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Honda · Honda XL / XR / SL four-stroke single (1970-)

XL250 / XL350 / XL500 / XR

Library entry covers 1972-1990

27 factory 41 guideline

Published source

Honda XL250S 1978 Owner's Manual (Honda Motor Co.), Maintenance Schedule pp.39-40

Factory owner's handbook. Covers 1978 XL250S owner's manual (US).

68 items for a 1989 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Wet sump (oil in crankcase)
Oil filtration: Centrifugal (slinger / rotor) filter
Valve gear: Overhead cam, screw/locknut adjusters
Ignition: Magneto (incl. magdyno, flywheel magneto)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Single carburetor
Cooling: Air / oil cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Shares engine oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, twin shocks
Front brake: Drum (or band / stirrup)
Rear brake: Drum (or band / belt rim)
Wheels: Spoked, tubed
Sidecar: No sidecar

Maintenance schedule

1989 Honda XL250 / XL350 / XL500 / XR

On the road: every 300 km

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 500 km

2 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline

On the road: every 1,000 km

2 items

Check chain slack and rear wheel alignment

Pre-ride / on the road

Guideline
Lubricate drive chain

Pre-ride / on the road

Factory

Manual: Drive chain: inspect. Factory: Maintenance schedule pp.39-40: every 600 mi (1,000 km); initial at 200 mi

Every 1,600 km or 6 months

2 items

Adjust rear drum brake and rod / cable linkage

Brakes

Guideline
Inspect tire tread, sidewalls and date codes

Wheels and tires

Guideline

Every 3,000 km or 12 months

1 item

Change engine oil

Engine

Factory

Manual: Engine oil: replace. Factory: Maintenance schedule pp.39-40: every 1,800 mi (3,000 km) or every year

Every 5,000 km or 12 months

8 items

Clean fuel tap filter / sediment bowl

Fuel and air

Guideline
Check / set ignition timing

Ignition and electrics

Guideline
Clean and gap contact breaker points, oil cam felt

Ignition and electrics

Guideline
Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Guideline

Non O-ring chains on old machines: remove, clean, soak in hot chain grease or lube, refit with the master link clip closed end leading.
Inspect chain and sprockets for wear (measure stretch)

Final drive

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Check wheel bearings for play

Wheels and tires

Guideline

Every 6,000 km or 1 month

1 item

Check battery electrolyte, top up with distilled water

Ignition and electrics

Factory

Manual: Battery: inspect. Factory: Maintenance schedule pp.39-40: every month or every 3,600 mi

Every 6,000 km

20 items

Check and adjust valve clearances

Engine

Factory

Manual: Valve clearance: inspect. Factory: Maintenance schedule pp.39-40: dealer item; first at 600 mi
Check engine breather and oil return

Engine

Factory

Manual: Crankcase breather: clean. Factory: Maintenance schedule pp.39-40: more often in rain or at full throttle
Headlight aim: inspect

Engine

Factory

Factory: Maintenance schedule pp.39-40 (columns 600 mi (1,000 km), 3,600 mi (6,000 km), 7,200 mi (12,000 km), 10,800 mi (18,000 km); note 5: for higher odometer readings, repeat at the frequency interval established here): dealer item; I at the 3,600, 7,200 and 10,800 mi columns; the 600 mi cell is under the ManualsLib watermark. (Read from the page images, ManualsLib Honda 1978 XL250S owner's manual pp.39-40.)
Inspect, clean and gap spark plugs

Engine

Factory

Manual: Spark plug: inspect. Factory: Maintenance schedule pp.39-40
Nuts, bolts, fasteners: inspect

Engine

Factory

Factory: Maintenance schedule pp.39-40 (columns 600 mi (1,000 km), 3,600 mi (6,000 km), 7,200 mi (12,000 km), 10,800 mi (18,000 km); note 5: for higher odometer readings, repeat at the frequency interval established here): dealer item; I at 600 mi and every column; note 4: more frequent service may be required when riding off-road. (Read from the page images, ManualsLib Honda 1978 XL250S owner's manual pp.39-40.)
Spark arrester (USA only): clean

Engine

Factory

Factory: Maintenance schedule pp.39-40 (columns 600 mi (1,000 km), 3,600 mi (6,000 km), 7,200 mi (12,000 km), 10,800 mi (18,000 km); note 5: for higher odometer readings, repeat at the frequency interval established here): dealer only; C at the 3,600, 7,200 and 10,800 mi columns; USA models only. (Read from the page images, ManualsLib Honda 1978 XL250S owner's manual pp.39-40.)
Starter decompressor: inspect

Engine

Factory

Factory: Maintenance schedule pp.39-40 (columns 600 mi (1,000 km), 3,600 mi (6,000 km), 7,200 mi (12,000 km), 10,800 mi (18,000 km); note 5: for higher odometer readings, repeat at the frequency interval established here): dealer item; I at 600 mi and every column. (Read from the page images, ManualsLib Honda 1978 XL250S owner's manual pp.39-40.)
Carburetor choke: inspect

Fuel and air

Factory

Factory: Maintenance schedule pp.39-40 (columns 600 mi (1,000 km), 3,600 mi (6,000 km), 7,200 mi (12,000 km), 10,800 mi (18,000 km); note 5: for higher odometer readings, repeat at the frequency interval established here): dealer item; I at the 3,600, 7,200 and 10,800 mi columns. (Read from the page images, ManualsLib Honda 1978 XL250S owner's manual pp.39-40.)
Carburetor idle speed: inspect

