Honda XR100R Service Manual Download Page 35

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Summary of Contents for XR100R

Page 1: ......

Page 2: ...inSI lation of components 1hal may be flKlui ed 10 perform service described in the follow ing sectiOns Section 4 through 13 describe parts of Ihe motorcycle grouped a Gording to location find Ihe sec...

Page 3: ...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 system parts...

Page 4: ...t interchangeable with English fasteners 4 Install new gaskets 0 ring5 cotter pins and lock plates when reassembling 5 When tightening baits or nuts begin with the la rger diameter or inner bolt first...

Page 5: ...hown GENERAL INFORMATION FRAM E SERIAL NUMBER 1 The frame serial number is stamped on the left side of the steering head VEHICLE IDENTIFICATION NUMBER VIN 3 The Vehicle Identification Number VIN is lo...

Page 6: ...Oil pump type Cooling svstem Air filtration Crankshaft type Engine dry weight Cylinder arrangement 4 SPECIFICATIONS 1 855 mm 173 0 in 1 869 mm 173 6 in 800 mm 131 5 in 816 mm 132 I in 1 050 mm 141 3 i...

Page 7: ...Clutch operation system Mechanical type Transmission S speed Primary reduction 4 438171 161 Final reduction 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...

Page 8: ...damper Front tire size 2 50 16 4 PR Rear tire size 3 60 14 4 PR Tire brand IRe Front GS 45ZIIRear GS 45ZI Front brake Internal expanding shoe Rear br lke Internal expanding shoe Caster angle 98 2000 2...

Page 9: ...te weI Clutch operation system Mechanical type Transmission 5 speed Primary reduction 4 437 71 1 6 Fi nal reduction 3 285 46 14 Gear ratio 2 692 35 13 200 1 823 31 17 3 1 400 28 20 1 1 30 26 23 0 960...

Page 10: ...03 0 Q25 0 010 FUEL SYSTEM EM STANDARD SERVtCE LIMIT Caburetor identification XR100R 98 2000 e cepl PD80C number Ca lifornia type 98 2000 California PDC3D type After 2000 PDCJL XR80R 98 99 PC20B 2000...

Page 11: ...0 081 Rocker arml Rocker arm 0 10 000 10 015 0 3937 0 3943 10 1 0 40 Shaft Rocker arm shaft 0 0 9 978 9 987 O 3928 0 3932 9 91 0 390 Rocker arm to shafl clearance 0 013 0 037 W OOOS 0 0014 0 08 10 003...

Page 12: ...0 04 1 1 0 04 Side rail After 2000 0 2 0 7 0 01 0 03 0 9 0 04 XR80R PiSTOn mark di reclion EX mark facing toward the exhaust side Piston 0 0 47465 47 490 18686 1 8697 47 40 1 866 Piston 0 0 measuremen...

Page 13: ...17 016 17 034 06699 0 6706 17 05 0 67 1 C XR lOOR 20 662 20 643 0 8119 0 8127 20 56 0 813 XA80R 17 022 17 043 0 6701 0 6710 17 06 0 672 C2 XR100R 19 520 19 541 0 7685 0 7693 19 56 W 770 XR80R 19 520...

Page 14: ...STANDARO SERVICE LIMIT Rear w heel Minimum l ire tread depth 3 0 0 12 Cold ire pressure 125 kPa 11 25 kgf cm 18 psi Rear w heel ri m runout Radial 2 010 08 Axial 2 010 08 Rea r aKle runout 0 20 0 008...

Page 15: ...GENERAL INFORMATION IGNITION SYSTEM I ITEM SPECIFICAnON i I i 09 j high i j iI i iti Ii i i i I 1 13...

Page 16: ...NOTES 1 U nut 2 Apply a locki ng agenl to the threads 3 Apply grcase to tho sliding surfa ce Apply Oil to the threads and scating surface ENGINE ITEM O TY THREAD TORQUE DIA mml N m Ikgf m Ibf ftl REMA...

Page 17: ...Steering stem lock nut 1 74 7 5 54 Steering Slem bearing adjLSsting nut 1 210 2 1 Fork lOP bridge pinch bolt 7 11 1 1 81 Fork bottom bridge pinch bolt 8 26 2 7 201 Front 3 le nut 1 12 62 6 3 461 NOTE...

Page 18: ...Bearing remover head 12 mm 07746 0050300 I I 12 For seal driver 07747 0010100 NOTE 3 07947 1 180001 U S A only Fork seal driver attachment 07747 0010300 Oriver 07749 0010000 10 11 12 Valve spring comp...

Page 19: ...em sliding surface Transmission gear rotaling surface Transmission goar tcelh and shift fork groove Pulse generater meunting belt threads Locking agent FRAME LOCATION MATERIAL REMARKS Steeriog stom ba...

Page 20: ...ION CABLE HARNESS ROUTING 98 2000 TANK SETIING RUBBERS 98 2000 XR 100R 98 99 XRSOR RUBBER 2000 XR80R ICYLINOER ONLY 98 2000 BRE A R TUBe fRONT BRAKE CLUTCH WIRE ALTERN OR MR ENC N STOP SWlfCH WIRe 1 1...

Page 21: ...GENERAL INFORMATION After 2000 FRClNT BRAKE CABLE THRO rTLe CABLE ENG INE STOP SWITCH W IRE F W BREATHER TUBE After 2000 THROTTLE CABLE FRONT BRAKE CABLE v CLUTCH CABLE ENGINE STOP SWITCH WIRE 1 19...

Page 22: ...GENERAL INFORMATION 98 2000 SPARK PLUG WIRE IGNITION COIL CLUTCH CABLE THROTTLE CABLE XR100R CALIFORNIA TYPE 2000 XR8OR CRANKCASE BREATHER TUBE CRANKCASE BREATHER TUBE AIR VENT TUBE AIR VENT TUBE 1 20...

Page 23: ...BURETOR AIR VENT TU BE C NKC BREATHER TU BE 98 2000 XR100R except California type 98 99 XR80R IG NITION CONTROL MODULE GENERAL INFORMATION SPARK PLlJG IGNfT ON COIL CLUTCH CABLE AL fE NATOR CONNECTOR...

Page 24: ...8 2000 XR100R California type IGNITION CONTROL MODULE 2000 XR80R IGNITION CONTROL MODULE 1 22 o lT RN o TOR CONNECTOR CRANKCASE BREATHER SEPARATOR ALTERNATOR CONNECTOR CRANKCASE BREATHER SEPARATOR CRA...

Page 25: ...IGNITION WIRE GENERAL INFORMATION TANK SETTI NG RUBBER CLUTCH CABLE W IRE CR N KCA E BREATHER SEPARATOR ALlrERN TOR WIRE WJTCH CABLE 98 2000 XR100R except California type 98 99 XR80R CRANKCASE BREATH...

Page 26: ...R100R California type CRANKCASE 8R1 O CRAN KCASE BREATHER SEPARATOR DRAIN TUBE CARB URI rOR DRAIN TUBe After 2000 XR100R CRANKCASE BREATHER SEPARATOR After 99 XR80R CRANKCASE BREATHER TUBE 1 24 CLUTCH...

