1986 Honda XR80R Manual PDF

The 1986 Honda XR80R is a lightweight, air-cooled, four-stroke dirt bike designed for off-road use and beginner riders. This manual covers the 79cc single-cylinder engine, 5-speed transmission, front and rear drum brakes, maintenance schedules, troubleshooting, and repair procedures. Below are key sections for safety, specifications, maintenance, operation, and troubleshooting.

1. Features at a Glance 2. Installation & Assembly 3. First-Time Setup 4. Specifications 5. Controls and Operation 6. Maintenance Procedures 7. Engine Service 8. Safety Features 9. Care & Cleaning 10. Regulatory Information 11. Troubleshooting

Features at a Glance

Key components: 79cc four-stroke engine, 5-speed transmission, front suspension, rear monoshock, drum brakes, kick starter.

Feature	Description
Engine Type	79cc air-cooled four-stroke single cylinder
Transmission	5-speed constant mesh
Starting System	Kick starter
Front Suspension	Telescopic fork
Rear Suspension	Swingarm with single shock
Front Brake	Drum brake
Rear Brake	Drum brake
Fuel Capacity	1.4 gallons (5.3 liters)
Seat Height	29.5 inches (750mm)
Dry Weight	150 lbs (68 kg)

Installation & Assembly

Unpack and inspect contents. Basic assembly required for new units.

Handlebar installation: Attach handlebars to triple clamp, tighten bolts to specification.
Front wheel assembly: Install front wheel with axle and secure with nuts.
Controls connection: Attach throttle, clutch, and brake cables.
Fuel system: Add fuel with proper fuel/oil mixture.

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

First-Time Setup

Pre-ride inspection and preparation.

Fluid levels: Check engine oil, fuel, and brake fluid.
Tire pressure: Inflate to recommended PSI (front: 12 psi, rear: 14 psi).
Control operation: Verify throttle, brakes, and clutch function properly.
Break-in procedure: Follow recommended break-in schedule for first 10 hours.

CAUTION! Always wear proper safety gear including helmet, gloves, and protective clothing.

Specifications

Engine: 79cc 4-stroke single cylinder, air-cooled
Bore x Stroke: 47.5mm x 44mm
Compression Ratio: 9.7:1
Carburetor: 18mm piston valve
Ignition: CDI
Transmission: 5-speed constant mesh
Final Drive: #420 chain
Front Tire: 2.50-16
Rear Tire: 3.00-14
Fuel: Regular unleaded gasoline

Controls and Operation

Familiarize yourself with all controls before operation.

Right Handlebar: Throttle, front brake lever, engine stop switch

Left Handlebar: Clutch lever, choke, light switch

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

Starting Procedure: Turn fuel valve ON, set choke, kick start firmly. Riding: Use clutch smoothly, shift gears progressively, brake evenly.

Maintenance Procedures

Regular maintenance ensures optimal performance and longevity.

Pre-ride inspection: Check tires, controls, lights, oil level.
Engine oil change: Every 6 months or 600 miles.
Air filter cleaning: Every 3 months or 300 miles.
Chain adjustment: Maintain 1-1.5 inches of free play.
Spark plug: Clean and gap every 1,000 miles.

Tip: Keep maintenance records for warranty and resale value.

Engine Service

Basic engine maintenance procedures.

Oil change: Drain warm oil, replace filter, refill with 0.7 quarts.
Valve adjustment: Check clearance every 1,000 miles.
Carburetor adjustment: Adjust idle speed and mixture as needed.
Spark plug replacement: Use NGK CR7HSA, gap to 0.024-0.028 inches.
Compression test: Should read 140-170 psi.

WARNING! Engine components get hot; allow to cool before servicing.

Safety Features

Engine cut-off switch: Immediate engine shutdown. Drum brakes: Front and rear independent braking. Protective covers: Engine guards and chain cover.

Care & Cleaning

Clean after each ride. Use mild soap and water; avoid high-pressure spray near bearings and seals.

CAUTION! Do not use harsh chemicals; protect electrical components from water.

Regulatory Information

EPA and CARB compliant for off-road use only. Not legal for street operation. Copyright © 1986 American Honda Motor Co., Inc. For support, contact Honda Customer Service at 1-866-784-1870 or visit www.honda.com.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, compression	Check fuel valve, spark plug, compression; verify choke operation.
Poor performance	Dirty air filter, carb issues	Clean air filter; check carburetor jets and settings.
Hard shifting	Clutch adjustment, oil level	Adjust clutch cable; check oil level and quality.
Brakes weak	Worn pads, adjustment needed	Inspect brake shoes; adjust brake cables.
Chain noise	Loose chain, lack of lubrication	Adjust chain tension; lubricate properly.

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

Service: 1-866-784-1870; www.honda.com