2001 HONDA XR100R 4-STROKE Motorcycle Factory Service & Work Shop Manual
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HOW TO USE THIS MANUAL
TtliS s ervice mll"ual describes the service proce dures
for the XA80R and XR100R.
Follow the Ma intenance Schedule ISection 31 recom-
mendat i ons 10 ensure thaI the veh icle is in peak
operating condition and the em ission levels arO within
the standards set by the Ca lifornia Air Resou rces Board.
Performing the f irst schedu led maintenance is very
important. It comp",ns&les fOf Ihe in itia l wear that
occurs during th ... brea):-in period.
Sections 1 and 3 apply to the who le motorcyc le.
Section 2 illustrates procedures for removal/inSI,, 'l ation
of components 1hal may be flKlui.ed 10 perform service
descri bed in the follo w ing sectiOns.
Sec tion 4 through 13 descr ibe parts of Ihe motorcycle,
grouped a(;Gording to locati on.
find Ih e sect ion you w8nt on th is page, then turn to
the t8bl e of COntents on the first page of t he section.
Most se<:tions have an assembly or system illustration.
service informat ion and tro ubl eshoot ing forthe section.
The subsequent pages give detailed procedure.
If yo u don't know the source of the tro uble, goto section
15. T roub les hooting
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CONTENTS
MAINTENANCE
LUBRICATION SYSTEM
FUEL SYSTEM
ENGINE REMOVAL/ INSTALLATION
CYLINDER HEAD/VALVES
CYLINDER/ PISTON
REAR WHEEL/ BRAKE / SUSPENSION
IGNITION SYSTEM
WIRING DIAGRAM
TROUBLESHOOTING
INDEX
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1. GENERAL INFORMATION
GENERAL SAFETY
SERVICE RULES
MODEL IDENTIFICATION
SPECIFICATIONS
TORQUE VALUES
TOOLS
GENERAL SAFETY
CARBON MONOXIDE
, -,
'-2
'-3
,-,
'-14
'-16
If the englOe must be runni ng to do some work, ma ke sure
t he area is w ell vent il ated . Ne ver run the en gi ne in an
enC losed area.
Th .. e xhaust contains poisonous carbon monoxide gas. that
ean causlIlon of con"d ou$II ess and may lead to death.
R..,n the engine ir> a" open area or with an exhaust evacuation
system in an enclosed area .
GASO LINE
Work i n II well ventilated area. Keep cigarettes, flames or
sparks away from the work area or where gasoline is sto red.
t,SWWiiM
Gasolinfl is eXlremely flam mable and is explosive under
certain condi tions, KEEP OUT OF REACH OF CHILDREN.
LUBRICATION & SEAL POINTS
'-17
CABLE & HARNESS ROUTING 1-18
EMISSION CONTROL SYSTEMS
' ·25
EMISSION CONTROL
INFORMATION LABEL 1-26
HOT COMPONENTS
' IWi.liliM
Engine and exhaust syst em parts become very h ot I>nd
remain hot for soml> time "fter the engine ;$ run . Wear
Insulated gloves or wait until the engine and exhaust system
have cooled before handling th ese parts_
USED ENGINE OIL
Uud engine oil may cauSe sk in cancer if repeatedly left in
contact wi th t he sk in for prolonged periods. Although this
i5 unlikely unless you handle used oil on a daily bltsis, it is
stjJI advisllble to thoroughly wash your hands with so"p
and water as soon as possible after handling used oil. KEEP
OUT Of REACH OF CHILDREN.
BRAKE OUST
N evef \,)~e an all tlose 01 01'1 bfllsh te e lell n the bf~ \O.e
assemblies.
t1;: II i.IAM
Inh"led as/Jestos fibers have bo!en fo und to taus .. respira t ory
disease a"d cancer.
E
1-1
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GENERAL INFORMATION
SERVICE RULES
1. Use genu ine HONDA or HONDA· recommended parts and 'ubricants or their eq uivalents. Paris thai don't meet HONDA's
desi gn specifications may cause damage to Ihe mot orcycle.
2. Use the special t ools designed for this product to avoid damage and incorrect assembly.
3. Use on ly met ric tools w hen serviCing the motorcycle. Metr ic bolts, nuts and s<:rews arQ not interchangeable with English
fasteners.