Page 27: ...lean carburetor settings as well as other systems to reduce carbon monoxide and hydrocarbons EXHAUST EMISSION CONTROL SYSTEM 98 2000 XR100R CALIFORNIA TYPE AFTER 20001 XR100R AND AFTER 99 XR80R The ex...

Page 28: ...98 20001XR1 00R CALIFORNIA TYPE AFTER 2000 XR1 00R AND AFTER 991 XR80R An Em ission Control Label is loc lled on the feaf fender as shown AO R CLE NEA HOUSING CRANO BREATHER SEPARATOR 98 2000 XR lOOR...

Page 29: ...nstallation of the body panels fuel umk and exhaust system Always replace the exhaust pipe gaSkets after removinglhe exhaust pipe from the engine When installing the exhaust system loosely install all...

Page 30: ...REMOVAL INSTALLATION 98 2000 Remove the right and left side covers lsee above Remove the cwo mounting boilSand seat assemblv Alter 2000 Remove Ihe nuts collars Remove the seat Installation is in the...

Page 31: ...fuel lan k holde band Remove The fuel Tank mounTing bolTS and fuel tank Installation is in the reverse order of removal TORQUE Fuel tank mounting bolt 12 N m 1 2 kgf m 9 Ibf ft TANK SHROUD AFTER 2000...

Page 32: ...he steering stem FRONT FENDER REMOVALJlNSTAllAT10N Remove the bolt nuts collars and front fender Installation is in the reverse order of removal MUDGUARD REMOVAL INSTALLATION Remove the seat page 1 1...

Page 33: ...om 10 Ibfoftl 12 N m 1 2 kglom 9 Ibl It Always rEphflce rhe 1051all a new exhaust pi pe gasket onto the exhaust emaUSI pipe port of tbe cy linder head gasket wirh a neW one Install the exhaust pipe t...

Page 34: ...FRAME BODY PANELS EXHAUST SYSTEM 2 6 Tighten the exhaust pipefmuffler mounting bolls to the specified torque TOROUE 26 Nom 1 2 1 kgfom 20 Ibfoft EXHAUST...

Page 35: ...SPARK ARRESTER 3 22 NUTS BOLTS FASTENERS 3 23 WHEELS TIRES 3 24 STEERING HEAD BEARINGS 3 25 Gasoline is extremely flammable and is explosive under certain conditions Work in well ventilated It ea Smo...

Page 36: ...Spoke wrench 4 5 X S I mm 3 2 SPECIFICATIONS j i iE 14 N m 1 4 kgf m 10 Ibfoft 25 N m 2 5 kgf m 18 1 bfoft 10 N m 1 0 kgf m 7 IbHt 12 N m t 2 kgf m 9 Ibf ft 12 N m 11 2 kgf m 9 Ibf ft 62 N m 16 3 kgf...

Page 37: ...OTE 2 I I I I 39 w SPARK PLUG I I I I 39 z 0 VALVE CLEARANCE I I I I I 3 10 m ENGINE OIL R R R R R m ENGINE OIL STRAIN ER SCREEN C C 3 13 w CAM CHAIN TE NSION A A A A A 3 13 ENGINE IDLE SPEED I I I I...

Page 38: ...EANER NOTE 1 C C C C J 8 w r SPARK PLUG J 9 w VALVE CLEARANCE 3 10 Z ENGINE OIL R R R R R 3 11 a w ENGINE OIL STRAINER SCREEN C C 3 13 w CAM CHAIN TENSION A A A A A 3 13 w ENGINE IOLE SPEED 3 14 DRIVE...

Page 39: ...PARK PLUG I I I I 39 0 w VALVE CLEARAN CE I I I I I 3 10 3 ENGINE OIL R R R R R 3 11 w Z ENGINE OIL STRAINER SCREEN C C 3 13 Q CAM CHAIN TENSION A A A A A 3 1 3 ENGINE IDLE SPEED I I I I I 3 14 w DRIV...

Page 40: ...OTE 1 C C C C 38 SPARK PLUG I I I 3 9 VALVE CLEARANCE I I I 3 10 z ENGINE OIL R 3 11 Q ENGINE OIL STRAINER SCREEN C C 3 13 CAM CHAIN TENSION A A A A A 3 13 ENGINE IDLE SPEED I I I 3 14 QRIVE CHAIN NOT...

Page 41: ...the fuel valve ON to drain the fuel tan k After the tank has drained completely remove the two boilS luel valve arid strainer screen W ash the fuel strainer screen in non flammable or high flash solve...

Page 42: ...left side cover page 2 2 Remolle the air cleaner housing cOllo r band and housing caller Remove the air cleaner element holder band and element from the housing Wash the element in non flamm able or h...

Page 43: ...quivalent Inspect or replace as described in the ma intenance schedu le pages 3 3 through 3 6 INSPECTION Ch eck the following and replace if necess ary recommended spark plug page 3 2 Insulator for da...

Page 44: ...n the spark plug Install and ha nd tighten the new spark plug then tighten it about 1 2 of a t lrn after the se li n 9 washer contacts the seat of the plug hole Instal l the spark plug cap VALVE CLEAR...

Page 45: ...9 mm 07708 0030100 Equillaleflt commereially Vallie adjuster B allailable in U S A 07908 KE90000 Not 1Ivailable in U S A 0 07908 KE90200 U S A ofl lyl TORQUE 10 N m 1 0 kgf m 7 Ibl h Recheck the lIal...

Page 46: ...HANGE rIS Ii iiiiJM If the engine must be runnjng l do some work make Sure the area is well ventilated Never run the engine In an enclosed IIrea The exhaust contains poisonous carbon monoxide gu that...

Page 47: ...SCREEN Perlorm tNs Remove the right crankcase cover page 9 3 maintenance IJefore filling he Remove the oil strainer screen and clean it er glne with oil Reinstall the oil strainer screen and right cra...

Page 48: ...ell ventilated Never run the engine In an enclosed ilrea The exhilust contains poisonous carbon monoxide gas that may cause loss of consciousness ilnd may lead to daath Run the engine in an open area...

Page 49: ...s ob i ned Make Sure the index marks on both adjusters are aligned w ith the irldex marks on the swi ngarm Tighten the eaTaxle nut to Ih specified torque TORQUE 62 N m 16 3 kgf m 46 Ibf ft Tighten bot...

Page 50: ...straightened SERVICE LIMIT 51 1 mm 120 1 inl Installing a new chain on badly worn sprockets will cause the new chain to wear quickly Inspect the driv and driven sprocket teet h lor w ear o r damage re...

Page 51: ...in slider if it is worn to the wear limit or if it has been damaged BRAKE SHOE WEAR FRONT BRAKE SHOES Ch9Ck the brake shoes and brake drum if Ihe arrow on the indicator plale aligns with the L mark on...

