***WARNING-You need to purchase the Honda CR80 Service Manual before starting this tutorial. The manual gives you very important information necessary to prevent you from screwing up your motor.!***
Disassembly Through
Ignition
TRT Home Page
Disassembly Through Transmission Installing
3rd Gear Assemble the Cases Assemble
Clutch
This is a very valuable shop tool. This is my hand made bench mule that holds the motor securely while you scatter its parts around the shop. | Remove the carburetor, reed cage assembly and the water hoses. |
Remove the cylinder head bolts. Take this time to grab a dozen or so zip lock bags. Place your hardware in these bags, segregating them by their place on the motor. You will thank yourself for this when you reassemble the thing. | Remove the cylinder base nuts and the clutch flange. |
GENTLY! rock and lift the cylinder. NOTHING on this motor (like dealing with children) requires beating or violent behavior. | Remove the circlip and gently push the pin out. Get crazy pushing the pin out and you will bend the rod, causing you to slow down and eat top end parts much quicker. |
Remove the ignition cover. Many do not run the cover, feeling the heat buildup harms the ignition. I vent the cover and use it because having a one pound chuck of steel and magnets spinning at 14,000 rpm two inches away from my wife's rear end does not bring me comfort. | I use an impact to remove the rotor nut. Secure the rod(rubber bands, towels or what have you) or the rod will make a mess of your cases. |
This mysterious object is a flywheel puller, available at near every motorcycle shop. Cost: $10-20. | Screw the puller DEEP into the rotor. Using two wrenches, screw down the inner puller screw and pop and remove the flywheel. It should not take much effort, unless the rotor has been on the crank a while. |
Remove these four 5mm screws and GENTLY remove the stator and pickup. The stator is the weak link in the ignition and really doesn't like processing magnetic impulses at 14,000 rpm. Plan to change this once a year. You will know its time if you pick up a mysterious high rpm miss or the motor starts to flatten out. The pickup is pretty bullet proof. | NOW, drain your oil as completely as you can. We are entering the messy zone of this project and the more you get out now, the less you will get on you, your bench and the shop floor. |