How to Rebuild the Honda XR80R Top End (1992)
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- Опубликовано: 27 июн 2017
- Rebuilding the top end on 92 XR80R because its an oil burning ole dog !
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In 13 and am going to be doing a top end rebuild for the 1st time on my 87' xr80, this video was very helpful. Thanks!
Glad it helped, you got this !!
Literally best video I have found to rebuild my 03 xr80r !! I was having so much trouble with my timing chain guides inside the head 🤦♂️🤦♂️
glad it helped, good luck with the build.
This was the best video to help me. Very clear on instructions . Thank you
Great to hear!
Thank you for being so descriptive. Going to do a big bore kit on my sons xr100r today and this answered all my questions. Thanx!
Glad to help, good luck with the build !!
Got her up and running=) The bike rips now, we did the BBR 120 kit
@@twistthrottleatv3504 awesome stuff, have lots of fun !
Hi, The xr80r are a really rare bike now a days. I’m glade your taking it apart and fixing it up, make sure you show that kid how to work on it taking apart and fixing things is a valuable skill. I also have been working on my xr80r as well take a look on my channel if you want.
David Smith yeah I’ve been working on my 1985 model. Runs great now. Use to not work, so I rebuilt carb reset timing new spark plug and cables going to it new chain new rear tire adjusters. Has a crack in the frame that I’m about to go weld.
If u don’t mind me asking what piston and rings did u use I am trying to redo my sons 1987xr80r and I really don’t won’t to bore the cylinder just trying to figure out what one I can use without boring it
Good demo! I have a '77 xr 75 its the same deal. ' i been learnin!
Thanks !
Sound like the coolest grandpa
How i wish you lived in north carolina . I glady pay for your service ! ! Gotta 2001 model that needs Genuine Honda Parts thrown at it. Very fun to ride !!
North Carolina, Nascar country woot ! ;)
yeah c'mon
Obviously this isn't your first Rodeo
Excellent Video
Good JOB
Thanks!
This will probably actually be very useful I got a 86
This video is a great learning tool ty
Thanks James.
Thank you I have a 1993 but helped me still
Glad to hear!
Thanks for making the video, I’m about to do the same thing to the same bike… 👍
Have fun!
Hey man, thanks for helping me with all that advice, im not used to working on these lil hondas, btw Ashton is the cutest lil guy ever😂
My pleasure!
@@SchnebsGarage im having another problem thats pissing me off, i can start the bike starts first kick runs for maybe 3 minutes revs high and just dies and wont start, wait an hour starts right up, ive tried all valve settings, by the way only runs with the valves really loose, wont start easy if there at spec, dont have a compression tester but it can pop my finger if i kick it with my finger over the spark plug hole, maybe you know whats wrong?
@@Sleepy_g11 sounds like a fuel supply problem. Float bowl is filling slowly which is why its starts after sitting then slowly drains and goes lean which will cause it to rev high. I'd start with checking that. If I remember correctly there's a small screen above the needle valve in the carb that may be gummed up. Also usually a plastic screen in the tank attached to the fuel shutoff switch.
@@SchnebsGarage Man thanks so much! Ive been trying to figure it out for days now been out there for 5 hours today, and yeah i thought it was a compression problem because somebody told me with low compression once it warms up it will die, i will have to try this, and yeah that was completely gummed up in there cleaned the jets needle valve and bowl, so im gonna go try pulling the card apart again, thanks man couldnt have gotten this far without you!
@@Sleepy_g11 Np at all. Also while youre at it check the fuel line, them old rubber lines sometimes disintegrate inside and could cause a partial blockage.
I just bought a 93 that smokes like a banshee.
Thanks!
Hope it helps ya out. Good ole machine, they keep running when a lot of others wont even start.
Thank you helped me heaps
Good stuff
Great video! How much did you adjust that lower Rough adjustment bolt?
It's about feel to be honest, you try to get most of the slack out of the chain, bear in mind all the timing parts are ancient on this particular machine. Its just not something the owner wanted to put any real money into just for his boys to sling a little mud around the farm. Thats what the YZ's are for ;).
Do you figure this would be pretty close to a 1977 XR80 to use as some guidance? I turn wrenches plenty but I've never had one of these little four strokes apart and it needs a good going over. The engine was stuck when I got hands on it. I got it loose and it'll pop and spit but feels like no compression and I'd like a good look at the jug anyhow.
