The 1986 Honda CR80 is a high-performance 80cc two-stroke motocross motorcycle designed for young riders. This manual covers the complete operation, maintenance, and repair procedures for the CR80, including engine specifications, chassis components, electrical systems, and troubleshooting guidelines. Below are key sections for safety, specifications, maintenance, operation, and troubleshooting.
Key components: 79cc two-stroke engine, 6-speed transmission, front and rear drum brakes, aluminum swingarm, adjustable suspension, and lightweight frame.
| Feature | Description |
|---|---|
| Engine Type | 79cc single-cylinder two-stroke |
| Transmission | 6-speed constant mesh |
| Frame | Steel semi-double cradle |
| Suspension Front | Telescopic fork, 7.1 inches travel |
| Suspension Rear | Pro-Link single shock, 7.9 inches travel |
| Brakes Front | Drum, 110mm |
| Brakes Rear | Drum, 110mm |
| Wheelbase | 50.4 inches |
| Seat Height | 31.7 inches |
| Fuel Capacity | 1.3 gallons |
Unpack and inspect contents. Assemble following these steps:
WARNING! Motorcycle is heavy; use proper lifting techniques. Ensure all fasteners are properly torqued.
The 79cc two-stroke engine requires proper fuel mixture and regular maintenance.
CAUTION! Always use proper fuel mixture to prevent engine damage.
Frame and suspension components require regular inspection and adjustment.
Front Suspension: Telescopic fork with oil damping. Adjust preload as needed.
Rear Suspension: Pro-Link system with adjustable spring preload.
Wheels: Spoke wheels with aluminum rims. Check spoke tension regularly.
Brakes: Front and rear drum brakes. Adjust cable tension for proper lever feel.
CDI ignition system provides reliable spark without battery.
Tip: Keep electrical connections clean and dry.
Regular maintenance ensures optimal performance and longevity.
| Service | Interval | Procedure |
|---|---|---|
| Air Filter | Every 15 hours | Clean and re-oil |
| Spark Plug | Every 25 hours | Clean and gap |
| Transmission Oil | Every 30 hours | Drain and refill |
| Piston/Rings | Every 50 hours | Inspect and replace |
| Wheel Bearings | Every 100 hours | Clean and repack |
| Swingarm Bearings | Every 100 hours | Clean and grease |
Proper operation techniques for maximum performance and safety.
WARNING! Always wear proper protective gear including helmet, boots, and gloves.
| Symptom | Possible Cause | Corrective Action |
|---|---|---|
| Hard starting | Fouled plug, improper fuel mix | Replace spark plug, check fuel mixture |
| Poor performance | Clogged air filter, exhaust restriction | Clean air filter, check exhaust for carbon |
| Transmission issues | Low oil, worn gears | Check oil level, inspect transmission |
| Brakes weak | Worn shoes, contaminated | Replace brake shoes, clean drums |
| Suspension bottoming | Low oil, worn springs | Check oil level, adjust preload |
Reset: None required for mechanical systems.
Always wear DOT-approved helmet, eye protection, gloves, boots, and protective clothing. Never operate under influence of drugs or alcohol. Ride within your skill limits. Maintain safe distance from other riders. Inspect motorcycle before each ride.
CAUTION! Motorcycle riding is dangerous. Proper training and protective gear are essential.
Genuine Honda parts recommended for optimal performance and reliability. Contact authorized Honda dealers for parts and service. For technical assistance, contact Honda Customer Service at 1-866-784-1870 or visit www.honda.com.
Service: 1-866-784-1870; www.honda.com