1971–1977 Honda XL250 / XL350 Workshop Manual (OEM)

Honda XL250 and XL350 Workshop Documentation

Documents the 1971–1977 Honda XL250 and XL350 motorcycles, detailing 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.
• Features 100 pages of high-resolution diagrams, exploded-view schematics, troubleshooting charts, and torque specification tables for all engine and chassis systems.

Technical Scope and Maintenance

This factory reference outlines the complete engine assembly for the XL250 and XL350. It details disassembly and inspection protocols for the camshaft, cylinder head, piston rings, and crankcase components. Technical chapters trace the lubricating oil circuit and provide clear diagrams of the primary kick-starter mechanism. Maintaining proper workshop safety and verifying these factory specifications before any tear-down is critical for a safe, reliable rebuild.

Electrical system sections map out ignition timing, charging characteristics for the 6V system, and specific wiring diagrams for multiple model-year iterations. Chassis documentation highlights maintenance for the telescopic front suspension, rear cushion assemblies, and braking systems, alongside adjustment procedures for the drive chain and steering head.

Specification Highlights

Reference tables supply essential clearance data, including intake and exhaust valve clearances specified at 0.05 mm and 0.08 mm cold, respectively. Engine assembly guides list torque values for cylinder head studs at 14.5–18.1 ft-lb (2.0–2.5 kg-m). Front fork fluid capacity is identified at 160–170 cc, depending on the model and assembly state. (Note: Coolant systems are not applicable, as these units utilize air-cooling.)