1986 CR80 Manual

The 1986 CR80 is a high-performance 80cc two-stroke motocross motorcycle designed for competitive racing and recreational riding. Featuring a liquid-cooled engine, 6-speed transmission, front and rear suspension systems, disc brakes, and lightweight frame construction. Below are key sections for safety, specifications, maintenance, operation, and troubleshooting.

Features at a Glance

Key components: Liquid-cooled 80cc two-stroke engine, 6-speed transmission, front disc brake, rear drum brake, adjustable suspension, aluminum frame.

Feature	Description
Engine Type	Liquid-cooled single cylinder two-stroke
Displacement	80cc
Transmission	6-speed constant mesh
Front Suspension	Telescopic fork with adjustable damping
Rear Suspension	Pro-Link swingarm with adjustable shock
Front Brake	Hydraulic disc
Rear Brake	Mechanical drum
Frame	Aluminum semi-double cradle
Fuel Capacity	1.5 gallons
Weight	154 lbs (dry)

Installation & Assembly

Unpack and inspect contents. Assemble on level surface.

1. Install front wheel: Align axle and tighten to specification.
2. Install handlebars: Position and tighten clamp bolts.
3. Install fuel tank: Secure with mounting bolts.
4. Add fluids: Fill with recommended oil and fuel mixture.
5. Install battery: Connect positive then negative terminals.

WARNING! Motorcycle is heavy; use proper lifting techniques. Ensure all fasteners are properly torqued.

First-Time Setup

Complete pre-ride inspection and adjustments.

1. Check tire pressure: Front 12-15 psi, Rear 10-12 psi.
2. Adjust suspension: Set sag and damping for rider weight.
3. Check controls: Verify throttle, clutch, and brake operation.
4. Fuel mixture: Prepare 32:1 gas/oil ratio.
5. Warm up engine: Start and run for 5 minutes before riding.

CAUTION! Always wear proper safety gear. Never operate without helmet and protective clothing.

Specifications

• Engine: 80cc liquid-cooled two-stroke
• Bore x Stroke: 47.5mm x 45mm
• Compression Ratio: 7.5:1
• Carburetor: 24mm piston-valve
• Ignition: CDI electronic
• Transmission: 6-speed, wet multi-plate clutch
• Final Drive: #520 chain
• Front Tire: 70/100-17
• Rear Tire: 90/100-14
• Ground Clearance: 12.2 inches
• Seat Height: 31.5 inches

Controls and Operation

Familiarize yourself with all controls before riding.

Left Handlebar: Clutch lever, horn button, high/low beam switch, turn signal switch.

Right Handlebar: Front brake lever, throttle grip, engine stop switch, start button.

Foot Controls: Gear shift lever (left), rear brake pedal (right).

Instrumentation: Speedometer, tachometer, neutral indicator, high beam indicator, turn signal indicators.

Maintenance Procedures

Regular maintenance ensures optimal performance and longevity.

1. Daily: Check tire pressure, chain tension, fluid levels
2. Weekly: Clean air filter, check brake pads, lubricate cables
3. Monthly: Change transmission oil, check spark plug, inspect suspension
4. Annually: Replace brake fluid, check wheel bearings, service carburetor

Tip: Always use genuine parts for replacement. Keep maintenance records.

Riding Instructions

Proper riding technique ensures safety and performance.

1. Starting: Pull choke, kick start with firm downward motion.
2. Shifting: Use clutch for smooth gear changes. Downshift when slowing.
3. Braking: Use both brakes together for controlled stops.
4. Cornering: Look through turns, maintain steady throttle.
5. Jumping: Approach jumps at controlled speed, stand on pegs.

WARNING! Always ride within your skill level. Never attempt maneuvers beyond your capability.

Care & Cleaning

Clean after each ride to prevent corrosion and maintain appearance.

1. Rinse with low-pressure water to remove mud and debris.
2. Use mild soap and soft brush for thorough cleaning.
3. Dry completely with soft cloth or air dry.
4. Apply protectant to plastic and rubber components.
5. Lubricate chain and pivot points after cleaning.

CAUTION! Avoid high-pressure water near seals and bearings. Never use harsh chemicals.

Regulatory Information

This vehicle is designed for off-road use only. Not legal for street operation in most jurisdictions. EPA certified for emissions compliance. Always obey local laws and regulations regarding off-road vehicle operation. For support, contact authorized Honda dealership or visit www.honda.com.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, compression	Check fuel level, spark plug, compression. Verify choke operation.
Poor performance	Clogged filter, carb issues	Clean air filter, check carburetor settings, inspect exhaust.
Hard shifting	Clutch adjustment, oil level	Adjust clutch cable, check transmission oil level.
Brakes weak	Worn pads, air in system	Inspect brake pads, bleed hydraulic system if needed.
Overheating	Coolant, jetting	Check coolant level, verify proper carburetor jetting.

Reset: For electrical issues, disconnect battery for 30 seconds then reconnect.

Service: Contact authorized Honda service center for major repairs.