4. Install new gaskets, 0·ring5. cotter pins, and lock plates when reassembling.
5. When t ighte ning baits or nuts. begin with the la rger diameter or i nner b olt first. Then tighten to the spec ifi ed torque
di agonally ill i "eramari/al steps unless Ii partieul iff sequence i~ specified,
6. Clean parts in clean ing solvent upon disassembly. l ubricate any sliding surlaces before reassembly.
7. After reassembly, check all parts for proper installa tion aod o~ratIO o .
8. Route all electrical wires as show 00 pages ' ·1 8 throu gh '·24, Cable and Harness Routing.
1-2
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MODEL IDENTIFICATION
j2) The eng ine serial number is stampe d on the lower
left of the crankcase.
(. ) The car bure tor identification number is stamped on
the right side of the ca r bu retor body as sh own.
GENERAL INFORMATION
FRAME SE RIAL NUMBER
(1) The fra me serial numbe r is stamped on the left side
of the steering head.
~
VEHICLE IDENTIFICATION NUMBER (VIN)
(3) The Vehicle I dentification N umbe r (VI N) is located on
r ight side of the st eering hea d on the Safety
CertificatiOn Label.
(5) The color Jab al is attached as shown. When ordering
COlor-COded part. always specify the designaTed COlo r
code.
1-3
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GENERAL INFORMATION
SPECIFICATIONS
XR100R
GENERAL
I TEM
DIMENSIONS Overall length
Overall width
Ov~ra ll heig ht
Wheelbase
Seat height
Footpeg height
Ground clearance
Ory weight
Curb we ight
FRAME
Fra me type
Front suspension
Front wheel travel
Rear suspension
Rear wheel trallel
Rear damper
Front ti re size
RI!M 'irt size
Ti te brand
Front brake
Rear brake
Caster angle
Trail length
Fuel tank capacity
FUel tank reserve capacitv
ENGI NE Bore and stroke
Disp lacement
Compression .ali o
Vallie train
'98 - 2000:
After 2000:
'98 - 2000:
After 2000:
'98 - 2000 :
After 2000:
'98 - 2000 :
After 2000:
'98 - 2000:
After 2000:
'98- 2000:
After 2000:
'98 - 2000
After 2000:
'98 - 2000:
Aft er 2000:
'98 - 2000:
After 2000:
'98 - 2000:
After 2000:
'98- 2000:
After 2000:
6ridgestone
'98- 2000,
After 2000:
'98 - 2000:
After 2000:
'98 - 2000:
After 2000:
'98 - 2000:
After 2000:
lnr"ke vallie
opens f "t 1 m m
closes 10.04 inl
Exhaust valve opens 11ft
closes
Lubricati Ol'l syst em
Oi l pump type
Coo ling svstem
Air filtrat ion
Crankshaft type
Engine dry we ight
Cyl inder arrangement
'·4
SPE CI FI CATIONS
1,855 mm 173.0 in)
1,869 mm 173.6 in)
800 mm 131 .5 in)
8 16 mm 132. I in)
1,050 mm 141 .3 inl
1,102 mm (43. 4 in!
1,255 mm 149.4 in!
1,264 mm (49.8 inl
170 mm (30.3 in)
175 mm (30.5 in!
320 mm 1 I 2.6 in!
308mm1 1 2. 1 in!
265 mm 110,4 in!
253 mm (10,0 in)
68 kg (ISO Ibsl
75 kg (165Ibs!
75 kg (165Ibs)
79 ~ g (17 4 Ib s)
Back bone
Telescopic fork
126 mm 15.0 in)
1 32 mm (S.2 in)
Swinga rm
120 mm 14.7 in)
140m m (5.5i n)
Con llent ional type oil damper
2.50· t 9-4 PR
3.00-16-4 PR
Front: M 23 Rear: M22
Internal ex panding shoe
Internal expanding shoe
28· lO'
29" 52'
110 mm (4.l in)
103 mm 14.1 i nl
6.2 t 11.64 US gal, 1,36 Imp gall
5.6 t 11.48 US gal, 1. 23 Imp ga ll
2. ,
e 10.55 US gaL 0.46 Imp gal)
... e 10.29 US gal. 0.2 4 Imp ga l)
53 .0 X 45,0 mm 12.09 X 1.77 in)
99. 2 em
J
16.1 cu-i,,)
9.4: 1
Silent, mu lt i- link chain drive and OHC w ith rocker arm
10· BTDC
35" ABDC
40· BBDC
50 ATDC
Forced pressure and wet sump
Trochoid
Air cooled
Oiled polvu.etl'la l'lC foam
Assembled type
21.4 kg 147.18 Ibs)
Si ng le cvlinder inclined 15" from lIertical
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GENERAL INFORMATION
GENERAL (Cant'd)
ITEM SPECIFICATIONS
CARBURETOR Ca .b uretor type Piston valve
Throttle bore 20 mm 10.8 in)
DR I VE TRA IN Clutch system M ulti -plate, wet
Clutch operati on system Mechanical type
Transmission S-s pe ed
Pri mary reduction 4.438171/161
Final reducti on 3_ 571 {SOT/ U TI
Gear ratio
,,,
3.083 {37T/ 12H
>e '
1.88202T/ 17Tl
3"
1.400 (28T/20H
."
