1985-1997 XR80R / XR100R Service & Repair Manual

85-97 XRBOR XR100R

IMPORTANT SAFETY NOTICE I,.di~.ta " It"'''8 pqssijility of #ft'n /«nDu/ ;IIj,,1')I or dea,. if iutrntiO/U .~ "ot followrd. CAUTION : IndiCilIU Q possibility 0/ pusong/ inj ury or equipment domoge if IflStfll Cl i oru Q~ flOI /oIlowN. NOTE : Gives helpful information . Detailed descri ptions of standard workshop procedures , safety pr i nCiples and service operatIOns are nol included . It is important to note that th is manual conta ins somlt warnings and cllutions aga i nsl some specific service methods whi ch could cause PERSONAL INJURY to service personnel or could damage II vehicle or render it unsafe. Please understand that those warnings c ould not cover all concei\lable ways in whi ch service. whether or not recommended bV Honda mi ght be done or 01 the possi bly hazltfdous consequences of each conceivable way. nor c ould Honda investigate all such ways . Anyone using service procedures or too ls, whether 01 not recommended by Honda must satisfy himself thOloughly that ner ther personal satety nor vehicle satety w ill be jeopardized by the service method or tools selected. l

HOW TO USE THIS MANUAL Follow the Maintenance lSchedule recommen- dations to ensure that the vehicle is always in peak operating condition and the emission le vels are within the standards set by the U.S. Environmental Protection Agency. Performing the first scheduled maintenance is very important. It compensat es for the initial wear that occurs during the break-in period. Sections 1 through 3 apply to the whole motorcycle, while sections 4 through 13 describe parts of the motorcycle, grouped ac- cording to location. Find the section you want on this page, then turn to the table of contents on page 1 of that section. Most sections start with an assembly or system illustration and all the requir ed specifications, torque values, general instructions, tools and troubleshooting for the section. The subsequent pages give detailed procedures for the section. If you don't know the source of the trouble, go to section 15 TROUBLESHOOTING. w Z " Z w CONTENTS GENERAL INFORMATION LUBRICATION MAINTENANCE FUEL SYSTEM ENGINE REMOVAL/INSTALLATION CYLINDER HEAD/V ALVES CYLINDER/PISTON CLUTCH REAR WHEEl/BRAKE/SUSPENSION REAR FENDER/ EXHAUST PIPE ELECTRICAL WIRING DIAGRAM TROUBLESHOOTING INDEX

GENERAL SAFETY SERVICE RULES MODEL IDENTIFICATION SPECIFICATIONS GENERAL SAFETY 1 -1 1 - 1 1-2 1-3 IJ 'hI> .. 1I_vin,. mu st M fll nning /0 (10 some work . make S life the artN ;s w('/f· ref/tilaleel. Nt'!'/'( run the engine in a closed area. The exhaust conlains poi so nous carbol/ mOl/oxide gas, IIIOf may CUllSt' loss of consciollsnen ami lead to death. Gasoline is atremei)' /lom",ablt· ami is t'xplal;\"( ' lI11der enlDill conditions. Do nor smoke Of allow flam es or .fporh in YOllr work areo. Of where gasoline is S lored. CAUTION Used engine oil moy cOllse skill cancer if repeatedly /e/I in COI/ · /ac/ with Ihe skin for pro/allgell periods. Allhough (his j{ Im/ike'y IInless YOII handle used oil all a daily basis, il is slill adl'isable /0 Ihoroughly K'asl! your hands willi soap and \Wller as soon as possible afler hondfing IIsed oil. SERVICE RULES 1. GENERAL INFORMATION TORQUE VALUES TOOLS CABLE & HARNESS ROUTING iii 1 -5 1-6 1 -7 Inhaled asbf!Slos fibers hal 't' been lound (f) C(lIlte re spirOWf)' (liseaJ't' and canct'r, Nt'I'er li St' (III air host' or Ilf)' hllll'h 10 dean brak(' as "st'mblies. Uu OS IIA .apprOL'ed l'aC/lllm cleaner IIr af· lemate method appral't'd h}' OS IIA clesilflled 10 "'inimht' Ih(' ho~ard callst'd by airbornt' asbestos fibers, Use genuine HONDA or HONDA- recommended parts and lubricants or their eqUivalents Parts that don 't meet HONDA's design speCifications may damage 10 Ihe vehicle 2. Use the special tools deSigned for thiS product to aVOid damage and incorrect assembly. 3. Use only melnc tools when servICing the vehicle. Metnc bolts. nuts, and screws are no t Interchangeable With English fasteners 4. Instal! new gaskets. O.rings. cotter pins, and lock plates when reassembling 5 When tightening bolts or nuts. begin With the larger -diameter or Inner bolts first Then tighten to the specified IOrque diagonally in t·5 s.teps. unless a particular sequence IS specified 6 Clean parts 10 non-flammable or high flash pomt solvent upon disassembly lubflcate any sliding surfaces before reassembly 7. After reassembly. check all parts for proper InstallatIOn and operation 8 Route all w ires as shown on pages '·7 through 1- 11 Cable and Harness Routmg 1-1

