dis- charged battery condition, is the result of electrical system problems. To locate and correct the cause of this condition, we suggest you contact your Honda dealer. When storing the motorcycle. or if it is not being used lor an extended period, the battery should he removed and stored in a cool place. The battery should be charged at least once a month during the storage period to preserve battery life. Fuse: The fuse holder (D is located on the frame pipe shown below. The recom- mended fuse for the XL-250 is 10A. When frequent failure of the fuse occurs, it usually indicates a short circuit or an overload in the electrical system. In this case the electrical system should be checked visually for shorts or other possible malfunctions If the problem cannot be located visually, the motorcycle should be examined by an authorized Honda dealer. ® Fuse holder Headlight Benin Adjustment The headlight must be kept properly ad- justed for safe nighttime riding. Vertical adjustment is made by pivoting the headlight case on its mounting bolts Horizontal adjustment is made by turning the adjusllng screw ® located on the headlight rim, (D Headlight mouming bolts @ Adjusting screw 63 Stoplight Switch Adjustment The stoplight switch ® must be adjusted so that the stoplight will come on when the rear brake is applied Rear brake free play (page 54) should be adjusted before performing the stoplight switch adjustment. The procedure for adjusting the stoplight switch is as follows: L Turn the main switch to the “ON" position. P .h a) Stoplight switch (2) Adjusting nut 64 . Turn the adjusting nut Q) to position the stoplight switch at a point where the stoplight will come on when the brake pedal is depressed, Turn the adjusting nut in direction ® to advance switch timing or in the opposite direction (E to retard switch timing. Headlight Replacement Replace the sealed beam unit as follows: 1. Remove the two headlight attaching screws and remove the headlight from the headlight case. 2. Remove the two retaining lock pins ® and lock screws 6) from the headlight rim. Remove the beam adjusting screw @. Remove the sealed beam unitl Install new sealed beam unit in the reverse order of removal. 3"?“ (D Headlight (1) Lock screws @ Beam adjusting screw @ Lack pins Tail/stoplight Bulb Replacement 1. Remove the two screws retaining the tail/stoplight lens. 2. Press the bulb G) inward and twist to the left and the bulb can be removed. 3. Replace with a good bulb. 4. Reinstall tail/stoplight lens. G) Tail/stoplight bulb ‘5 SPECIFICATIONS ITEM 1 ., .. 7‘. , DIMENSIONS 1 Overall length I 2,120 mm (33.5 in.) Overall width 840 mm (33.1 in.) Ovarall height 1,125 mm (44.3 in) Wheel base ‘ 1,355 mm (54.5 in.) WEIGHT 1 Dry weight ‘ 126 kg (278 lbs) CAPACITIES . Engine oil . 1.5! (1.6 US qt.) Fuel tank 81 (2.105 gal., 1.7 Imp. gal.) Fuel reserve tank 21 (0.5 US gal., 0.4 Imp. gal.) From fork ‘ 146 cc (4.9 ms.) 66 ENGINE Bore and stroke Compression min Displncement Comack breaker point gap Spark plug gap Valve mppet clearance CHASSIS AND SUSPENSION Custer Trail The size. from Tire size, rear 74.0x57.8 mm (2.913x2.275 in.) 91:1 248 cc (15.1cu-in.) o.3~o.4 mm (0.012~0.016in1) o,6~0.7 mm (0.024~0,028 in.) IN 0.05 mm (0.0021113 EX 0.08 mm (0.003 in.) 595° 140 mm (5.5 in.) 2.75—21 (4 PR), 21 psi 4.00—18 (4 PR), 21 psi 67 POWER TRANSMISSION Primary reduction Final reduction Gear ratio. Ist. 2nd. 3rd. 4th. 5th. ELECTRICAL Battery Generator F use LIGHTS Headlight Tail/Stoplight Meter lights Neutral indicator light High beam indicator light 6V—6AH A.C. Generator 10 amp. 6V—35/25W 6V—3/32 Cp 6V71.5W 6V-1.5W 6V71.5W 68 Ax: 1.6.655sz 3 65,“ 3:32 :5? E: a m ....... @EmfllalflL m «TTHW , :ffl;ifl¢:?fl1 33 S: no; a ‘3 r/Emwé Jzn‘ 3 , E<¢0