Honda XR100R Manuals

Manuals and User Guides for Honda XR100R. We have 1 Honda XR100R manual available for free PDF download: Service Manual

Honda XR100R Service Manual

Honda XR100R Service Manual (228 pages)

Brand: Honda | Category: Motorcycle | Size: 31.68 MB

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

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