Oct 03, 2018  From the in-depth knowledge required for XL250s rebuilds to simple resources for 1980 Honda XL250s specs, you'll find it all in this handy repair manual. It's the perfect guide for all things related to 1978-1984 Honda XL and XR models. Complete service repair workshop manual for the: Honda XL250R XL250S XL250 XL 250 This is the same manual motorcycle dealerships use to repair your bike. Manual covers all the topics like: Engine Service, General Information, Transmission, Chassis, Lighting, Steering, Seats,.

From the in-depth knowledge required for XL250s rebuilds to simple resources for 1980 Honda XL250s specs, you'll find it all in this handy repair manual. It's the perfect guide for all things related to 1978-1984 Honda XL and XR models. You'll love that you can finally tackle some of those repair or restoration projects for this popular classic bike right in your very own garage. Plus, you'll get to know your motorcycle better than ever before thanks to this Honda XL250s and Honda XL500s service manual.

A major bonus with this repair guide is that it covers a wide range of models from this era in Honda's history. For collectors, that makes it an all-in-one guide for some of their favorite bikes.

This Haynes M567 repair manual covers Honda XL250, XR250, XL500 and XR500 dual-purpose (enduro) bikes from 1978-1984, including:

• Honda XL250S, UK 1978-1982, US 1978-1981
• Honda XL250R, UK 1982-1984, US 1982-1983
• Honda XR250, UK 1979-1980, US 1978-1980
• Honda XR250R, US only 1981-1982
• Honda XL500S, UK 1979-1982, US 1979-1981
• Honda XL500R, UK 1982-1984, US 1981-1982
• Honda XR500, UK 1979-1989, US 1979-1980
• Honda XR500R, US only 1981-1982

Book Excerpt: 1978-1984 Honda XL250, XR250, XL500, XR500 Repair Manual

ENGINE, CLUTCH AND GEARBOX

ENGINE REASSEMBLY: SETTING THE BALANCER CHAIN TENSIONER

1. Once the crankshaft halves have been assembled, the balancer chain tension should be set to provide the correct operating conditions for the chain and sprockets.

   To achieve this, it is necessary to vary the distance between the front and rear balancers, and it is for this purpose that the front balancer holder is provided.

   The front balancer shaft runs in the eccentric bore of a tubular holder. The right-hand end of the holder terminates in an adjuster plate which is located by a single retaining bolt.

   When adjustment is necessary the holder is rotated in the crankcase, effectively moving the axis of the front balancer shaft forwards or backwards.

2. To adjust the chain tension it will first be necessary to fit the adjuster spring to the adjuster plate or flange. Check that the holder moves freely in the casing and turns fully anti-clockwise under spring pressure. Check that the chain is tensioned in this position.
3. The lower edge of the adjuster plate is marked by a series of lines. The balancer chain tension is set by moving the adjuster plate back (clockwise) by one graduation from the fully tensioned position. Holding this position, refit and tighten the locking bolt to 16-20 lbf ft (2.2-2.8 kgf m).
4. Occasionally it may prove impossible to obtain sufficient adjustment within the range of movement provided by the elongated slot.

   If this proves to be the case it will be necessary to move the adjuster plate in relation to the holder. Disconnect the adjuster spring.

   Release the circlip which retains the balance weight, then slide the latter off the end of the balancer shaft.

   Remove the plain washer which is fitted behind the adjuster plate to the holder. It will be seen that the adjuster plate is located by tangs which engage in corresponding slots in the holder.

   Withdraw the adjuster plate and reposition it one slot further round (clockwise) to bring the range of adjustment within the scope of the plate.

WHEELS, BRAKES AND TIRESFRONT WHEEL: REMOVAL AND REFITTING

1. As no centerstand is fitted, some alternative means of supporting the machine with the wheel clear of the ground must be found prior to wheel removal.

   A stout wooden box or similar is usually suitable, but ensure that there is no risk of the machine toppling whilst it is being worked on.

   Commence dismantling by slackening off the front brake cable adjustment at both ends, then disconnect the cable at the wheel after disengaging the cable at the operating lever. The speedometer drive cable should be released by its single retaining screw.

2. Straighten and remove the split pin (XL models only) which secures the wheel spindle nut, then remove the nut itself. Remove the clamp bolt(s) at the other end of the spindle, then withdraw the spindle and lower the wheel clear of the forks.
3. With the wheel removed from the machine, the brake backplate assembly can be removed for examination. Refer to next section for brake inspection.
4. The wheel may be refitted by reversing the removal procedure. When lifting the wheel into position ensure that the lug on the left-hand fork leg engages with the slot in the brake backplate. If this requirement is overlooked the brake will lock on the first application.

Subject: 1978, 1979, 1980, 1981, 1982, 1983, 1984 Honda XL250, XR250, XL500, XR500 service, maintenance, repair. ISBN-10: 1850102686 | ISBN-13: 9781850102687 | Haynes M567

Complete coverage for your vehicle

Written from hands-on experience gained from the complete strip-down and rebuild of a Honda Motorcycle XL250, Haynes can help you understand, care for and repair your Honda Motorcycle XL250. We do it ourselves to help you do-it-yourself, and whatever your mechanical ability, the practical step-by-step explanations, linked to over 900 photos, will help you get the job done right. Regular servicing and maintenance of your Honda Motorcycle XL250 can help maintain its resale value, save you money, and make it safer to ride.