Didn't think they made an XR80 in 1977. They were XR75's and yes for the most part the engines are fairly similar in design so yes this video might be helpful to you. Something I do before I do one of these older builds is to go to a parts store and look at a cutaway parts diagram, helps to remember all the little things before I take one apart.
@@SchnebsGarage Checked the VIN, does XL75 make more sense? I got it from a scrap run, mostly there but had a hard life. I don't have the heart to scrap it.
@@heliarche sorry, thats actully what I meant to type, XL75 is correct. I'm all about second (or third) chances around here. Dont wreck em, save em because once they're crushed theres no uncrushing em ;).
Good luck with that build and have fun !!
is there a timing mark on the cam sprocket that you need to line up?
yes there's a small circle stamped into the cam gear that has to face straight up. The bolts will be horizontal with the top of the cylinder head as well. On the stator there's the T and F that must line up with a mark on the crankcase.
I got a 1987 xr100r blown away by how healthy the motor sounds and runs you think it’s more likely it’s been rebuilt or just low hours ?
87? Oh its most likely had a few rebuilds, top ends arent as bad as on two strokes but I'd bet its had a few.
@@SchnebsGarage is it hard to rebuild or replace parts on the motor ? Or once the motor goes out is it even worth keeping ?
@@troyholland3436 It's fairly easy to work on those engines. Still plenty of aftermarket parts for em as well compared to a lot of other brands.
@@SchnebsGarage and as long as the motor still runs and sounds fine you think I should still be fine? Or could certain parts be worn and me just not notice? It sounds decent but do hear a bit of a ticking noise
@@troyholland3436 Drive it, those things are tough as nails. It'll let you know when there's a problem.
What did you get for replacement rings? The stock bore is 47.5mm and I can’t find the rings, only replacement rings I’ve found are 48mm.
Think we got this particular set from the Honda Dealer, but you can find em on EvilBay and Amazon. Wiseco piston kits are everywhere these days.
@@SchnebsGarage thanks for the reply. wisco doesn’t make any 47.5 rings, I found one company in Aussie that makes piston and ring kit for that size. I tried oem parts on Motorsport and they don’t offer it, not sure about my local Honda dealer or that other company you mentioned. I almost went with the wisco 48mm piston and rings, and have cylinder punched out.
@@ericdavis219 Sorry, Evilbay...nickname for Ebay. Worst case scenario you could go with a big bore kit, little more money but solves a few problems at once and potentially cheaper than sleeving your cylinder (machine shops arent cheap around here).
Also I wouldn't rule out the 48mm rings, they need to be filed anyway and would probably work in a pinch.
Hey Im gonna try to fix my moms old Honda CH80 motor scooter for her she says it starts but wont run it basically just puts air out the exhaust any idea what it could be i assume low compression but I don't know for sure any help would be apprieciated.I just want to start in the right spot and not waste time. Thanks.
I'm not that familiar with a CH80 but motors are motors for the most part. They need, fuel, spark and of course enough compression to run. If I were in your place I'd do a compression test first as that will tell you whether or not that engine needs major work or just some cleaning and tweaking.
How do you know when the timing chain is tight enough, by feel or by noise after it's started? I wish you have have shown actually putting everything (cam, rockers, chain, etc.) Still appreciate the video, thank you.
timing chain tension is mainly noise, it'll clatter if its too loose. Just tighten it until the clatter just goes away.
Do you knw where to get plastics for this bike? I have a 1992 honda xr 80 just like u!
Got plastics for my sons YZ85 from Motosport.com...here's a link for your bike, quality was good as original and fir was perfect....
www.motosport.com/dirtbike/rides/honda/xr80-parts
Schneb thanks, i will have a look!
Ebay!
What top end kit did u use and do I have to bore it out
The owner only wanted rings put in and he brought them with the bike. They were from a local Honda dealer so should be easy to get. As for boring the cylinder no you cant just bore most 2 stroke bike cylinders, they are plated with Nicasil to harden the aluminum. Your usual options if needed would be to bore it and install a press in sleeve to bring it back to better than original (cast iron). This is definately a machine shop job and will cost you a few hundred right off the hop. Pistons and rings can be bought from most suppliers, (rocky mountain atv/mc is one of the better ones). Honesly with the age and condition of the machine most people do a big bore kit and bump them to 100cc and those kits are getting harder to find. Good luck..
