Honda XR80R, CRF80F, XR100R, CRF100F Repair Manual 1992-2009

The 1992-2009 Honda XR80R, CRF80F, XR100R, CRF100F repair manual covers:

• Honda XR80R 1993-2003
• Honda CRF80F 2004-2009
• Honda XR100R 1992-2003
• Honda CRF100F 2004-2009

Note: see Clymer M312-14 for coverage of older XR80 & XR100 models.

Book Excerpt: 1992-2009 Honda XR80R, CRF80F, XR100R, CRF100F Repair Manual CLUTCH, OIL PUMP, PRIMARY DRIVE GEAR AND EXTERNAL SHIFT MECHANISM

This chapter describes service procedures for the clutch cable and components installed behind the right crankcase cover. Components covered include the following:

1. Clutch.
2. Clutch release lever.
3. Oil pump.
4. Primary drive gear.
5. External shift mechanism.

RIGHT CRANKCASE COVER

REMOVAL

1. Drain the engine oil (Chapter Three).
NOTE: Before removing the kick pedal and kick shaft index mark alignment.
2. Unbolt and remove the kick pedal (Figure 1).
3. Remove the right footpeg/brake pedal assembly (Chapter Fourteen).
4. Disconnect the clutch cable adjuster at the handlebar to provide additional cable slack. Refer to Clutch Cable in this chapter.

CAUTION: If the kick pedal is stuck, spray penetrating oil around the kick shaft splines. Give the oil time to dissolve some of the rust, then tap the pedal to slide it off the shaft. If the kick pedal is tight from corrosion or damaged splines, mount a small two-jaw puller across the kick pedal boss, centering the pressure bolt against the kick shaft, then operate the puller to remove the kick pedal. Do not pry the kick pedal off as this may damage the right crankcase cover.

CARBURETOR SERVICE

Disassembly (80 cc Models) - Refer to Figure 19.

1. Remove the carburetor as described in this chapter.
2. Remove the hoses (A, Figure 20)n connected to the carburetor and float bowl nozzles (B).
3. Remove the float bowl screws and float bowl (C, Figure 20). Be careful of any gas that spills out of the float bowl. Remove the O-ring installed in the float bowl groove. Discard the O-ring.
4. remove the float pin (A, Figure 21), float ( B) and fuel valve. Unhook the fuel valve (Figure 22) from the float.
NOTE: The fuel valve seat is permanently attached to the carburetor body. Do not attempt to remove it.
5. Remove the pilot jet (A Figure 23).
6. Hold the needle jet holder and remove the main jet(B, Figure 23) and the main jet holder (C).
7. Remove the needle jet holder (D, Figure 23).
8. Use a small round wooden stick and push the needle jet (E, Figure 23) out through the bottom of the carburetor.
NOTE: A D-shaped pilot screw wrench is required to remove the air screw on 2006 and later models. Refer to Carburetor Adjustment in this chapter for the tool part numbers.
9. Lightly seat the air screw (A, Figure 24), counting the number of turns for reassembly reference. Remove the screw (A, Figure 25) and spring (B ) from the carburetor.
10. Remove the throttle stop screw (B, Figure 24 and C, Figure 25) and spring (D, Figure 24).
11. Separate the carburetor body and float bowl.
12. Remove the float bowl drain screw and O-ring from the float bowl. Discard the O-ring.
NOTE: Do not remove the choke valve mechanism. Instead check its operation as described in Inspection in this section.
13. Clean and inspect all parts as described in Inspection in this section.

Subject: 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009 Honda XR80R, CRF80F, XR100R, CRF100F service, maintenance, repair. ISBN-10: 1599693275 | ISBN-13: 9781599693279 | Clymer M222