1_130 ( 26T/23T)
51h 0.923 (2H/26H
Gearshift pallern Left foot operated return system, l - N - 2 -3 - 4- S
ELECT RIC AL Igni ti on system Condenser Discharged Ignit ion
Sian ing system Kiclcs ta r1e r
1-5
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GENERAL INFORMATION
XR80R
GENERAL
ITEM SPEC IFICATI ONS
DIMENSIONS Overall length '98- 2000: 1, 74 0 mm (68.5 in l
Atter 20 00: 1.743 mm (68.6 in)
Overall wi dth '98 - 2000: 755 mm (2 9.7 in)
A fte r 2000: 778 mm (30.6 in)
Overall heig ht '98 - 2000 : 980 mm (38.6 in)
After 2000: 1.030 mm (40.6 in )
Wheelbase '98 - 2000 : 1,210 mm (47.6 in)
A fter 2000' 1.208 mm (47.6 in)
Seat height '98 - 2000: 725 mm (28.5 in)
Atter 2000: 727 mm (2 8.6 in)
Footpeg height '98 - 2000 : 265 mm (10 .4 in)
AfTer 2000: 257 mm (10.1 in)
Ground clearance '98 - 2000 : 220 mm (S. 7 inl
AfTer 2000 : 206 mm 18.1 in)
Dry weight '98 - 2000 : 64 ~ g (1 41 lbsl
AfTer 2000: 70 ~g !154 1bsl
Curb weig ht '98 - 2000 : 69 ~g (152 Ibs)
After 2000: H kg (163 Ibs)
FRAME Frame type Back bone
Front suspension Telesco pi c fork
Front wheel travel 126 mm (5.0 in)
Rear suspension Sw i ng<l rm
Rear wheel travel 110 mm (4.3 in)
Rear damper Conventional type oil damper
Front ti re si ze 2.50-1 6-4 PR
Rear tire size 3.60-14- 4 PR
Ti re brand IRe Front: GS-45ZI IR ea r: GS-45ZI
Front brake Interna l ex panding shoe
Rear br{lke Internal expanding shoe
Caster angle '98- 2000: 28' 30'
AfTer 2000: 27· 34'
Trail length '98 - 2000 : 75 mm (3.0 in)
After 2000: 68 mm (2.7 in)
Fuel tank capacity '98 - 2000 : 6.2 t (1. 64 US gal, 1.36 Imp gal)
AfTer 2000: 5,6 e (1.48 US gal, 1.23 Imp gal)
Fuel tank reserve capacity '98 - 2000 : 2.1 t (0.55 US gal, 0. 46 1mp gal)
AfTer 2000: 1.1 t (0.29 US gal. 0.24 Imp gal)
ENGINE Bore and stroke 47.5 X 45,0 mm (1 87 X 1.77 inl
Displacement 79.7 cm
J
(4. 86 cu-in)
Compression ra ti o 97
,
Va lve (Jain Chain d riv e and OHC with rocker arm
Intake valve
opens f at 1 mm
S" BTDC
closes (0 .04 in ) 40' ABDC
Exhaust valve opens 11 ft 40· BBDC
clo ses 8' ATDC
Lubr ication system Forced pressure and wet sump
Oil pump type Trochoid
Coo ling system Air cooled
Air filtrat ion Oiled polyurethane foam
Crankshaft ty pe Assembled type
Eng ine dry we i ght 18.9 kg (41 .7 Ibs)
Cy l inder arrangement Single cylinder inclined 15° from vertical
1-6
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GENERAL INFORMATION
GENERAL (Cont'd)
I
ITEM SPECI FICATI ONS
CARBURETOR Carburetor type Pist on valve
Throltle bore 18 mm (0 .7 in)
DRIVE TRAIN Clutch system Mulli-plate. w eI
Clutch operation system Mechanical type
Transmission 5-speed
Pri ma ry reduction 4.4 37 ( 71 /1 6)
Fi na l reduct i on 3.285 (46.'14 )
Gear rat io
'"
2.692 (35/13)
200 1.823 (3 1/ 17 )
3"
1.400 (28/20)
""
1 .1 30 (26/23)
""
0.960 (2 4/25 )
Gearshift pattern
Left foot ope rated return system. 1 - N - 2 - 3 - 4 - 5