Page 52: ...djustment tighten the lock nut Major adjustments can be made with t le lower adluster on the brake panel Loosen the lock nut and turn the adjusting nut until the free play is within specification Afte...

Page 53: ...ng lhe nallre play adjustment CLUTCH SYSTEM Measure the clutch lever free play al the tip of the clutch lever FREE PLAY 10 20 m 3 8 3 4 in M inor adjustm ants can bo mado w ith Iho upper adjuster Loos...

Page 54: ...118 1 4 of a turn Hold the adjusting screw and lighten the lock nut Turn the lower adjuster out until there is free play at the lever end is 2S mm 1 0 inl Tighte n the lock nut Then turn the upper ad...

Page 55: ...veral times Chock the entire assembly for signs of leaks damage or loose fasteners Replace damaged components which cannot be repaired Tighten all nuts and bolts Refer to section 11 for lark service R...

Page 56: ...has cooled before removing Or installing the spark arrester lid Perform this operation in a welllventilated a ea free from combustible materials Use adequate eye protect on 8 2000 Remove the two bolts...

Page 57: ...free of cracks and holes Replace if necessary Install the new gasket and spark arrester in the muffler Tighten the three botls securely NUTS BOLTS FASTENERS Check thaI ali chassis nuts and bolts are...

Page 58: ...eness refer to silclions 11 and 12 Measufll the tread depth at the center of tho ti lls_ Replace the l ires w hen the tread depth reaches the following limits MINIMUM TREAD DEPTH FRONT 3 0 mm 0 12 inl...

Page 59: ...handiebar rotarian Support the motorcycle securely and raise the front wheel off the ground Check that the handlebar moves freely from side 10 side If t he handlebar moves uneven ly binds or has vert...

Page 60: ...LUBRICATION SYSTEM I PISTON PUMP CONNECTING V OIL STRAINER MAINSHAFT CO UNTER SHAFT 4 0...

Page 61: ...the engine If any portion 0 1 the oil pu mp is worn beyond the specified service limits replace the oil pump as an assembly After the oil pump has been installed check that there are no oil leaks SPE...

Page 62: ...Retighten the oil check bo lt and be sure there are nO oil leaks OIL PUMP 4 2 REMOVAL Drain thE engine oillpago 3 12 Remove the following Right crankcase cover pagE 9 3 Oil through Turn the crankshaft...

Page 63: ...mps shaft Measure the tip clearance between the inner and OUHn rotors SERVICE LIMIT 0 20 mm 1 0 008 in TIP CLEARANCE Measu re the pum p body clearance between the BODY CLEARANCE outer rOlor and pump b...

Page 64: ...e shaft and drive gear Check the drive gear and shh for wear or damage SHAFT ASSEMBLY OUTER ROTOR OLL PUMP DRIVE GEAR BOLTS LN NER ROTOR 60LT XR80Rl OLL PUMP GEAR COVER SCREW IXR t OOR L nstaLL the oi...

Page 65: ...gning the boss on the cOlier wilh tM cutout in the pump body Tighten the two oil pump plate screws to the specified to que TORQUE 3 N m 1 0 3 kgf m 2 Ibf ft Check the oil pump operation by u ling the...

Page 66: ...pump mounting screws or bolts XR OOR Tighten the two screws XR80R Tighten the two boils Inslall the oil through align the cutout to the drive pin Install the right crankcase cover page 9 12 After ins...

Page 67: ...MEMO...

Page 68: ...FUEL SYSTEM XRSOR 5 0...

Page 69: ...Ientilated area Smoking or allowing flames or sparks in the wort area OJ where gasoline is stored C ln cause a fire or explosion Refer to section 2 for fuel tank removal and installation When disassem...

Page 70: ...cept 38 X 38 California typo 2000ICalifomia Iypc 35 X 35 After 2000 35 X 35 XR80R J5 Jet needle clip posilion XR 100R 3rd groove from top XR80R 98 99 2nd groove from top AFTER 99 3rd groove from tOp P...

Page 71: ...on Floa va lve faulty Float IlIVel too high Air jets clogged Air cleaner element contaminated Flooded carburetor FUElSVSTEM Engine sta lls hard to start rough idling Fuel line restricted Ignition malf...

Page 72: ...e 1 20 211 loosen tile connecting tube band screw Remove the bolts Remove the two boits and mud guard Remove the two air cteaner housing mounting bolts then remove the housing from the left sine of th...

Page 73: ...BODY Gasoline is Kfr mefy flammable and s plosive under certain conditions Work in a well ventilated area Smoking or aI owing flames or sparks in the work area or where the gasoline is stored can cau...

Page 74: ...ARBURETOR DISASSEMBLY 5 6 Disconnect the fuel tube air vent tube and drain tube XRU R Remove the screw set plate Choke lever and washer XRI R Remove the three screws and float chamber XR80R Remove the...

Page 75: ...floal valve XR100R Remove the following Jet hOlder Main jet Needle jet holder Needte jet Slow jel ThrOIII stop screw spring Turn Ihe pilot screw in and record the number of turns it takes before it se...

Page 76: ...E SCREW P HIROTTLE STO CLIP 1 JET NEEDLE 4 O RING HIROTTLE VALVE AFTER 2000 5 8 JET HOLDER MAIN JET SLOW JET THROTTLE STOP SCREW SPRING AIR SCREW JeT NEEDLE JET SET PLATE HOLDER NEE 1 OLE JET FLOAT VA...

Page 77: ...ressed air XRIOOR Install he following Throll e stop screw sprin Slow jet Needle jet Needle je holder Main jet Jet hOlder CAUTION H ndle 11 Jets with c re Th 1 c n easily be scored or su rched Install...

Page 78: ...and lIoat valve in the ca rbureTor body Ihcn install T he float pin through the body and lIoat FLOAT LEVEL INSPECTION With the loaT valve seated and the float arm jusl touChing The valve measure the...

Page 79: ...at chamber XR IOOR Install and lighten the three float chamber screws XflSQR Install and lighten the two float chamber screws XR IOOR Install the washer choke lever and set plate then tighten the scre...

Page 80: ...in tUDe CARBURETOR INSTALLATION 5 12 CARBURETOR BODY Instair the new O ring into the carburetor bOdy grooves Install the carburetOr body to the inta ke manifQld and tighten the nuts securely Install t...

Page 81: ...top After 99 3rd groove from 10P Install the jet need le into the throttle valve and secure it w ith the needle clip retainer Instal l the t hrottle valve spring onto t he th rottle cable Connect the...

Page 82: ...ine must be running to do some work make SUre the area is well venfilated Neller run the engine in an enclosed area The exhaust contains poisonous carbon monoxide gas that may cause lou of consciousnf...

Page 83: ...o the tachometer manufacturer S instructions 4 Slart the engine and adjust the idle speed with the throttle stop screw IDLE SPEED 1 400 100 rpm Ii urn lhe ilot screw il l or out slowl to obl il l the...

Page 84: ...er with graduations of 50 rpm or smaller that w ill accurately indicate 50 rpm change 1 Turn the air screw clockwise until it seats lightly and then back it out to the specification given CAunO N Dama...