GENERAL INFORMATION MOOEL IDENTIFICATION ' 85 XR80A SHOWN : (1) VEHICLE IDENTIFICATION NUMBER The vehicle identification number is attached to the right side of the steering head. The engine serial number is stamped on the lower left side of the crankcase. 1-2 (2) FRAME The frame serial number is stamped on the left side of the steering head. The carburetor identification number is stamped on the right side of the carbureto r.

GENERAL INFORMATION SPECIFICATIONS ITEM XABOR XR1QQR Overall length 1, 730 mm (68.1 in) 1,855 rnm (73.0 in) <I> Overall wi dth 755 mm (29 .7 in) 800 mm (3 1 .5 in) Z 0 Overall height 955 mm (37 . 6 in) 1, 030 mm ( 40 .6 in ) in Wheel base 1, 195 mm (47 . 1 in ) 1,255 mm (49 .4 in ) z w Seat height 725 mm (28 .6 in) 770 mm (30 . 3. in) " 0 Ground clearance 210 mm ( 8.3 in) 265 mm (10.4 in ) Dry weight 64kg (141 . 1Ib) 68 kg (149 .9 )b l Type Diamond Diamond Front suspension/ travel Telescopic / 140 mm (5.5 in ) Telescopic f 140 mm (5.5 in ) Caster angle 28 · 30' 28 · 30' Trail 75 mm (3.0 in) 110mm (4 .3 in) w Front fork. oil capacity 83 cc (2 .8 US OZ , 2 .9 Imp ezl 88 cc (3.0 US OZ , 3.1 Imp ez l " " Rear suspension i travel Swingarm / l1Q rnm (4 . 3 in) Swingarm / 12Q mm (4 .7 in) '" ~ Tire size l Front 2. S0 - 16 - 4PR 2. 50 - 19 - 4PR Cold pressure 15 psi (1.0 kg / cm 2 , 100 kPa ) 15 psi ( 1.0 kg cm !, 100 kPa ) Rear 3, 60 - 14 - 4PR 3. 00-16-4PR 18 psi (1. 25 kg /cm~, 125 kPa) 18psi (1. 25kgcrr. 2 ,125kPa ) Front brake Cable operated leading trailing Cable operated leading trailing expanding shoe expanding shoe Rear brake Rod operated leading trailing Rod operated leading trailing expanding shoe expanding shoe Fuel tank capacity 6.5 t( 1.71 US gal, 1,43 Imp ga l) 6 .5 1( 1. 71 USgal,l,43Impgal ) Fuel tank reserve capacity 0.9 t (0.24 US gal, 0.20 Imp gal) 0 .9 t (0 . 24 US gal , 0.20 Imp gal) Type Gasoline, air cooled 4-stroke Gasoline, air cooled 4-stroke Cylinder arrangement Vertical Single cylinder Vertical Single cylinder Bore x stroke 47 .5x 45 .0 mm (1 . 87 x 1. 77 in) 53 .0 x 45 .0 mm (2 . 09 X 1 . 77 in ) Displacement 79 .7 cc (4 . 86 cu -in) 99 ,2 cc (6 . 05 cu-in) Compression ratio 9. 7: 1 9.4 : 1 Valve train Over Head Camshaft , chain driven Over Head Camshaft , chain driven Oil capacity 0 .9 t (0 . 95 US qt. 0.79 Imp qt) 1.0 t (1.06 US qt , 0.88 Imp qt ) Lubrication system Forced pressure and wet sump Forced pressure and wet sump w Air filtration system Oiled polyurethane foam Oiled polyu rethane foam z '-" Cylinder compression l, l77 ± 196 kPa 1, 128 ± 147 kPa Z (12 ,O± 2 .0 kg / cm 2 , 171 ± 28 psi) (11 , 5 ± 1 , 5 kg cm 2 , 164 ± 21 psi) w Intake valve Opens 8" BTDC 10" BTDC Closes 40' ABOC }- . 35 ' ABDC }- . Exhaust valve Opens 40" BBDC at ., mm ( 0.04 In ) 40" BBDC _ at ., mm ( 0.04 m) Closes 8" ATDC lift 5" ATDC lift Valve clearance (cold) Intake 0. 05 mm (0 .002 in) 0.05 mm ( 0.002 in ) Exhaust 0. 05 mm (0 . 002 in) 0,05 mm (0 . 002 in) Idle speed 1 ,500 ± 100 rpm 1, 400 ± 100rpm) ' 85, ' 86: After ' 86 : ' 85 , '86 : After ' 86 : Type Piston valve Piston valve '" Identification number PC10D PC20e PD36D P080C 0 tu Main jet .92 095 :: 95 '" ::> Slow jet :: 35 :: 38 " '" Air screw (XR80R), Pilot screw 1- 1/ 2 1-3 4 2-5/8 1-3 4 " u (XA 1 OOR) initial opening turns out turns out turns out turns out Float level 21.5 mm (0 . 85 in) 12 5 mm (0.49 in ) 1-3

