Honda XL250 XL350 Motorcycle Service Manual 1972 – 1978

Description

This 101 page, Honda XL250 XL350 Motorcycle Service Manual is a reproduction (by Honda) of the original, out of print manual. This book provides detailed service information, step-by-step repair instruction and maintenance specifications for 1972 – 1978 HondaXL250 XL350 motorcycles.

The cover shown may differ from the cover that you receive.  Some covers say “1973-78” but we’ve confirmed that the manual covers 1972-1978.

Honda XL250 XL350 Service Manual Vehicles Covered

1972 Honda XL250
1973 Honda XL250
1974 Honda XL350(K0)
1974 Honda XL250K1
1975 Honda XL350K1
1975 Honda XL250K2
1976 Honda XL350
1976 Honda XL250
1977 Honda XL350
1977 Honda XL250
1978 Honda XL350

Did you know that your Honda XL350 engine oil should be changed every 3000 miles? This manual will tell you everything you need to know in order to care for your motorcycle.

Table of Contents

ENGINE
DISASSEMBLY WORK
REMOVAL OF ENGINE
CYLINDER HEAD COVER AND ROCKER ARM SHAFTS
CAMSHAFT AND CYLINDER HEAD
CAM CHAIN AND CAM CHAIN TENSIONER
CYLINDER AND PISTON
LUBRICATING OIL CIRCUIT
OIL FILTER SCREEN
CENTRIFUGAL OIL FILTER
OIL PUMP
CLUTCH
KICK STARTER
CRANKSHAFT AND CONNECTING ROD
TRANSMISSION
GEAR SHIFT MECHANISM
BREATHER
CARBURETOR
THROTTLE VALVE AND JET NEEDLE
FLOAT, MAIN J AT AND SLOW JET

CHASSIS
FRONT BRAKE AND FRONT WHEEL
FRONT WHEEL
ADJUST FRONT BRAKE
FRONT BRAKE
REAR BRAKE AND REAR WHEEL
REAR WHEEL
ADJUST BRAKE PEDAL
ADJUST DRIVE CHAIN

STEERING SYSTEM
STEERING HANDLE
STEERING STEM
ADJUST CLUTCH LEVER
ADJUST THROTTLE GRIP
PASSAGES OF THROTTLE, CHOKE AND CLUTCH CABLES

FRONT SUSPENSION
CONTENTS
REAR CUSHION
REAR CUSHION
REAR FORK
FRAME
AIR CLEANER ELEMENT

ELECTRICAL SYSTEM
PRECAUTIONS FOR SERVICE WORK
GENERAL DESCRIPTION
IGNITION SYSTEM
CHARGING SYSTEM
BRAKE LINING INDICATOR

MAJOR MODIFIED POINTS OF XL 350
AIR-CUT VALVE
COMPARATIVE SPECIFICATIONS BETWEEN XL250, XL250K1 and XL350
DRIVE CHAIN CONNECTOR AND DISCONNECTOR OPERATION

TROUBLE SHOOTING

MOTOCROSS RIDING

SPECIAL TOOLS

MAINTENANCE SCHEDULE

SPECIFICATIONS

TORQUE SPECIFICATIONS

SERVICE DATA

Honda XL250 WIRING DIAGRAMS

SUPPLEMENT TO Honda XL250K2, XL350K1

SUPPLEMENT TO Honda XL250 K3, XL350 K2 1976

SUPPLEMENT TO Honda XL 350 1977