Page 85: ...ge 1 Turn the air screw clockwise urtti l it seats lightly then back it out 10 the specification given CAUTION FUEl SYSTEM Damage to the air Sl rew seat will Ol cur if the a L_ A IR S C R EcW _______...

Page 86: ...rnia type 112 turns in from factory preset After 2000 3 4 turns in Irom fa ctory preset XR80R Selween 3 000 _ 8 000 ft 1 000 2 500m 98 _ 2000 lf90 After 2000 92 Except C lifornia lyP il 1 turn in from...

Page 87: ...MEMO...

Page 88: ...N m 4 kgl m 33Ibfo t Aftllr 2000 26 N m 2 7 kgl m 20 IbHt 39 N m 4 0 kg m 29 Ibf f l 6 0 39 N m 4 0 kg m 291bHt 12 N m 1 2 kgf m 9 Ib ft 34 N m 3 5 gf rn 25 It f ft 10 N m 10 kgl m 7 Ibf ftl 26 N m 2...

Page 89: ...der pislon ISection 81 Cvlinder headNalvcs Section 7 SPECIFICATIONS m M STANDARD Engine oil capacity XR 100R At disassembly 1 0 t 1 06 us qt 0 88 Imp qt XRSOR At disassembly 0 92 0 95 us qt 0 79 Imp q...

Page 90: ...e cover page 2 2 Seat page 2 21 Muffler page 1 41 Kickstaner pedal page 9 31 Left crankcase cover Ipage 13 91 Carburetor page 5 4 Disconnect the spark plug cap Remove the tank setting rubber Disconnec...

Page 91: ...rear wheel forward to maximize slack in the drive chain Remove the f xing plate bolts fixing plate and drive sprocket 9 9 20001 Disconnect the crankcase breathe tube from the XRI00R breather separato...

Page 92: ...VAL INSTALLATION 6 4 Removethe bolt nut Remove the two bolts and crankcase protector Remove the two bolts and left footpeg mounting bolts Remove the three bolts nuts and front engine hanger plate I HA...

Page 93: ...hanger collar and hanger bolts Use a floor jack o r other adjustable suppor to carefully maneuver the engine into place Place the engine into the f rame and install the REAR ilngine hanger bolts from...

Page 94: ...fied torque TORQUE 98 2000 26 Nom 12 7 kg m 20 Iblott Aher 2000 34 N m 13 5 kgf m 25 Ibl hl Tighten he rear engjn hanger nuts to the specified torque TORQUE 98 2000 34 N m 3 5 kgfom 25 Ibl hl Alter 20...

Page 95: ...Nom 4 0 kgf m 29Ibf h Install the kickstarter pedal and tighten the bolt to the specified torque TOfIOUE 12 Nom 0 2 kgl m 9 Ibf h Install t he drive sprocket onto the countershaft Install the fixing p...

Page 96: ...R O O RJ CCA L IF O R N A J1 il E l XR I00R separator TYPE California type Aller 20001 XR100Rand Alter 991XR80R 6 8 Connect the spark plug cap Install the following leI cran case co er page 13 121 Mu...

Page 97: ...MEMO...

Page 98: ...CYLINDER HEAD VAlVES 12 N m 1 2 9 Ibl hl 20 N m 2 0 kg om 14 Ibf fII ______ 14 N m 11 4 kgf m 10 Ibl hl 7 0 10 N m I kg m 7Ibf h 98 20001 XR 100R XR80R AFTER 2000 XR100R 12 N m 1 2 kgl m 9 Ibl h...

Page 99: ...ce When disassembling mark and store lhe disassembled parts 10 ensure Ihat they am reinstalled in thei original lociltions Clean all disassembled parts with cleaning solvent and dry them by blowing th...

Page 100: ...e problem c n be diagoosed by a comprenion lesl or by Iracing engine noises 10 Ihe lop end w th a Ounding rod stethoscope II the performance s pOo t low speeds check 10 w h le smoke in Ihe criilnkcase...

Page 101: ...y and crank the engine wit h the kickstarter unli l the gauge reading StOPS rising COMPRESSION PRESSURE XR 100R 21 kPa 11 5 kgffem 164 psi at 300 rpm XR80R 1176 kPa 112 0 kgflcm 171 psI at 1 000 rpm L...

Page 102: ...se the cam chain tension at this lime 8ecareluJ flOllo lel Remove the cam sprocket bolt turn the crankshaft Ihe cam sprOCl et counterclockwise one full turn 360 and remove boilS faU 10 lhe the othel c...

Page 103: ...JOURNAL Inspect the camshaft journal surfaces fo scoring or evidence of insufficient lubrication Mcasl lre the 0 0 01each camshaft journal SERVICE LIMIT t9 90 mm 10 783 In NOTE Inspect the oil passag...

Page 104: ...1 0 SERVICE LIMIT 10 1 mm 0 40 in Calcu late the rocker arm to shaft clearance SERVICE LIMIT 0 08 mm 0 003 in CAMSHAFT OIL CLEARANCE W pe any oi l from the journals of the camshaft cylinder head and...

Page 105: ...ervice limit CYLINDER HEAD REMOVAL Remove the followings engine page 6 2 camshaft page 7 3 carbu retor intake pipe cam chain tensiOr le r set pl lle bolt set plate and adjuster Remove the cylinde r he...

Page 106: ...seal Valve spring seal INSPECTION CVlINDER HEAD Remove carbon depOsits from the combustion chamber Chack the spar1 plug hole and valve areas for cracks_ Chock the cylinder head for w arpage w ith a st...

Page 107: ...the head and always rotate the reamer clockwise TOO L Valve guide turner 5 5 mm 07984 098000 1 or 07984 0980000 Measure and reco rd each valve guide 1 0 SERVICE LIMIT IN EX 5 50 mm 0 217 in S u btrac...

Page 108: ...Valve guide driver 5 5 m m 07942 00 10100 or 07942 3290 100 U S A onlvl Ddve n the guide from the top of the head using JiI the special tool as shown TOOL Valve guide driver 5 5 mm 07942 0010100 or 0...

Page 109: ...burned Or badly worn or if it contacts Ihe seal unevenly rep lice t le valve Inspoct the width of each valve seat STANDARD 1 1 mm 0 06 in SERVICE UMIT 2 1 mm 10 08 I ll If the seat is 100 wide too na...

Page 110: ...cutter to remove the top 1 4 of tho existing valve seat material Use a 6O degree culter to remOve the bottom 1 4 of the old seat Remove the cutter and inspect the area you have refaced Install a 4S de...

Page 111: ...ng Refinish the seat to specifications using a 45 degree finish culter After cutting the seat apply lapping compound 10 the valve face and lap the valve using lighl pressure Alter lapping wash all ros...

Page 112: ...lIallle springs Install Ihe lIallle spring retai ner InSla l1 the lIalve COilers uSing the spec ial tool as shown TOOL Valve spring compressor 07757 0010000 CAUTION To prevent loss of unsion do not om...

