Honda 1975-1991 XL75 XR75 XL80S XR80 XR80R XL100S XR100 XR100R Motorcycle Repair Manual

Description

This Clymer Honda Honda 1975-1991 XL75 XR75 XL80S XR80 XR80R XL100S XR100 XR100R Repair Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for the following off-road motorcycles:

XL75 (1977-1979)
XR75 (1975-1978)
XL80S (1980-1985)
XR80 (1979-1984)
XR80R (1985-1988, 1990-1991)
XL100S (1979-1985)
XR100 (1981-1984)
XR100R (1985-1991)

1975 1976 1977 1978 1979
1980 1981 1982 1983 1984 1985 1986 1987 1988 1989
1990 1991

The chapter breakdown is as follows:

QUICK REFERNCE DATA

CHAPTER ONE / GENERAL INFORMATION

Manual organization / Service hints / Torque specifications / Safety first / Special tips / Parts replacement / Expendable supplies / Serial numbers / Tune-up and troubleshooting tools / ”Off the road” rules / Safety

CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Emergency troubleshooting / Engine starting / Engine performance / Engine noises / Excessive vibration / Front suspension and steering / Brake problems

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Routine checks / Pre-checks / Service intervals / Tires and wheels / Crankcase breather hoses (XL series models) / Battery (XL series models) / Periodic lubrication / Periodic maintenance / Engine tune-up

CHAPTER FOUR / ENGINE
Engine principles / Engine cooling / Servicing engine in frame / Engine removal/installation / Cylinder head and camshaft / Camshaft and rocker assemblies / Cam chain / Valves and valve components / Cylinder / Piston, piston pin and piston rings / Oil filter rotor and primary drive gear (1975-1976 XR75) / Primary drive gear / Oil pump / Crankcase and crankshaft / Cam chain and tensioner / Kickstarter / Break-in procedure

CHAPTER FIVE / CLUTCH AND TRANSMISSION
Clutch operation / Clutch / Clutch release mechanism / Clutch cable / External shift mechanism / Drive sprocket / Transmission and internal shift mechanism / Preliminary transmission inspection (all models) / 4-speed transmission and internal shift mechanism (XR75) / 4-speed transmission and internal shift mechanism (XL75 and XL80S) / 5-speed transmission and internal shift mechanism / Internal shift mechanism inspection

CHAPTER SIX / FUEL AND EXHAUST SYSTEMS
Carburetor operation / Carburetor service / Carburetor adjustments / Throttle cable / Fuel tank / Crankcase breather system (U.S. XL series models) / Evaporative emission control system (California XL series only) / Exhaust system

CHAPTER SEVEN / ELECTRICAL SYSTEM
Charging system / Rectifier / Voltage regulator/rectifier (1982-on XL100S) / Alternator / Contact breaker point ignition / Ignition coil / Lighting system (XL series models) / Switches / Horn (XL series models) / Fuse (XL series models)

CHAPTER EIGHT / FRONT SUSPENSION AND STEERING
Front wheel / Front hub / Wheels / Tire changing / Tire repairs / Handlebar / Steering head / Front fork

CHAPTER NINE / REAR SUSPENSION
Rear wheel (dual-shock models) / Rear wheel (Pro-Link models) / Rear hub and driven sprocket inspection (all models) / Rear hub and driven sprocket (XR80R and XR100R) / Rear hub and driven sprocket (all other models) / Drive chain / Shock absorbers (dual-shock models) / Swing arm / Swing arm (Pro-Link models) / Pro-Link system / Shock absorber (Pro-Link models) / Pivot arm assembly

CHAPTER TEN / BRAKES
Drum brakes / Front brake cable / Rear brake pedal assembly

CHAPTER ELEVEN / FRAME
Sidestand / Footpegs / Frame

INDEX

WIRING DIAGRAMS