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XR80R
Honda XR80R Service Manual
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Remove
the
swingarm
pivot
nul/b
olt
and
swinga
rm
.
Remove
the
dr
ive
chain
case
and
cha
in
guard,
Remove
t
he
two
screws
a
nd
d
rive
cha
i
n
slide
r
.
Remove
the
dust
seals
and
p
i
vot
collar.
INSPECTION
Measure
each
bush
ing
1.0.
and
the
pivot
collar
O.D
.
SERVICE
LIM
IT
:
Bushing
1.0.
:
1
5.20
mm
(
0
.5
98
in
f
Pivot
co
l
la
r
0.0.:
1"
.9
4
mm
10
.
588
inl
REAR
WHEEL/BRAKE
/
SUSPENSION
DRIVE
I
CASE
D
R
IV
E
SUDER
£.
,.1'
''_
DUST
SEAL
J,
12-15
200
202
Table of Contents
How to Use this Manual
2
Contents
2
General Information
3
General Safety
3
Hot Components
3
Used Engine Oil
3
Service Rules
4
Model Identification
5
Specifications
6
XR100R General
6
XR80R General
8
Lubrication System Item
10
Fuel System Item
10
Cylinder Head/Valves Item
11
Cylinder/Piston Item
12
Clutch/Gear Shift Linkage Item
13
Crankshaft/Transmission/Kickstarter Item
13
Front Wheel/Brake/Suspension/Steering Item
14
Rear Wheel/Brake/Suspension Item
14
Ignition System Item
15
Torque Values
16
Engine
16
Frame
17
Table of Contents
18
Tools
18
Lubrication & Seal Points
19
Cable & Harness Routing
20
'98-2000 View
20
After 2000 View
21
2000/XR80R View
22
XR100R California Type View
22
'98-2000/XR100R (Except California Type) View
23
'98-'99/XR80R View
23
'98-2000/XR100R California Type View
24
98 -2000/XR100R California Type View
26
After 2000/XR100R View
26
After '99/XR80R View
26
Emission Control System
27
Source of Emissions
27
Exhaust Emission Control System
27
Crankcase Emission Control System
27
After '99/XR80R
28
After 2000/XR100R
28
Emission Control Information Label
28
'98-2000/XR100R California Type, after 2000/XR100R and after '99/XR80R
28
Frame/Body Panels/Exhaust System
29
Service Information
29
Side Cover
30
Removal/Installation
30
Seat Removal/Installation
30
Fuel Tank Removal/Installation
31
Tank Shroud (after 2000) Removal/Installation
31
Number Plate Removal/Installation
32
Front Fender Removal/Installation
32
Mud Guard Removal/Installation
32
Muffler/Exhaust Pipe Removal
32
Muffler/Exhaust Pipe Installation
33
Maintenance
35
Spo~E Wrench. 4.5
36
Maintenance Schedule
37
Note
37
Note 3
37
I I
37
Note 3: 07947-1
37
Note
38
Fuel Line
41
Fuel Strainer Screen
41
Throttle Operation
41
Air Cleaner
42
Crankcase Breather ('98 - 2000/XR100R California Type Only)
43
Spark Plug
43
Removal
43
Inspection
43
Replacing a Spark Plug
44
Valve Clearance Inspection
44
Adjustment
45
Engine Oil
45
Oil Level Inspection
45
Recommended Engine Oil
46
Engine Oil Change
46
Engine Oil Strainer Screen
47
Cam Chain Tension
47
Engine Idle Speed
48
Drive Chain Slack Inspection
49
Cleaning Inspection and Lubrication
49
Upper Drive Chain Slider
51
Lower Drive Chain Slider
51
Brake Shoe Wear
51
Front/Rear Brake Shoes
51
Brake System
52
Front/Rear Brake
52
Clutch System
53
Side Stand
54
Front/Rear Suspension Inspection
55
Spark Arrester
56
Nuts, Bolts, Fasteners
57
Wheels/Tires
58
Recommended Tire Pressure and Tire Size
58
Steering Head Bearing
59
Lubrication System View
60
Lubrication System
61
Cylinder Head Oil Check Bolt
62
Oil Pump Removal
62
Oil Pump Inspection
63
Oil Pump Assembly
64
Oil Pump Installation
65
Fuel System View
68
Fuel System
69
Air Cleaner Housing Removal/Installation
72
Carburetor Removal
72
Throttle Valve
72
Carburetor Body
73
Carburetor Disassembly
74
Carburetor Assembly
76
Float Level Inspection
78
Carburetor Installation
80
Pilot Screw Adjustment
82
Idle Drop Procedure
82
Air Screw Adjustment
84
Best Idle Procedure('98-'99)
84
Idle Drop Procedure (after '99)
85
High Altitude Adjustment
86
Engine Removal/Installation View
88
Engine Removal
90
Engine Installation
93
Cylinder Head/Valves View
98
Cylinder Head/Valves
99