Page 113: ...e 7 4 Tighten he lock nut Install he cylinder head Install the cam chain tension adjuster w ith a new O ring Install the cylinder head mounting bolt bul do not tighten XR1 00R Insta ll the new O ring...

Page 114: ...the cutout of the intake arm shaft with the bOlt hole as shown PLJsh the exhaust arm shaft in completely Coat the camShaft iounals w ith molybdenum disulfide grease Install the camshaft onto the cam h...

Page 115: ...the cylindor head su rface and 0 mark faCing 0 Install and tighten the cam spfO Ket bolts TORQUE 12 N m 1 2 kgl m 9lbl hl NOTE Install the dowel bott iblackl on the intal e side Loosen the lock nut a...

Page 116: ...he specified tOrque TORQUE 12 N m 1 2 kgf m 9Ibf ft Install the following Left crankcase cover ipage 13 12 fuel tanlo ipage 2 3 Seat page 2 2 Side cover page 2 2 Start rhe engine and let it idle CAUTI...

Page 117: ...MEMO...

Page 118: ...CYLINDER PISTON 12 Nom 1 2 kglom 9lbHt 8 0...

Page 119: ...W rp g e 0 10 0 004 Piston XR IOOR PiSlOn mark direction N mark lacing toward the intake sida piston ri ngs Piston 0 0 52 960 52 990 2 0850 2 0862 52 90 2 083 piston pin Pi ton 0 0 me su remMt point 1...

Page 120: ...04 rail Aft8f 0 2 0 7 0 01 0 03 0 9 0 04 Cylinder to pis on clea rance XR 100R 0 01 0 04 0 0004 0 00161 0 10 0 004 XRBOA 1 1 1 0 04 0 0004 0 0016 0 1010 004 Connectil1g rod small end XR100A 14 012 _ 1...

Page 121: ...owel pins Loosen the lock nLJt and remove the cam ch in tensione bolt Remove the cam chain tensione tensioner od and spring PISTON REMOVAL On oot let the pis on pin clips flt l lnlalM crankcase Remove...

Page 122: ...piston 0 0 SERVICE UMIT 0 10 mm 10 004 In Calculate the taper and OUI of round at three levels in X and Y a is Take the maximum reading to determine them SERVICE UMIT Taper 0 10 rnm 0 004 in Out of r...

Page 123: ...easule the diameter ot the piston at spec I Ca IOn given 110m the bonom and 90 degrees to the piston pin hole PISTON 0 0 MEA SUREMENT POINT XR100R 10 mm 0 4 ifl XR80R 7 mm 0 3 in SERVICE LIMIT XR100R...

Page 124: ...After 2000 XR80R 98 99 After 99 0 5 mm 10 02 inl 0 4 mm 0 02 Inl 0 5 mm 0 02 inl 0 4 mm 0 02 inl 1 1 mm 0 04 inl 0 9 mm 0 04 inl 1 1 mm 0 04 inl 0 9 mm 0 04 inl PISTON RING INSTALLATION Clean the pis...

Page 125: ...ips NOTE Do not al 9 the piston pin clips end gap w ith the p iston CuH lIt Do not let the piston pin cli ps tall into the crankcase CYLINDER INSTALLATION Install a new O ring on the cam ch ain tensio...

Page 126: ...s with Clean engine oil Insta ll the cylinder wh ile compressing tne piston rings NOTE Avoid piston ring damage during installation 00 not let the cam Chain fall into ttTe crankcase Install the cam ch...

Page 127: ...MEMO...

Page 128: ...CLUTCH GEARSHIFT LINKAGE 13 Nom 1 3 Ibf ft 12 Nom 1 2 kgfom 9 Ibf ft 9 0 AFTER 99 XR80R AFTER 2000 L _ XR 100R 39 N m 4 0 kgfom 29 Ibf ft...

Page 129: ...reeps with clutch dIsengaged inspect the transmission oil level before servicing the clutch system SPECIFICATIONS ITE M Clutch lewr flee pia Clutcll spring free length Clutch disC th i c ens ClutCh pl...

Page 130: ...y or additive used Check 10 oil additive Clutch slips Clutch lilter stiding Worn clutch discs Wuk c J Ch spr nos No clutCh lever free play Check for oil additive Hard to shift M i lI djus ted clutch c...

Page 131: ...REMOVAL Drain the engine o i p e 3 12 Disconnecllhe clutch cable Remove the bolt and kick starter pedal Remove the two bolts and right 1001 peg Remove the nine boilS and right crankcase cover CLUTCH...

Page 132: ...d dowel pins RIGHT CRANKCASE COVER DISASSEMBLY Remove the clutch adjusting screw lock nut Remove the clutch adjusting lever O ring and clutch adjusting screw Remove the following Coller pin Clutch lif...

Page 133: ...ure plate Spl ine washer Clutch outer INSPECTION Clutch lifter bearing Tum the in ner race of the lifter bearing w ith VO ll finger The bearing should turn smoothly ar d f eely without excessive play...

Page 134: ...ow signs of scoring or discoloration Measure the disc thickness of each disc SERVICE LIMITS XR100R 2 7 mm 0 11 In XR80R 2 5 mm 10 10 inl Clutch plUe Check each disc plale for warpage on a surface plal...

Page 135: ...nSTal l the follow ing Clutch outer Spli ne washer XRI00R Assemble the fo ur cl utch discs three plates and cl utch cenTer Then install them in the ClUTCh OUTer XRBOR Assemble the three clutch d iscs...

Page 136: ...nd ctutch lifter pin Install the right crankcase cover page 9 12 PRIMARY DRIVE GEAR 9 8 REMOVAL Remolle the right crankcase Caller page 9 3 Remove the oil pump page4 2 Remove the oil th rough and spri...

Page 137: ...imary drive gear Washer Oi l through drive pin Attach lhe gea r holde r belween lhe primary dflve and driven gear as shown TOOL Gear holder 07724 0010100 InSlall and l ighten the lock nul to the speci...

Page 138: ...ight crankcase cover page 9 12 GEARSHIFT LINKAGE 9 10 DISASSEMBLY Remove the following Right crankcesc cover page 9 3 Oil pump page 4 2 Clutch assembly pege 9 5 Remove the bolT and gearshift pedal Rem...

Page 139: ...e for wear or damage nd replace if necessary_ ASSEMBLY Instal the gearshift spindle into the crankcase so that the return spring pin is positioned between the spring ends If you remove the shift retur...

Page 140: ...plate boit Install the stopper arm retLJrn spring and tighten with the boit to the specified torque TORQUE 13 N m 41 3 kgf m 9 lbf h l Install the gearsh ft pedal and f ghlen the boll Insta ll the fo...

Page 141: ...h adjusting lever Inst all the clutch adjusting lover to the right crankcaso cover Install the clutch adjusting screw lock nut Install the dowel pins and new gasket Install the right cran kca cover an...