Man I have gone through hell and back trying to find rings for mine. Standard bore is 47.5mm and all the rings pistion etc. that I have found are 48mm i didnt know if these rings would work on standard bore or not any info would be extremely helpful.
The rings are larger than the bore, you have to file them by hand and keep checking the ring gap. Watch from 9:00 roughly on and you'll see what I mean.
I know what u mean I just wanted to be sure before i ordered them thank you.
@@lancestephenson9375 Good luck with the build!
Hey man thanks for my 2nd bike i got a 1998 honda xr80r for free, guy said all it needed was spark plug hole rethreaded, that was fine, but it has NO compression, and while i was cleaning the right side of the engine there is a gasket sticking out between the fins ? Thats not good, so ill be ordering some new parts for it pretty soon here, thanks man!
Edit: lol just watched the rest of the video i guess the gasket is normal, welp need more parts now😂
Ya thats usually the way things work out for me. I find because these things have usually been apart many times by the time I get them its worthwhile to just strip em and at least get a look inside before you start riding it and blow up something major.
@@SchnebsGarage so i got it running and riding now just cleaned the carb buy like i said no compression i have to poor fuel in the carby and it bogs sometimes and its just pretty hard to start, any ideas what this might mean?
@@Sleepy_g11 its an old bike, could be multiple things, rings almost always but cylinder may be worn right out, valves leaking, bad cam, valve adjustment, timing chain. The list is long.
@@SchnebsGarage replaced the rings, fixed the compression, now, how hard is it to put the engine back in, and whats the best way
@@Sleepy_g11 Its a reasonably easy engine to put in because that front mount comes out and gives you lots of room to work with. I usually lift the engine in and put the main (rear) bolt in first then just swing the front upwards and start any of those bolts and the rest is cake.
Around the 15 min mark the cam chain tensioner is not installed correctly.
where did you get the top end rebuild kit
They got the rings and gaskets from a local dealer. Was a budget build so we reused the piston since it was in decent shape. Normally I'd put a new piston in any rebuild but its not my bike.
Both header bolts broke off of my xr 80 what can i do?
I'll assume they broke off flush as is the norm. Drill em, heat the cylinder with a torch and use an easy out probably the safest and easiest way. Worst case scenario is you damage the threads you could tap them out to the next size up and use bigger studs. Think they're M6 standard so an M8 should work. Havent had to do them on a honda 80 yet as I always use a propane torch on those nuts before attempting to take off the exhaust. Good luck.
is it just me or do these xr's smoke like hell bc i have one and it smoked so mutch but i replaced the rings
Every one of these I've ever seen smokes about as bad as most 2 strokes lol. They were never really a 'tight' engine but most people throw rings in them and never even measure the cylinders which are almost always worn. Also the valves are notorious for being neglected which also add to the oil entering the combustion chamber.
yes bruh
My 1990 xr80 smokes like a 2 stroke, with a big bore kit and new valve stem seals it is a little better but it still smokes periodically. It's just normal for those to smoke I guess.
Did the piston rings need to be replaced due to no compression?
It had enough compression to run, but was burning as much oil as gas.
@@SchnebsGarage so could the piston rings be the cause of low compression?
@@SchnebsGarage thanks for responding
@@desmondswofford5733 ;) Absolutely, in this case they were very worn. Other causes of course worn cylinder, and leaky valves. But rings are the number one cause of bad compression by a landslide.
@@SchnebsGarage ok thanks man. I am about to do a top end rebuild on my brothers xr80. This really helped 👍
Is it the same with an 86 model?
Pretty much identical I believe.
does anyone know what the torque for the head side bolt
20 Nm / 14 ftlbs for the cam holder nuts. ie head bolts.
Is that 20 lbs.?
That cylinder has deep scoring and pitting I would’ve honed it first
It was honed, and yes its ancient but the owners didnt want to put money into a new cylinder or sleeve it so we did what we could on the budget they had available.
Schneb that’s understandable you did a great job it it I got a 2003 Honda xr100r I’m planning on doing a full restoration on
@@jeffreymiddleton8281 Awesome I love seeing these old machines get a new lease on life.!
Schneb me to their a blast to ride their a small bike but they haul me around pretty good for being 180 pounds I’m going to be putting a heavy duty rear shock in it
the cam journals in that head looked trashed.
Yer not wrong, they werent in good shape. But you're dealing with an ancient machine thats just for screwing around on the farm, it'll continue to work for years to come in the state its in.