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Maintenance schedule Simple weekly checks and servicing guides to keep you on the road	Printed manual	Digital manual
Comprehensive procedures Guide you through every step from minor adjustments to major overhaul	Printed manual	Digital manual
Fully illustrated With hundreds of photos	Printed manual	Digital manual
Hints and practical advice From the DIY experts provide inside information	Printed manual	Digital manual
Specifications and data Enable testing and measuring for wear	Printed manual	Digital manual
Wiring diagrams Enable tracing of electrical faults	Printed manual	Digital manual
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What's covered

Honda CB100 (1970-1972)
Honda CB125S (1973-1982)
Honda CL100 (1970-1972)
Honda CL100S (1971-1973)
Honda CT125 (1977)
Honda SL100 (1969-1973)
Honda SL125 (1971-1973)
Honda TL125 (1973-1975)
Honda TL125S (1976)
Honda TL250 (1975-1976)
Honda XL100 (1974-1978)
Honda XL125 (1974-1978)
Honda XL175 (1973-1978)
Honda XL250 (1972-1976)
Honda XL350 (1974-1978)

Table of contents

This Honda Vintage Motorcycle Manual is 368 pages.

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Service hints / Torque specifications / Safety first / Special tips / Parts replacement / Expendable supplies / Serial numbers / Tune-up and troubleshooting tools

CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Troubleshooting instruments / Emergency troubleshooting / Engine starting / Engine performance / Excessive vibration / Front suspension and steering / Brake problems

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Routine checks / Service intervals / Tires and wheels / Crankcase breather hose / Battery / Periodic lubrication / Engine oil change / Oil filter screen cleaning / Front fork oil change / Periodic maintenance / Drive chain adjustment/ Front brake lever adjustment / Rear brake pedal adjustment / Clutch adjustment / Air filter service / Fuel shutoff valve and filter service / Engine tune-up / Camshaft chain tensioner adjustment / Valve clearance adjustment / Spark plugs / Contact breaker point adjustment / Static ignition timing adjustment / Dynamic ignition timing adjustment / Idle speed adjustment / Specifications

CHAPTER FOUR / 100 AND 125 CC ENGINES
Engine principles / Engine cooling / Servicing engine in frame / Engine removal/installation / Camshaft / Cylinder head / Cylinder head cover and camshaft / Camshaft chain / Valves and valve components / Cylinder / Piston, piston pin and piston rings / Oil pump / Crankcase and crankshaft / Camshaft chain and tensioner / Kickstarter / Break-in procedure / Specifications

CHAPTER FIVE / 175, 250 AND 350 CC ENGINES
Engine principles / Engine cooling / Servicing in frame / Engine removal/installation / Cylinder head cover and camshaft / Camshaft chain / Cylinder head / Valves and valve components / Cylinder / Piston, piston pin and piston rings / Oil pump / Crankcase and crankshaft / Camshaft chain and tensioner / Kickstarter / Break-in procedure / Specifications

CHAPTER SIX / CLUTCH AND TRANSMISSION
Clutch operation / Clutch / Clutch inspection / Clutch cable / External shift mechanism / Drive sprocket / Transmission and internal shift mechanism / 5-speed transmission and internal shift mechanism / Specifications

CHAPTER SEVEN / FUEL AND EXHAUST SYSTEMS
Air cleaner / Carburetor operation / Carburetor service / Carburetor adjustments / Throttle cable / Fuel tank / Fuel filter / Crankcase breather system / Exhaust system / Specifications

CHAPTER EIGHT / ELECTRICAL SYSTEM
Charging system / Rectifier / Voltage regulator/rectifier / Alternator / Breaker point ignition / Capacitor discharge ignition / Ignition coil / Ignition pulse generator / Ignition advance mechanism / Lighting system / Switches / Specifications

1978 Honda Xl250s Manual Download Free

CHAPTER NINE / FRONT SUSPENSION AND STEERING
Front wheel / Front hub / Wheels / Tire changing / Tire repairs / Handlebar / Steering head / Front fork / Specifications

CHAPTER TEN / REAR SUSPENSION
Rear wheel / Rear hub and driven sprocket / Drive chain / Drive chain case / Swing arm / Specifications

CHAPTER ELEVEN / BRAKES
Drum brakes / Front brake cable / Front disc brake / Brake pad replacement / Brake caliper body / Specifications

INDEX

Craigslist Honda Xl250

COLOR WIRING DIAGRAMS

Models covered:
1970 1971 1972 HONDA CB100
1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 HONDA CB125S
1970 1971 1972 HONDA CL100
1971 1972 1973 CL100S
1977 HONDA CT125
1969 1970 1971 1972 1973 HONDA SL100
1971 1972 1973 HONDA SL125
1973 1974 1975 HONDA TL125
1976 TL125S
1975 1976 HONDA TL250
1974 1975 1976 1977 1978 HONDA XL100
1974 1975 1976 1977 1978 HONDA XL125 1973 1947 1975 1976 1977 1978 HONDA XL175
1972 1973 1974 1975 1976 HONDA XL250
1974 1975 1976 1977 1978 HONDA XL350

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1978 Honda Xl250s Manual Download Pdf

CB100 (1970-1972)
CB125S (1973-1982)
CL100 (1970-1972)
CL100S (1971-1973)
CT125 (1977)
SL100 (1969-1973)
SL125 (1971-1973)
TL125 (1973-1975)
TL125S (1976)
TL250 (1975-1976)
XL100 (1974-1978)
XL125 (1974-1978)
XL175 (1973-1978)
XL250 (1972-1976)
XL350 (1974-1978)

1978 Honda Xl250s Wire Diagram

Online manual

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1978 Honda Xl250 Specs

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1978 Honda Xl250s Manual Download Windows 7

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