Page 142: ...pecified torque TORQUE 39 N m 4 0 kgf m 29 Ihf f1 Instal the kickslarler pedal and tighten the bo ll 10 the specified torque TOROUE 12 N m 1 2 kgf m 9 Ibf f11 Connect the clutch cable Pour Ihe recomme...

Page 143: ...MEMO...

Page 144: ...CRANKSHAFT TRANSMISSION KICKSTARTER 10 0...

Page 145: ...706 C XA100R 20 662 20 643 0 81 19 0 8127 XA80A 17 022 17 Q43 0 6701 0 6710 C2 XAlooA 19520 19 541 0 7685 0 7693 XA80R 19 520 19 541 0 7685 0 7693 C3 XA100A 18 016 18 034 0 7093 0 7100 XP OOP 7 016 17...

Page 146: ...dogs or Sl015 Bent l Irk shaft Worn Of benl shift f lrKs Broken shih drum stopper Broken shift IInloage relUrn spring Hard to hit Improper clulCh operation Incorrect clutCh adjustment Incoffect engin...

Page 147: ...10 11 for remov 1 of necessary parts before separating the crankcase Unhook the return spring and remove the collar and return spring Remove the two bOlts PlaCe the left cran case down Sep r t the ri...

Page 148: ...l clearance al symmetrical points as shown SERVICE LIMIT 0 010 mm 0 00001 in Turn the outer race ot the cran kshaft bearing with your tinger The bearing should turn smoolhly and quietly Also check tha...

Page 149: ...measuring locations are shown in the illusfra tion SERVICE LIMIT Right 0 085 mm 0 0033 in Left 0 070 mm 0 0028 In l INSTALLATION Install the crankshaft into thllieh cran kcase TRANSMISSION REMOVAL Rem...

Page 150: ...mair shaft and countershah TRANSMISSION INSPECTION Check the gear dogs dog holes and teelh for abnor mal w ear or lac of lubrication Measure the 1 0 of each gear SERVICE LIMITS Gear 1 0 M4 M5 11 05 m...

Page 151: ...Oo es for abnormal wear or damage SHIFT FORK Check the shih fork tor abnormal wear or daforma ion Measure the shift lark 1 0 and claw thiCkness SERVICE LIMITS Shift fork 1 0 12 05 mm 0 492 in Fork cla...

Page 152: ...ailable In U S A or Bearing remove 12 mm 07936 166010A U S A only and Remover weight 07936 371020A Or 07936 3710200 U S A only Drive new bearings into the crankcases using the special tools as shown T...

Page 153: ...I or Bearing emOVM 12 mm 01936 166010A U S A only and Remove weight 019J6_ 371020A 0 01936 3110200 U S A only Olive new bearings into the cran cases using the special tools as shown TOOLS Mainshaft b...

Page 154: ...nstall the washers and snap rings with the chamfered edges facing the thrust load side Do not reuse worn snap rings which could easily spin in the groove Check that the snap rings are seated in the gr...

Page 155: ...XR80R31T THAUSTWASHER THR UST WASHER XR 100R ONLY C3 GEAR l8T SPLINE WASHER D STAR IDLE GEAR 29T THRUST WASHER C4 GEAR 26T SPLI NE WASHER GEAR BUSHING XR 100R ONLY Cl GEAR XR 100R 37T XR80A 3ST SPLIN...

Page 156: ...shift drum A ssemb tile mainsl l8f Md COlJntelsnaf as snowr Install the mainshaft and countershaft as an C U T H FT assembly into tho left crankcase Install the shift dlum into the left crankcase Inst...

Page 157: ...move the starler ratchet and ratchet spring INSPECTION Check the kickstarte spindle tor belli Check the friction spring for fatigue Measure the 1 0 ot pinion gear SERVICE LIMIT 18 06 mm 0 711 in Measu...

Page 158: ...g NOTE Dress the surfaces with an oil stone if necessary to correct any minor roughness or irregularities After cleaning lubricate the Cf nkshllft bea ings and other contacting surfaces w ith clean en...

Page 159: ...CRANKSHAFT TRANSMISSION KICKSTARTER Tighten the tWO bolts Install the return spring and collar NOTE Hoo the each spring end as shown Install the removed parts in the reverse order 01 removal 10 15...

Page 160: ...FRONT WHEEl BRAKE SUSPENSION STEERING 26N m 2 7 kgf m 20 N m 1 1 9f m Slbf ft 23 N m IT 17 IbH t 62N m 20 N m 2 0 kgf m 14 1 bHt 6 3 kgf m 46 Ibf ft 11 0...

Page 161: ...ITEM STANDARD SERVICE LIMIT lID Front wheel Minimum lire tread depth 3 0 0 121 Cold lire pressu re 100 kPa 1 00 kg fern 15 psil Front wheel rim lunoul Radial 20 1 08 Axial 2 0 O OSI Front aXle runOU...

Page 162: ...7 Ibl tt 3 No m 0 3 kg m 2Ibf ft 07701 0020200 07H 6 0050100 07746 0050300 07749 0010000 07746 0010 100 07746 0040200 07747 00 10100 07747 00 10300 07944 1150001 07746 0010200 07946 GC40000 Commercial...

Page 163: ...R REMOVAL Remove the number plate page 2 4 NU PLATE Remove the wire bands W REJ NO S Remove the two screws holder and clutch lever CLUTCH LEVER BRACKET bracket Rflmove the screw ground cable and engin...

Page 164: ...ver brackeT Remove the handlebar upper ho lder bolts and TS hOlder Remove the handlebar INSTALLATION Place the handlebar onto the lower holders aligning the punCh ma rks on the handleba r with the top...

Page 165: ...ever bracket onto the handlebar Install the holder w ith its punch mark facing up Align the mating surface of the brackeT WiTh The punch mark on the handlabar Tighten the upper screw first then the lo...

Page 166: ...g surface of the clamp with tho punch mar on the handlebar Tighten the screw securelV Place the clutch lever bracket onto the handlebar Install the holder with its punCh mark facing up Align t he mati...

Page 167: ...agent Support the motorcvcle securely using a safety stand or a hoist Remove the bolt and front brake cable guide Irom the left fo r slider DisconnecT the fronTbrake cable Remove the a le nUl axle and...

Page 168: ...c heck that the bearing outer race f IS tightly in the hub Always r8pJac 1111 Remove and discard the bearings jf they do not turn beaM s In pa rs smoothly qUietly or if they fit loosely in Ihe hub 11...

Page 169: ...ring using the speciallools TOOLS Drivet Attacl lment 32 X 35 mm Pilot 12 mm Place Ihe rim on the work bench 017 9 100oo 07746 0010100 07746 0040200 Place the hub wilh the lef side down and begin laci...

Page 170: ...e right wheel hub Inst all the Irom wheel between the 1or K legs while alig ning the brake panel groove with the boss on the left fork slider ApplVa thin layer of grease to the front axle suriace Inst...

Page 171: ...times to seat the axle and check brake operation Tighten the axle nul to t he specified torque TORQUE 62 N m 16 3 kgf m 46 Ibf ftl Install the brake cable guide to the left fork slider and tighten the...

