1980 1990 Honda Xr80R Carburetor Disassembly 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 Repair Guide

Difficulty

Moderate

Steps

Time Required

                          30 minutes

Sections

1980 -1990 Honda XR80R Carburetor Disassembly
13 steps

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Introduction

The most common issues that may be due to a poor carburetor are when the engine is in too high or too low RPM when the motorcycle is at idle. Additionally, a poor carburetor can lead too having throttling issues, when you open the throttle nothing happens, or vise versa.

If you are having any of the listed issues, this guide will help disassemble the carburetor in order to clean or fix anything within the part.

What you need

Step 1

              1980 -1990 Honda XR80R Carburetor Disassembly

The Carburetor is located to the rear of the engine block, right under the gas tank.

The Carburetor is located to the rear of the engine block, right under the gas tank.

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Step 2

Before beginning the disassembly process, first turn your fuel off by turning the dial located on the left side of the motorcycle, to the off position.
Disconnect the fuel line from the gas tank located on the the fuel dial.
Disconnecting fuel line may require prying with a flat head screwdriver.

Before beginning the disassembly process, first turn your fuel off by turning the dial located on the left side of the motorcycle, to the off position.

Disconnect the fuel line from the gas tank located on the the fuel dial.

Disconnecting fuel line may require prying with a flat head screwdriver.

Step 3

Remove the rear plastic panels, one on either side, by unscrewing the two 8 mm screws located at the bottom of each panel, by using the 8 mm socket wrench.
Anytime screws are removed, they should be placed in container so they are not lost.
After the screws are removed, the panels can be easily pulled off with hands.

Remove the rear plastic panels, one on either side, by unscrewing the two 8 mm screws located at the bottom of each panel, by using the 8 mm socket wrench.

Anytime screws are removed, they should be placed in container so they are not lost.

After the screws are removed, the panels can be easily pulled off with hands.

Step 4

Remove the seat by unscrewing the two 8 mm screws located 2/3 to the rear of the seat, on either side.
One screws are removed, the seat can be easily lifted off the motorcycle.

Remove the seat by unscrewing the two 8 mm screws located 2/3 to the rear of the seat, on either side.

One screws are removed, the seat can be easily lifted off the motorcycle.

Step 5

Unhook the elastic strap located on the backside of the gas tank.

Unhook the elastic strap located on the backside of the gas tank.

Step 6

Remove the gas tank by unscrewing the two 8 mm screws located on both sides, by using the socket wrench.
Once screws are removed, the gas tank can be easily taken off the motorcycle.
Be careful to keep the gas tank upright in order to prevent the gas spillage.

Remove the gas tank by unscrewing the two 8 mm screws located on both sides, by using the socket wrench.

Once screws are removed, the gas tank can be easily taken off the motorcycle.

Be careful to keep the gas tank upright in order to prevent the gas spillage.

Step 7

Loosen screw, located to the left of the carburetor, using Philip head screw driver.
The Air intake now can be pulled off from the Carburetor.

Loosen screw, located to the left of the carburetor, using Philip head screw driver.

The Air intake now can be pulled off from the Carburetor.

Step 8

Remove the two 8 mm nuts that hold the carburetor to the engine block.
The carburetor can now be freely removed from the engine block.
Make sure to plug the Carburetor-Engine Block pipe with a clean rag so no damaging dirt can get into the engine.

Remove the two 8 mm nuts that hold the carburetor to the engine block.

The carburetor can now be freely removed from the engine block.

Make sure to plug the Carburetor-Engine Block pipe with a clean rag so no damaging dirt can get into the engine.

Step 9

Unscrew the the top of the carburetor and pull out the wire that is connected to the fuel needle. Set the top aside.
If the motorcycle was recently ran, there might be fuel still trapped in the carburetor, so be careful of spillage.

Unscrew the the top of the carburetor and pull out the wire that is connected to the fuel needle. Set the top aside.

If the motorcycle was recently ran, there might be fuel still trapped in the carburetor, so be careful of spillage.

Step 10

Using the Phillips head screwdriver, remove the two 10 mm screws located on the underside of the carburetor.
Once the screws are removed, the two carburetor halves can then be taken apart.

Using the Phillips head screwdriver, remove the two 10 mm screws located on the underside of the carburetor.

Once the screws are removed, the two carburetor halves can then be taken apart.

Step 11

On the bottom half of the carburetor, remove the pin that is holding together the fuel bubbler and fuel pin by using needle nose plyers.

On the bottom half of the carburetor, remove the pin that is holding together the fuel bubbler and fuel pin by using needle nose plyers.

Step 12

In order to remove the Pilot Jets, you will use the Flathead screwdriver to unscrew the two jets from the top.

In order to remove the Pilot Jets, you will use the Flathead screwdriver to unscrew the two jets from the top.

Step 13

Once fully disassembled, use carburetor cleaner and a rag to fully clean the interior and components of the carburetor, or replace any damaged parts.

Once fully disassembled, use carburetor cleaner and a rag to fully clean the interior and components of the carburetor, or replace any damaged parts.

To reassemble your device, follow these instructions in reverse order.

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                    Caleb Loomis

Member since: 08/26/2020

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                       Embry-Riddle Aeronautical University, Team S3-G26, Cromer Twal Fall 2020                        

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