Honda XL250 / XL350 Workshop Manual

Honda XL250 and XL350 Workshop Documentation

• Covers 1971–1977 Honda XL250 and XL350 motorcycles, including the XL250 K1, K2, K3 and XL350 K1, K2, K3 variants with dedicated supplement sections
• Official Honda publication, compiled for machines produced from November 1971 through 1977
• Includes 100 pages of high-resolution diagrams, exploded-view schematics, troubleshooting charts, and torque specification tables for all engine and chassis systems
• Delivered as a direct download the moment payment clears
• Indexed PDF search covers every chapter and appendix
• Stored against your account so you can retrieve it after a hard-drive loss
• This 1971–1977 Honda XL250 and XL350 service manual provides the foundational technical data used for engine, frame, and electrical system maintenance across multiple production years and variant configurations.

Technical Scope and Maintenance

This factory manual details the complete engine assembly for the Honda XL250 and XL350, covering disassembly and inspection protocols for the camshaft, cylinder head, piston rings, and crankcase components. Technical chapters outline the specific lubricating oil circuit and provide clear guidance on the primary-kick starter mechanism. Electrical system coverage includes ignition timing, charging characteristics for the 6V system, and specific wiring diagrams for multiple model-year iterations. Chassis segments document maintenance for the telescopic front suspension, rear cushion assemblies, and braking systems, including adjustment procedures for the drive chain and steering components.

Specification Highlights

Reference tables document essential clearance data, including intake and exhaust valve clearances specified at 0.05 mm and 0.08 mm cold, respectively. Engine assembly documentation lists torque values for cylinder head studs at 2.0–2.5 kg-m (14.5–18.1 ft-lb). Front fork fluid capacity is identified at 160–170 cc depending on the model and assembly state. Valve clearance for the intake is listed at 0.05 mm in the cylinder head specification table. Coolant systems are not applicable, as these units utilize air-cooling. The Suzuki QuadRunner magneto pick-up coil resistance is irrelevant here, as this publication exclusively documents the Honda XL ACG output at 80W. An official 100-page Honda OEM workshop manual covering the 1971–1977 Honda XL250 and XL350, documenting engine, chassis, electrical, and carburetor specifications for the various K-series and model-year-specific builds.

Document Reference: Honda Motor Co., Ltd. Service publications office, compiled on the basis of machines produced as of November 1971