Page 172: ...front brake drum 1 0 SERVICE LIMIT 96 0 mm 13 78 Inl Measure the brake lining thickness SERVICE LIMIT 2 0 mm 0 08 inl DISASSEMBLY SHOES Remove thl brake shoes and springs Remove the nut bolt and brake...

Page 173: ...AKE PANEL Apply grease 10 the anchor pin and brake cam Instalilhe bra e cam inlO the brake panel Apply oil to Ihe dust seal and inslal l il onlO Ilia brake panel Install the wear indicator plata on t...

Page 174: ...ighten the nul Inst 11 the brake shoes and springs INSTALLATION Connect the brake cable Adjust the front brake lever free play page 3 18 Instal l the brake panel into the left wheel hub page 11 10 REM...

Page 175: ...ut do nOt remove il yel Loosen the fork bollom pinch bolt and remove the fork leg DISASSEMBLY Loosen the screw then remove the band and boot Remove Ihe fol1c bott flMWiiiM Th e fork bolt s under sprin...

Page 176: ...w ith a he w rench turns Wlill lile sock91 tKlil tampo rarily iIlslall the 0111 spring aoo 00 11 16 PCiIi the fork tCiba out from the fork slider Remove the oil lock piece Remove the fork piston and...

Page 177: ...tubefsliderfpist on Check the la rk tube fork slider and fork piston for score marks and excessive or abnormal wear Check the fork piston ring for wear or damage Check the rebound spring for fat igue...

Page 178: ...ork piston into the fork tube Install the oil lock piece to the end of the fork piston Install the fork tube into the fork slider HOld the fork slider in a vis w ith soft jaws or a shop towel Ifthl8lo...

Page 179: ...nstail ihe dust seal Pour the specified amount of fork fluid into the fork tube FORK FLUID CAPACITV XRlooR 98 looO 88 l S em 3 0 O Ol US OZ 3 1 0 09 Imp ozi After lOOO 86 l S em l 9 0 02 US OZ 3 0 0 0...

Page 180: ...to a new O ring and install it onto he fork bolt InSlall the fork bolt onto t he fork tube Install the fork boot and tighten the boot band screw loosely_ INSTALLATION Install the fork tube into the s...

Page 181: ...ecified torque TOROUE 26 N m 12 7 kgf m 20 Ibf ftl Slide the lork boots up until they just touc h t he bottom of the steering stem then l ighten the band screws Instalilhe Iront w heel page 11 10 Inst...

Page 182: ...P CONE RACE falling out of the steet ng head then remove the adjustment nut Do tIOf III ow v Remove the steering top inner race and steet balls s tHIbans to tall 001lOl Ihe Remove the steering stem an...

Page 183: ...e moving the lower bearing iflfler race from the stem Remove the lower bearing inner raco with a chisel or eq lJivalent loot being careful flat to da mage the stem Remove the dust seal and washer Inst...

Page 184: ...EERING STEM 1 ApplV grease to the bottom races nd 21 steel balls STEEL Insen the steoring stem into the steering head pipo App grease to the top races and 21 steel balls then INNER Instali lhe upper i...

Page 185: ...othly without play or binding then loosen the bearing adjust nut Retighten the bearing adjusting nut 10 the specified torque TORQUE 2 N m 0 2 kg m 1 Ibf hf Rechflck that Ihe steering stem moves smooth...

Page 186: ...62 N m 16 3 gf m 46 Ibf tt 98 2000 64 N m 16 5 kgf m 47 Ibfoft After 2000 AFTER 99 XR80R AfTER 2000 XR IOOR r e 62 N m 6 3 kgf m 46Ibf tt 44 N m 14 5 kg m 33Ibf ft JK Nem 5k9fem L 34 N m 13 5 kgf m 25...

Page 187: ...AW l 2 0 0 08 Rear a le rlJllout 0 20 0 008 Driv chain Slack 25 35 n _1_3 8 Size link XR100R DID 98 20001Al1er 2 1001 428GM 118LJ428HGI 118R8 RK 98 2000JAfter 2000 28HS 118RJ 428FD 118RJ XR80R DID 98...

Page 188: ...ngs Bent swingarm pivot Tire pressure too high Sleers t o one side or does not track straight Sent rear axle 62 Nom 6 3 gfom 46 1 bHt U NUT 32 Nom 3 3 kg m 24 Ibl fl U NUT 34 N m 3 5 kgf m 25 Iblottl...

Page 189: ...the axle nut Loosen the adiust OJ Push the rear wheel forward Remove the drjv chain from the driven sprocket Remove the flxle from Ihe right side and remove the rear wheel Remove the brake panel from...

Page 190: ...e hub using the special tOOls page 12 6 Wheel rim runout r l CheCk t he rim runou t bv placing Ihe whee l in a 12 4 lurning stand Spin the wheel slowly and read the runout using a dial indicalor Actua...

Page 191: ...instatl the bearing remover shaft and drive the bearing out of the wheel hub Remove the distance cottar and drive oulthe other bearing TOOLS Bearing remove head 12 mm Beating remover haft 017 f6 S030...

Page 192: ...the wOlk bench 01749 0010000 07746 0010200 07746 0040200 PI3ce the hub w Ith the left side down and begin lacing with new spokes Adjust tile hub position so that the distance from the hub lell end sl...

Page 193: ...ve with the swing lrm boss Apply thin layer 01 gre lse to the axle Intall the axle and right drive chain adjuster from ttle righl side Install the drive chain o er the driv sprocket Install the left d...

Page 194: ...e 3 19 REAR BRAKE 12 8 REMOVAL Remove the brake panel f om the rea wheel page 12 3 INSPECTION Measure the ear brake drum I D SERVICE LIMIT 96 0 mm 3 78 in Measure the bra e lining thickness SERVICE LI...

Page 195: ...ra e arm Remove the indicaTOr plate dust seat and bra ecam ASSEMBLY BRAKE PANEL SPRINGS BRAKE ARM INDICATOR PLATE DUST SEAL _ w BRAKE CAM BRAKE SHOES Apply grease to the anchor pin and brake cam Insta...

Page 196: ...arm and the brake cam Instali l he brake arm pinch bolt and l ighten the nut to the specified torque TOROUE 10 N m 1 1 0 kgl 01 7 Ibf ft Install th brake shoes and spri ngs INSTALLATION Install the br...

Page 197: ...7LME GE20100 Remove the spring seat and spring INSPECTION Measure the spring free length SERVICE LIM ITS XRlooR 98 loaD 133 8 mm 5 27 in After 2000 137 6 mm 5 42 in XR80R 133 3 mm 5 25 in Visually inS...

Page 198: ...the frame Install the upper and low er mounting bolts and nuts Tighten the upper mounling bolts nuts to Ihe specified torque TORQUE 98 2000 34 N m 13 5 kgf m 25lbf ftl After 2000 44 N m 14 5 kgf m 33...

