Honda XR100 Bottom End Rebuild: Transmission, Clutch, & Stator

A very detailed walkthrough of the rebuild of the bottom end of my 2003 Honda XR100. I will go through the process of installing the transmission gears, kick-starter items, clutches, oil pump, and the stator with the flywheel. As always, if you have any questions/comments/concerns please leave them below and I will try to get back to you!

[@McEwenn]

do you remember the torque spec on the primary drive gear? cant find it anywheres online

[@Hunters_Mechanics]

I can't believe I missed it in editing! It's 29 ft*lb / 39 Nm

[@chadriddle3517]

Absolutely a gem of a video for xr100r. Owners ! Thank you sir , your very clear and concise with your explanations. Very thankful

[@blamelesswheel9172]

I’ve been working on a xr100r myself and This series has been the most helpful source of information out of any other source I could find.

[@Hunters_Mechanics]

Glad to hear it!

[@heep34987yt]

Great videos on this build. Can’t wait to see how it turns out. Keep up the good work. Subscribed👍

[@user-ht8yb4wd7n]

Dang, I already commented a few days ago, but you have a gift for this stuff. Extremely helpful on my current XR100R rebuild, but also just in general regarding a mechanic's approach. Excellent.

[@louisgoldkamp2907]

Veery nice work and good descriptive video, this is how all informative engine building videos should be done. the only thing I would have done differently is cleaning the cases while everything was apart and bearings removed, but that is really preference. Please keep making videos.

[@Hunters_Mechanics]

Appreciate the comment!

[@ashlee896]

How mutch would it roughly run to do a bottom end as well as top end done by a shop?

[@matthewnield8928]

Loved this video series. You ever gonna do a top end video?

[@Hunters_Mechanics]

I've been working on it for a long while, there's so much prep work I did on camera that I want to be able to show what I did, but not make the video 1.5 hours, but there's a lot of audio issues with it being in that basement so I am having to re-record some audio sections in my current garage so it doesn't sound off, it's coming!

[@chase2475]

Do you know Rember what the torque spec is for the crank case bolts

[@VinnyV_01]

If I have a first gear issue, do I need to break the whole engine opened like this?

[@user-ht8yb4wd7n]

Where do you like to get your parts like bearing sets, seals, cables, etc.

[@Hunters_Mechanics]

I usually buy my parts on partzilla but they don't have like aftermarket kits, just OEM, if I need those kits or even tools I'll use RockymountainATV or Motosport

[@user-ht8yb4wd7n]

@@Hunters_Mechanics great - thanks

[@aidenallran3975]

Is that pin on the inside of the crankshaft end necessary? Visible around 19:45 in the video. I’m wondering bc I’m doing a crankshaft replacement on my xr100, old crankshaft had a pin there but the new oem one does not. Can’t really think of a purpose for it either

[@Hunters_Mechanics]

It helps direct the oil flow to the crankshaft to lube the crankshaft bearings. As far as understood, the spring helps keep is sealed against the case so it doesn't just leak inside the case and starve the crank, and the hole in the middle helps create oil pressure for the crank bearings. I would not leave it out lol

[@aidenallran3975]

@@Hunters_Mechanics thank so much for the response man super helpful. How is the pin meant to be affixed inside the crankshaft? Mine just sits in there loosely in the hole, and can be easily pushed out the side again. Is that how it is supposed to be? Thanks again I really appreciate the help.

[@aidenallran3975]

@@Hunters_Mechanics referring to the small roller pin that sits sideways through the small pin holes in the crankshaft

[@Hunters_Mechanics]

@@aidenallran3975 There's nothing that holds it in place, it just sits on the little dowel. Forums talked about how people remove the clutch cover and that pin just falls out. It makes it easier being on a tilted stand like mine instead of inside the chassis so it has less of a chance to fall out

[@aidenallran3975]

@@Hunters_Mechanics Ah I think we have a misunderstanding. I’m referring to the little dowel pin that sits sideways in the crankshaft. The small dowel that the oil guide and spring rest on. It fell out, and when I put it back in it seems to have a very loose fit, not held in by anything. Wondering if that was normal, really holding me up on this rebuild. Trying to make sure I do it right.

[@angusmethane3802]

Your assembly lube bill must rival the United States national debt figure