Honda XL250 / XL350 Workshop Manual (1971–1977)

Honda’s factory workshop manual covers the XL250 and XL350 through their K3 variants. It starts with the XL250 and XL250 K1 procedures, explains where the XL350 differs, and adds three supplements for the later variants through the 1977 XL350 K3.

PDF Search, Navigation, and Printing

Text search and wiring diagrams. Workshop text is searchable across the main chapters and supplements. Use the printed contents pages to locate chapters, as the PDF has no embedded bookmarks. Zoom in to read small wire-color codes and connector labels. The XL350 General Version diagram’s labels are primarily available on the page image.

The download is one printable English PDF with 100 pages, including the cover and all three supplements.

Engine, Chassis, and Electrical Service

These are selected workshop topics. The manual also covers throttle and clutch cable routing and air-cleaner element service.

• Engine repair covers engine removal and post-installation adjustments, cylinder-head and rocker-arm disassembly, valve-guide replacement, valve-seat inspection, cam timing and chain service, and cylinder, piston, crankshaft, and connecting-rod checks.
• Lubrication and drivetrain covers the pressure-fed oil circuit, filter screen and centrifugal filter, trochoid oil pump, clutch, primary kick-starter, transmission, shift drum, shift forks, and crankcase breather.
• Carburetor service covers the throttle valve and jet needle, float and jets, and float-level and idle adjustments. The XL350 section explains how the air-cut valve works.
• Chassis service covers front and rear wheels, drum brakes, steering-head bearings, telescopic fork disassembly and seal replacement, rear shocks, swingarm inspection, and drive-chain adjustment.
• Electrical diagnosis covers ignition-coil tests, breaker points and timing, generator output, rectifier and regulator checks, battery service, and continuity checks for lighting, stop switches, horn, neutral, and engine-stop circuits.
• Troubleshooting charts match symptoms to probable causes and remedies for no-starts, unstable idle, power loss, overheating, clutch and shifting faults, braking and suspension problems, and charging or battery faults.
• Workshop reference tables provide torque specifications, clearances, fluid capacities, wear limits, electrical test values, carburetor settings, and maintenance schedules.

The manual suits professional mechanics and experienced owners with the tools to measure wear and check clearances. Honda marks certain scheduled jobs for dealer service unless the owner has the proper tools and mechanical proficiency.

XL350 Changes and Later Supplements

Base XL350 and XL250 K1. The XL350 chapter includes a bearing-selection table for the connecting-rod big end. It also shows how to cut, press-fit, and stake the endless drive chain used on the XL250 K1 and XL350. The brake lining indicator section identifies the frame-number change for front and rear indicators on the XL350 General type.

XL250 K2 / XL350 K1. The supplement covers revised fuel-cock markings and handlebar switches, inspection of the side stand with its shock-absorbing rubber pad, an updated maintenance schedule, and separate wiring diagrams.

1976 XL250 K3 / XL350 K2. The supplement covers the three-piece oil-control ring, tachometer idler-shaft oil orifice, revised kick-starter spindle and idle gear, and the XL250 K3 change to a ball bearing at the crankshaft. It also gives carburetor settings, suspension inspection data, muffler and spark-arrestor service, cable routing, and a shared wiring diagram.

1977 XL350 K3. The final supplement covers fuel-filter screen service, revised rocker-arm shaft installation, carburetor disassembly and adjustment, and the updated maintenance schedule. The wiring diagram series runs through the shared XL250 K3 / XL350 K2 sheet.

Diagrams, Special Tools, and Repair Cautions

The oil-circuit, primary kick-starter, ignition, and charging illustrations show how those systems are laid out. The charging tests help determine whether to check generator output or turn to the regulator when the battery keeps discharging. Exploded views support work on the engine, carburetor, wheels, brakes, fork, rear suspension, and exhaust.

The special-tool list identifies the valve spring compressor 07957-3290000, valve guide remover 07942-3290100, rear cushion service tool 07959-3290000, front fork seal driver 07947-3290000, and drive-chain connector/disconnector 07975-3000001.

Honda explains how a misaligned countershaft oil seal can block the oil feed and cause the shaft and gears to bind. The manual also cautions against reversed battery polarity and high-speed generator operation with the rectifier terminal disconnected. Additional precautions cover contaminated brake linings, flammable fuel and solvents, battery-charging gases, and hot exhaust components.

The motocross chapter describes XL250 electrical changes for competition use and gives sprocket, chain, and rear-axle combinations.

Piston Ring and Fork Service Data Preview

For the XL250 K3, the supplement gives a standard top-ring end gap of 0.15–0.35 mm and a service limit of 0.75 mm. The table distinguishes the normal inspection range from the wear limit.

For the XL250 K3 and XL350 K2, the front fork section lists 165 cc for a dry assembly and 150–155 cc after draining.