GENERAL INFORMATION ITEM XR80R XR1QOR Clutch Cable operated, Wet multi pl ate Cable operated, Wet multi plate Transmission 5-speed constant mesh 5-speed constant mesh Primary reduction 4.437 (71 / 16) 4.437 P1 / 16) z Gear ratios: 1 1 2. 692 (35/13) 3.083 (37 / 12) <l II 1.823 (3 1/ 17) 1. 882 (32/17) '" r- III 1.400 (28/20) 1.400 (28 / 20) w " N 1. 130 (26/23) 1. , 30 (26/23) '" V 0.960 (24/ 25) 0. 923 (24/ 26) " Final reduction 3.285 (46/ 14) 3.571 (50/ 14) Gearshift pattern Left-foot operated return system Left- f oot operated return system l-N-1-3-4-5 l-N-Z-3-4-5 '85 through '91 After '91 Ignition system Flywheel magneto. contact points Flywheel magneto, CDl contact points Ignition timing initial IS" BTDC / l,800 ± 150 rpm 13' STDC / Z,050 15.5"BTDCj l , 900 J: 150 rpm ± 200 'pm Full advance 30' BTDC/ 3.400 ± 200 rpm 28' BTDC/ 3,650 30' STDC/3, 300 ± 200 rpm ± 200 'pm ~ " Contact point gap O.3~O.4 mm (0. 012-0 . 016 in) 0. 3-0.4 mm S1 '" (0.012-0.016 in) r- u Alternator output 15W/ 5,OOO rpm 15W / 5,000 rpm 7. 7W / 5,000 rpm w ~ w Spark plug NGK NIPPONDENSO NGK NIPPONDENSO Standard CR7HSA U22-FSR-U CR7HSA U22-FSA-U For cold climate CR6HSA U20-FSR-U CA6HSA U20-FSR-U (Below S' C, 4, ' F) For e)(l:ended high CR8HSA U24-FSR-U CR8HSA U24-FSA-U speed riding Spark plug gap 0. 6-0 .7 mm (0.024-0.028 in) 0. 6-0.7 mm (0.024-0.028 in) 1-4