Cylinder Compression Test
101
Camshaft Removal
101
Cam Lobe Height
103
Camshaft Journal
103
Camshaft Holder
103
Camshaft Oil Clearance
104
Cylinder Head Removal
105
Cylinder Head Inspection
106
Valve Spring
107
Valve Guide Replacement
108
Valve Seat Inspection/Refacing
109
Valve Seat Assembly
111
Valve Seat Installation
113
Camshaft Installation
114
Cylinder/Piston View
118
Cylinder/Piston
119
Cylinder Removal
121
Piston Removal
121
Cylinder/Piston Installation
122
Piston Ring Installation
124
Piston Installation
125
Cylinder Installation
125
Clutch/Gearshift Linkage View
128
Clutch/Gearshift Linkage
129
Right Crankcase Cover Removal
131
Right Crankcase Cover Disassembly
132
Clutch Removal/Inspection
133
Clutch Installation
135
Primary Drive Gear Removal
136
Primary Drive Gear Installation
137
Gearshift Linkage Disassembly
138
Gearshift Linkage Assembly
139
Right Crankcase Cover Installation
140
Crankshaft/Transmission/Kickstarter View
144
Crankshaft/Transmission/Kickstarter
145
Crankcase Separation
147
Crankshaft Removal/Inspection
148
Crankshaft Installation
149
Transmission Removal
149
Transmission Disassembly/Inspection
150
Mainshaft/Countershaft
151
Shift Drum
151
Shift Fork
151
Transmission Bearing Replacement
151
Left Crankcase
152
Right Crankcase
153
Transmission Assembly
154
Mainshaft
154
Countershaft
155
Transmission Installation
156
Kickstarter
157
Removal/Disassembly/Inspection/Installation
157
Crankcase Assembly
158
Front Wheel/Brake/Suspension/Steering View
160
Front Wheel/Brake/Suspension/Steering
161
Handlebar Removal
163
Handlebar Installation
164
Front Wheel Removal/Inspection
167
Front Wheel Disassembly
168
Front Wheel Assembly
169
Front Wheel Installation
170
Front Brake Removal
171
Front Brake Inspection/Disassembly
172
Front Brake Assembly
173
Front Brake Installation
174
Fork Removal
174
Fork Disassembly
175
Fork Inspection
177
Fork Tube/Slider/Piston
177
Fork Assembly
178
Fork Installation
180
Steering Stem Removal
181
Bearing Race Replacement
182
Steering Stem Installation
184
Rear Wheel/Brake/Suspension View
186
Rear Wheel/Brake/Suspension
187
Rear Wheel Removal
189
Rear Wheel Inspection
190
Wheel Bearing
190
Wheel Rim Runout
190
Driven Sprocket
190
Rear Wheel Disassembly
191
Wheel Bearing Removal
191
Rear Wheel Assembly
191
Wheel Bearing Installation
192
Rear Wheel Installation
193
Rear Brake
194
Removal/Inspection/Disassembly
194
Rear Brake Assembly
195
Rear Brake Installation
196
Shock Absorber Removal
196
Shock Absorber Disassembly/Inspection
197
Shock Absorber Assembly/Installation
198
Shock Linkage Disassembly
198
Shock Linkage Inspection/Installation
199
Swingarm Removal
200
Swingarm Inspection
201
Bushing Replacement
202
Swingarm Installation
202
Brake Pedal Removal/Disassembly
203
Brake Pedal Assembly/Installation
204
Ignition System View
206
Ignition System
207
Ignition System Inspection
210
Ignition Coil Primary Peak Voltage
210
Ignition Pulse Generator Peak Voltage
211
Alternator Exciter Coil Peak Voltage
212
Ignition Coil Removal/Installation
213
Ingition Control Module Removal/Installation
213
Engine Stop Switch Inspection
214
Ignition Timing
214
Flywheel/Stator Removal
215
Flywheel/Stator Installation
217
Stator Base Removal
218
Oil Seal Replacement (XR100 Only)
219
Stator Base Installation
219
Ignition Switch (after 2000) Inspection/Removal/Installation
219
Wiring Diagram
221
After 2000
222
Troubleshooting
223
Engine Does Not Start or Is Hard to Start
223
Engine Lacks Power
224
Poor Performance at Low and Idle Speeds
225
Poor Performance at High Speeds
226
Poor Handling
226
Index
227
5
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Honda XR80R Specifications
General
Brand
Honda
Model
XR80R
Category
Motorcycle
Language
English
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