Page 199: ...Shock absorber arm nutJbolt Remove the shock absorbe connecting rod and shock absorber a m INSPECTION Remove the dust seals and collars and check the bushing for damage Measure the bushing 1 0 SERVIC...

Page 200: ...each nuts to the specified torque as I shown Install the lower chain slider and lighten the bolt Install the left foot peg and tighten thc two bolts to the specified torque TORQUE 39 N m 14 0 kgf m 2...

Page 201: ...ve the two screws and drive chain slider Remove the dust seals and pivot collar INSPECTION Measure each bushing 1 0 and the pivot collar O D SERVICE LIMIT Bushing 1 0 15 20 mm 0 598 inf Pivot collar 0...

Page 202: ...al tools fOOLS Driver Attaehment J2 X 35 mm INSTALLATION 077 49 0010000 077 46 0010100 Apply grea5e to the swingarm inner bushing collar and dust seal Insert the pivot collar into the swingarrn and in...

Page 203: ...edal return spring 10 the swingarm Atter inSlalling Ihe swingarm inspect and adjust Ihe following Drive ctlain Ipage 3 151 Rear brake page 3 111 Rear suspension page 3 211 BRAKE PEDAL REMOVAL DISASSEM...

Page 204: ...8 Remove the bra e pedal return spring Remove the two bolts and right foot peg Remove the bral e pedal and collar ASSEMBLYI INSTAllATION Apply grease to the pivot collar sliding surface then install t...

Page 205: ...he spring onto the brake rod In51all the joint pin onto the brake arm Pl sh dow the bra e pedal md install the bmke rod into the joint pin Install the brake ildjusting nut and adjusl the brake pedal f...

Page 206: ...IGNITION SYSTEM m 4 3Ibf hl 64 N m 16 5 kgf m 47 Ibf ftl 13 0...

Page 207: ...the troubleshooting sequence on page The ignition timing does not normally need 10 be adjusted since the Ignilon Control ModUle ICM is fa tory preset m The re M may be damaged if dropped Also if the c...

Page 208: ...ter u s A only or P ak voltage adaptor IUniversal holder Flywheel plJlier 13 2 07 HGJ 0020100 not available in U S A with commercially available digital multimeter impedance 10 M O DCV minimum Q7125 0...

Page 209: ...tor or peak voltage tester 7 Faulty e cite r coil measure the peak voltage FaUlty ignition pulse generator measure the pea k vol tagel 9 FaUlty ICM when above No I 8 are normal Peak voltage is normal...

Page 210: ...vo ltage tester U S A only TOOLS Peak voltage tester U S A only or Peak vouge adaptor 07HGJ OO20100 not available in U S A with commercially available digiUI multimeter impedance to M a DCV minimum I...

Page 211: ...roubleshooting char1 on page 13 3 IGNITION PULSE GENERATOR PEAK VOlTAGE NOTE Check cylinder compression and check that thc spark pl ug is installed correctly Remove the fuel lank Ipage 2 31 Discorlnec...

Page 212: ...bleShooting chart on page 13 3 11 all items are normal the ignition pulse generator is faulty Set page 13 10 for ign ition pulse generator replacement ALTERNATOR EXCITER COil PEAK VOLTAGE NOTE Check c...

Page 213: ...or loose connection If both pea k voltages measu re are abnormal check each item in the troubleshooting ehar1 page 13 3 II all items are normal the alternator exciter coil is faulty page 13 10 for Sla...

Page 214: ...ous t Jlrbon monoll de gu that m8Y cause loss of t onsdoU neu Jlnd may lead to de Jth Run the engine In an open II ell Or with an exhaust eucuation system In enclOSed area Warm up the engine Stop the...

Page 215: ...ion pulse genera tor connectors Remove the SH bolts and left cran kcase cover Remolle the gasket Hold the flywheel using the universa l holder then remove the flywheel nut TOOL Jnive rSlIl holder l772...

Page 216: ...oodruff key 07733 0010000 or 07933 0010000 Remove the two stator mounting bolts Release the w ire grommet from the cr an kcase groove XRIDOR Remove the pulse generator mounting bolt Stator and pulse g...

Page 217: ...Insta ll the pulse generator and two hOlts then set the w ire grommet into the cran casc groove Instllil the stator and tighten the two bolts Clean anI oil from the crankshaft taper Install the woodru...

Page 218: ...ket Install the left crankcase cover and tighten the bolts Connect the ignition pulse generalor and alternator connectors STATOR BASE REMOVAL XHfOOR Remove the three screw and stalor base XRSOR Remove...

Page 219: ...e two screws IGNITION SWITCH AFTER 2000 INSPECTION Oisconn ctthe ign ition SWitch connectors Check tor continuity at the connectors at the ignition switch side There should be no continuity when Ihe i...

Page 220: ...n the ignitIon switch body and remove the ignition switch Insta llalion is in the reverse o rder of removal NOTE During installation align the guide on the ignition switch with the groove on the brack...

Page 221: ...ANGE Bu BLUE Lb LIGHT BLUE G GR EN lq lIGHT GREEN I R __ RED P PINK w _ __ WHITE Gf GAAY n h 0 ENGINE STOP SWITCH CONTINUITY fREE PUSH OlOA 0 IGNITION CONTROL MOCULE I IGNITION COIL IGNITlON PULSE GEN...

Page 222: ...STOP IGN ITION SWITCH SWITCH CONT ITY NO IG E FREE PUSH r n CORD BIIW BI COLOR CONT INUITY IG ON OFF r CORD BIIW COLOR E n G BLACK Y YEllOW Su BLUE G GREEN A AEO W WHITE Br SROWN o ORANGE Lb UGHT BLUE...

Page 223: ...tart 5 Test cylinder compression Low compression Possible cause Cloggeo luelline and Wier Clogged fuel tank breather tube Faulty spark plug Fouled spark plug Faulty ignition control module Broken or s...

Page 224: ...ondition Incorre t _ I Correct j 10 Remove cylinder head cover and inspect Valve train nOI __ lubrication ILJbricated properly I Valve train ILJbricated properly J 15 2 Possible cause Brake dragging W...

Page 225: ...mixture POOR PERFORMANCE AT LOW AND IDLE SPEED 1 Check calburetor pi lot or air screw Incorrect adjustment I Correct j Possible cau See section 5 2 Check fOI leaking intake pipe ___ Lea king ________...

Page 226: ...Correct j 4 Check ignition timing Inco ecl _____ Faulty ignition control module I Faulty ignition pulse generator Correct j 5 Check valve spring Weak _ Faulty spring j Not w eak POOR HANDLING Possibl...

Page 227: ...KICKSTARTER 10 13 LUBRICATION SEAL POINTS 1 17 LUBRICATION SYSTEM DIAGRAM 4 0 MAINTE NANCE SCHEDULE 3 3 MODEL IDE NTIFICATION 3 MUD GUARD 2 4 MUFFLER EXHAUST PIPE 2 4 16 INDEX NUMBER PLATE 4 NUTS BOL...

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Honda XR100R, Service Manual

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