GENERAL INFORMATION TORQUE VALUES ENGINE ITEM THREAD OIA. X PITCH TORQUE N·m ~kg·m, ft-lbJ Camshaft holder nut 8 x 1.25 18 - 22 n.B - Z.2. 13 -1 6) Cam sprocket 6 x 1.0 10-14 (1.0-1.4, 7-10) Valve adjuster lock nut 5 x 0.5 8-12 (Q.8-1.2, 5.8-9.0) Flywheel nut 12 x 1.25 60 - 70 (6.0-7.0. 43-51) Primary drive gear '4 x 1.0 35-45 (3.5-4.5, 25 -3 3) Drain plug 12 x 1.25 20-30 (2.0-3.0,14-22) Spark plug 10 x 1.0 10 - 17 n.D-1.7, 7- 12) FRAME ITEM THREAD OIA. X PITCH TORQUE N·m (kg-m. ft -I bl Engine hanger bolt (rear, upper, lower) 8 , 1 .25 40-5014.0 - 5.0,29 - 36) Foot peg bolt 10 x 1.25 35 - 45 (3.5 - 4.5, 25 - 33) Rear brake pedal pivot bolt 10xl.25 35 - 45 (3.5- 4 .5, 25-33) Kick starter pedal 6 x 1.0 10 - 14 (1.0 - 1.4. 7-10) Gearshift pedal 6 x 1.0 8-12 (0.8-1.2,6-9) Side stand pivot bolt tOxt.25 35-45 (3.5-4.S, 25 - 33) Exhaust pipe mount bolt a x , .25 24 - 30 (2.4-3.0,17-22) Exhaust pipe joint nut 6 x '.0 10 - 14 (1.0-1.4, 7-10) Front fuel tank mount bolt 6 x '.0 10-14 (1.0- 1.4, 7-lm Seat mount bolt 6 x 1.0 10-14 (1.0-1.4, 7-10) Air cleaner case mount bolt 6 x '.0 10 - 14 (1.0 - 1.4, 7- 10) Engine hanger plate bolt 8 x , .25 30 - 40 (3.0-4.0, 22 - 29) Final driven sprocket 8 x 1.25 30 - 35 (3.0-3.S, 22 - 251 Shock arm-to-swing arm bolt 10 x 1.25 40 - S0 (4 .0-5.0, 29-36) Shock arm-to-shock link bolt 10 x 1 .25 40 - S0 (4.0 - 5.0, 29 - 36) Shock absorber mount bolt (upper, lowed 8, 1 .25 30 - 40 (3.0 - 4.0,22 - 29) Front axle nut 12 x , .25 55-70 (5.5 -7 .0, 40-51) Front fork lower pinch bolt 8 , 1 .25 24-30 (2.4-3.0,17-22) Swing arm pivot bolt 12x1.25 55 - 70 (5.5- 7 .0, 40- 51) Steering stem nut 22 x 1.0 60 - 90 (6 .0 - 9.0, 43 - 65) Handlebar holder bolt 6 x 1.0 10-14 (1.0-1.4, 7-10) Shock link-to-shock arm bolt 10 x 1.25 40-50 (4.0 -5.0, 29-36) Bearing adjustment nut 22 x 1.0 1- 2 (0.1-0.2,0.7-1.4) Rear axle nut 12 x 1.25 55 - 70 (5.5-7.0, 40-51) Front fork upper pinch bolt 7 x 1.0 9-1310.9-1.3,7-91 Torque specifications listed above are for specific tightening points. If a specification is not listed, follow the standard torque values below. STANDARD TORQUE VALUES ITEM TORQUE N·m (kg-m, ft -Ib) ITEM TORQUE N·m ( kg -m, ft-Ib) 5 mm bolt, nut 4.S - 6 (0.45-0.6, 3.3 - 4.3) 5 mm screw 3.5 - 5 (0.35 - 0.S. 2.5 - 3.6) 6 mm bolt. nut 8-12 (0.8-1.2, 5.8 - 8.71 6 mm screw and 6 mm 7- 11 m.7 - 1.1, 5-8) b olt With 8 mm head 8 mm bolt, nut 18-2511.8-2.5,13-18) 6 mm flange bolt, nut 10 - 14 (1.0 -1.4, 7.2-10) 10 mm bolt, nut 30 - 40 (3. 0-4.0, 22 - 29) 8 mm flange bolt, nut 24-30 (2.4-3.0,17 - 22) t 2 mm bolt, nut 50 - 60 (5. 0 - 6.0, 36 - 43) 10 mm flange bolt , nut 30 - 40 (3.0 - 4.0,22 - 291 1-5