Fuel and air

Factory

Factory: Maintenance schedule pp.39-40 (columns 600 mi (1,000 km), 3,600 mi (6,000 km), 7,200 mi (12,000 km), 10,800 mi (18,000 km); note 5: for higher odometer readings, repeat at the frequency interval established here): dealer item; I at 600 mi and every column. (Read from the page images, ManualsLib Honda 1978 XL250S owner's manual pp.39-40.)
Check throttle cable(s) free play and return

Fuel and air

Factory

Manual: Throttle operation: inspect. Factory: Maintenance schedule pp.39-40: dealer item; fuel lines inspected at the same interval
Clean / inspect air filter

Fuel and air

Factory

Manual: Air cleaner: clean. Factory: Maintenance schedule pp.39-40: more often in dusty areas
Fuel lines: inspect

Fuel and air

Factory

Factory: Maintenance schedule pp.39-40 (columns 600 mi (1,000 km), 3,600 mi (6,000 km), 7,200 mi (12,000 km), 10,800 mi (18,000 km); note 5: for higher odometer readings, repeat at the frequency interval established here): dealer item; I at the 3,600, 7,200 and 10,800 mi columns. (Read from the page images, ManualsLib Honda 1978 XL250S owner's manual pp.39-40.)
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Factory

Manual: Clutch free play: inspect. Factory: Maintenance schedule pp.39-40: first at 600 mi
Cam chain tension: adjust

Final drive

Factory

Factory: Maintenance schedule pp.39-40 (columns 600 mi (1,000 km), 3,600 mi (6,000 km), 7,200 mi (12,000 km), 10,800 mi (18,000 km); note 5: for higher odometer readings, repeat at the frequency interval established here): dealer item; A at 600 mi and every column. (Read from the page images, ManualsLib Honda 1978 XL250S owner's manual pp.39-40.)
Grease and check center / side stand and springs

Rear suspension and frame

Factory

Manual: Side stand: inspect. Factory: Maintenance schedule pp.39-40
Inspect rear shocks for leaks and damping

Rear suspension and frame

Factory

Manual: Suspension: inspect. Factory: Maintenance schedule pp.39-40: dealer item; more often off-road
Adjust front drum brake

Brakes

Factory

Manual: Brake system: inspect. Factory: Maintenance schedule pp.39-40: first at 600 mi
Brake light switch: inspect

Brakes

Factory

Factory: Maintenance schedule p.40: dealer item; I at the 3,600, 7,200 and 10,800 mi columns; the 600 mi cell is under the ManualsLib watermark. Note 5: for higher odometer readings, repeat at the frequency interval established here.
Replace brake linings / skim drums (wear based)

Brakes

Factory

Manual: Brake shoe wear: inspect. Factory: Maintenance schedule pp.39-40
Check spoke tension and wheel true

Wheels and tires

Factory

Manual: Wheels/spokes: inspect. Factory: Maintenance schedule pp.39-40: dealer only; more often off-road

Every 6,500 km or 12 months

1 item

Lubricate brake cam spindles, check linings and drums

Brakes

Guideline

Every 9,500 km or 12 months

5 items

Clean carburetor float bowl(s), check float level and jets

Fuel and air

Guideline

Ethanol fuel varnishes old carbs quickly in storage.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Lubricate control cables and lever pivots

Controls and cables

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 9,500 km or 2 years

3 items

Clean centrifugal oil filter (rotor / slinger)

Engine

Guideline
Lubricate and check automatic advance unit

Ignition and electrics

Guideline
Magneto: clean slip ring and pickup brush, check HT lead

Ignition and electrics

Guideline

Every 12,000 km

4 items

Clean oil strainers / mesh screens

Engine

Factory

Manual: Engine oil filter screen: clean. Factory: Maintenance schedule pp.39-40: dealer item
Replace spark plugs

Engine

Factory

Manual: Spark plug: replace. Factory: Maintenance schedule pp.39-40
Balancer chain tension: adjust

Final drive

Factory

Factory: Maintenance schedule pp.39-40 (columns 600 mi (1,000 km), 3,600 mi (6,000 km), 7,200 mi (12,000 km), 10,800 mi (18,000 km); note 5: for higher odometer readings, repeat at the frequency interval established here): dealer only; A at the 7,200 mi (12,000 km) column. (Read from the page images, ManualsLib Honda 1978 XL250S owner's manual pp.39-40.)
Check steering head bearing adjustment

Front end

Factory

Manual: Steering head bearing: inspect. Factory: Maintenance schedule pp.39-40: dealer only; first at 600 mi

Every 16,000 km or 2 years

2 items

Compression test (or leak-down)

Engine

Guideline
Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 19,500 km or 2 years

2 items

Replace air filter element

Fuel and air

Guideline
Grease swingarm pivot

Rear suspension and frame

Guideline

Every 19,500 km or 3 years

1 item

Replace points and condenser

Ignition and electrics

Guideline

Every 29,000 km

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 32,000 km or 4 years

2 items

Repack / replace steering head bearings

Front end

Guideline

Many old machines use loose balls in cups and cones. Taper roller conversions are common.
Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 40,000 km or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 40,000 km or 10 years

1 item

Magneto overhaul / re-magnetize, replace capacitor

Ignition and electrics

Guideline

Weak spark when hot is the classic symptom. Old capacitors fail with age, not miles.

Every 48,500 km or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 12 months

1 item

Check speedometer / odometer against a known distance

Controls and cables

Guideline

Old speedos drift with tire size and drive wear. Use phone GPS over a measured 10 miles / km.

Every 2 years

2 items

Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline

Every 4 years

1 item

Replace fuel lines

Fuel and air

Guideline

Old rubber and modern ethanol fuel do not mix well.

Every 6 years

2 items

Replace inner tubes and rim tape with tires

Wheels and tires

Guideline
Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.