ELECTRICAL Ignition system Ca p ac itive Discharged Ignition
Starti ng system Kickstarter
1-7
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GENERAL INFORMATION
LUBRICATION SYSTEM
, ,
Un·t· mm (n)
ITEM
STA NDARD SE RVI CE LIMIT
Engine oi l capacity I XR100R AI d ra ining 0. 91 (0.95 us qt 0.79 Imp qt)
At disassembly 1.0 ~ (1.06 us qt, 0.88 Imp qt )
XR80R At draining 0.8 e (0,85 us qt. 0.70 Imp qt )
At disassembly 0.9 ~ (0.95 us QI. 0.79 Imp qt )
Recommended erlgine oil HO NDA GN4 or HP4 ( -stroke oil or
equivalent motor oil
API se rvice Classification: SF or SG
Viscosity: SAE 1 0W-30
---
Oi l pum p rot or Tip clea rance
0.15 (0 .006) 0. 20 lO .008 )
Body clearance 0.15 - 0. 21 (0 .006 - 0.008) 040 (0.016)
Side clearance 0. 02 - 0.07 (0.001 - 0.003) 0.Q2 5 (0,010)
FUEL SYSTEM
" EM
STANDARD SERVtCE LIMIT
Caburetor i dentificat ion XR100R '98 2000/e )( cepl PD80C
number
Ca l ifornia type
--
'98 2000/Cal ifo rnia PDC3D
type
After 2000 PDCJL
XR80R '98 - '99 PC 20B
2000 PC20F
After 2000 PC20J
Main jet XR100R '98- 2000 #95
Aher 2000
'"
XRBOR #95
Slow jet XR 100R '98 2000/e )( cept #38 X #38
Ca lif orni a t ype
'98 2000/C al if orni a #35 X #35
'VP'
After 2000 #35 X #35
XR BO R
#3'
Jet needle clip posit ion XR 100R 3rd groove from t op
XR80R '98 -'99 2n d groove from top
After '99 Jrd groove from t op
Pilot screw opening XR 100R See page 5, 14
Air screw opening XR80R See page 5·16
Float level XR100R 12.5 mm (0 .<19 in)
XR80R 21.5 m m (0 .85 in)
Engine i dle speed XR1 00R 1,400 ± 100 rpm
XR8 0R
l,5()O ± 100 rpm
Thr ottle grip free pl ay 2.0 - 6.0 mm (1/1 2 - 1/4 i n)
1-8
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Print one or all pages of your manual
$39.99
Upon purchasing this manual, you will receive a .PDF file containing an email contact. After contacting us, you will receive a reply with a link to access the manual for your 2001 HONDA XR100R 4-STROKE MOTORCYCLE.
This comprehensive manual covers every nut and bolt on your machine, providing detailed guidance for a wide range of tasks from simple oil changes to complex transmission swaps. With hundreds of pages, it includes numerous illustrations to assist you and easy-to-understand text throughout.
The manual features a convenient search function, allowing you to quickly find the information you need, and you can easily print out specific pages as required. It serves as a Factory Service Repair Manual, offering step-by-step instructions to equip you with the essential knowledge for maintenance and repairs, mirroring the expertise of factory-trained technicians.
By utilizing the insights provided in this service repair manual, any owner can confidently make informed decisions regarding the maintenance and repair of their machine.
Our commitment extends beyond delivering a high-quality service manual; we also provide exceptional customer service, ensuring your satisfaction is guaranteed!