GENERAL INFORMATION TOOLS SPEC IAL DESCRIPTION TOOL NUMBER AL TEANATIVE TOOL REF , PAG E(S) Steering stem socket 07916 - 3710100 10- 14,16 Hex wrench, 6 mm 07917 - 3230000 - or equivalent commerciallv 10-9, 11 available in U.S.A . Bearing remover set, 12 mm 07936-1660001 Not available in U.S.A . 9~ 7 - Bearing spindle assy, 12 mm 07936 - 1660100 9~7 - Remover weight 07741-0010201 - or 07936 - 3710200 9~7 Bearing remover, 17 mm 07936 - 3701300 , ,- 12 Bearing remover handle 07936 - 3710100 11 -1 2 Remover weight 07741 - 0010201 or 07936 - 3710200 11-12 Ball race remove r 07944 - 1150001 M9360 - 277 - 91774 IU.S.A. onlyl 10- 14 Spring compressor attachment 07967 - KC1OOOO 11 -9 Valve guide reamer 07984 - 0980000 0798 4- 098000A (U . S.A. only) 6~B Steering stem driver 07946 - GC40000 - or steering stem driver 07946 - MBOOOOO 10- 15 and steering stem driver attachment 07946-GC4000A COMMON DESCRIPTION TOOL NUMBER ALTERNATIVE TOOL REF . PAGE(S) Float level gauge 07401 - 0010000 4~9 Valve adjusting wrench 07708-0030400 - or valve adjuster 07908 -KE90200 3-7 (U .S.A. only) or equivalent commercially available in U.S.A. Valve adjusting wrench. 8 x 9 mm 07708-0030100 3-7 Spoke wrench , 4.5 x 5.1 mm 07701 -0020200 equivalent commerc ially 3-15 Socket w rench, 30 x 32 mm 07716 - 0020400 available in U.S.A. 10- 14,17 Extension 07716 - 0020500 Universal holder 07725 - 0030000 13-4, 6 Rotor puller 07733 - 0010000 or rotor puller 07933 - 0010000 13-4 Valve guide remover, 5.5 mm 07742-0010100 or 07942-3290100 6~ 7 Valve guide driver, 5.5 mm 07742 - 0020200 6~ 7 Attachment. 32 x 35 mm 07746 - 0010100 9-8,9, 10-6, 11 -5 , 13 Attachment, 37 x 40 mm 07746-0010200 9-8, 10- 15 . 11 -5 Attachment, 42 x 47 mm 07746-0010300 9~ 7 Pilot, 12 mm 07746-0040200 10-6, 11 -5 Pi lot, 17 mm 07746 - 0040400 9~B Pi lot , 25. mm 07746 - 00 40600 9~7 Bearing remover shaft 07746 - 0050100 equivalent commercially 10-6, 11 -4 8earing remover head, 12mm 07746-0050300 available in U.S.A . 10- 6,11 -4 Fork seal driver body 07747 - 0010100 Fork seal driver 07947 - 1180001 10-12 Fork seal driver attachment 07747 - 0010300 10-12 Driver 07749 - 0010000 Valve spring compressor 07757-0010000 6- 6,6-11 Gear holder 07725 - 0010100 equivalent commercially available in U.S.A. 8-3,8-8 Digital multimeter KS-AHM-32 -003 U.S.A. on ly 13-4,5,6, 11 , 12 1-6

1985-1997 XR80R / XR100R Service & Repair Manual

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