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Honda XL350R 1984 User Manual

Honda XL350R 1984
232 pages
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SHOPM
XL35
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Honda XL350R 1984 Specifications

General IconGeneral
IgnitionCDI
Final DriveChain
Front SuspensionTelescopic fork
Rear SuspensionPro-Link single shock
Rear BrakeDrum
Front Tire3.00-21
Rear Tire4.60-17
Engine Typesingle cylinder
CarburetionKeihin
Front BrakeDisc
Seat Height880 mm (34.6 inches)
Fuel Capacity12 liters (3.2 gallons)
Transmission6-speed

Summary

How to Use This Manual

General Safety

Safety precautions for engine operation and battery handling.

Service Rules

Guidelines for using genuine parts, tools, and proper assembly procedures.

General Information

Specifications

Key technical data and dimensions of the motorcycle.

Torque Values

Specific torque settings for engine and frame fasteners.

Tools

List of special and common tools required for maintenance.

Lubrication

Specifications

Oil capacity, viscosity, and recommendations.

Torque Value

Torque specification for the oil drain plug.

Troubleshooting

Common lubrication problems and their causes.

Maintenance

Specifications

Engine and chassis specifications for maintenance.

Maintenance Schedule

Schedule of periodic maintenance tasks and intervals.

Fuel System

Specifications

Fuel tank capacity and carburetor specifications.

Troubleshooting

Common fuel system issues and troubleshooting steps.

Carburetor Removal

Step-by-step guide for removing the carburetor assembly.

Engine Removal and Installation

Specifications

Engine weight and oil capacity specifications.

Torque Values

Torque specifications for engine mounting bolts.

Engine Removal

Detailed steps for removing the engine from the motorcycle.

Cylinder Head and Valves

Specifications

Standard and service limit values for cylinder head components.

Troubleshooting

Diagnosing cylinder head and valve problems.

Cylinder Head Removal

Steps to remove the cylinder head from the engine.

Cylinder Head Disassembly

Disassembling the cylinder head.

Cylinder and Piston

Specifications

Dimensions and limits for cylinder and piston components.

Troubleshooting

Diagnosing cylinder and piston issues.

Cylinder Removal

Steps to remove the cylinder.

Piston Removal

Steps to remove the piston from the cylinder.

Clutch, Oil Pump, and Kick Starter

Specifications

Standard and service limit values for clutch and oil pump parts.

Torque Values

Torque specifications for clutch, oil pump, and kick starter components.

Troubleshooting

Diagnosing clutch and oil pump problems.

Clutch

Detailed procedures for clutch removal and inspection.

Alternator

Torque Values

Torque specifications for alternator components.

Left Crankcase Cover Removal

Steps to remove the left crankcase cover.

Alternator Removal

Procedure for removing the alternator rotor and stator.

Crankshaft and Balancer

Specifications

Dimensions and limits for crankshaft and balancer parts.

Torque Values

Torque specifications for crankcase and balancer bolts.

Crankcase Separation

Steps to separate the crankcase halves.

Crankshaft Inspection

Inspecting crankshaft runout and bearing play.

Transmission

Specifications

Dimensions and limits for transmission gears and shafts.

Troubleshooting

Diagnosing transmission shifting and gear engagement issues.

Transmission Disassembly

Steps to disassemble the transmission.

Transmission Gear/Shaft Inspection

Inspecting transmission gears and shafts for wear.

Front Wheel, Suspension, and Steering

Specifications

Specifications for front wheel, fork, and steering stem.

Torque Values

Torque settings for front wheel, fork, and steering components.

Troubleshooting

Diagnosing steering, suspension, and wheel issues.

Front Fork

Procedures for front fork removal, disassembly, and assembly.

Rear Wheel, Brake, and Suspension

Specifications

Specifications for rear shock, wheel, and brake components.

Torque Values

Torque settings for rear wheel, brake, and suspension components.

Rear Wheel

Procedures for rear wheel removal, installation, and inspection.

Shock Absorber

Procedures for shock absorber removal, disassembly, and assembly.

Hydraulic Brake

Specifications

Specifications for brake fluid, discs, and caliper components.

Torque Values

Torque settings for brake system fasteners.

Troubleshooting

Diagnosing hydraulic brake system problems.

Brake Fluid Replacement/Air Bleeding

Procedures for draining, filling, and bleeding the brake system.

Rear Fender and Exhaust Pipe

Rear Fender

Procedures for rear fender removal and installation.

Exhaust Pipe

Procedures for exhaust pipe and muffler removal and installation.

Battery and Charging System

Specifications

Alternator and battery specifications.

Troubleshooting

Diagnosing battery and charging system issues.

Battery

Procedures for battery removal and specific gravity testing.

Alternator Output Test

Testing the alternator output.

Ignition System

Specifications

Spark plug types, gap, and ignition timing.

Troubleshooting

Diagnosing ignition system problems.

Ignition Timing

Procedure for checking ignition timing.

Spark Plug

Information on spark plug inspection and adjustment.

Switches, Horn, and Lights

Specifications

Specifications for lights and indicators.

Troubleshooting

Diagnosing lighting and switch issues.

Ignition Switch

Procedures for testing and replacing the ignition switch.

Headlight

Procedures for headlight removal and replacement.

Troubleshooting

Engine Does Not Start or Is Hard to Start

Troubleshooting steps for starting problems.

Engine Lacks Power

Troubleshooting steps for low engine power.

Poor Performance at Low and Idle Speeds

Troubleshooting steps for poor low-speed performance.

Poor Performance at High Speed

Troubleshooting steps for poor high-speed performance.

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