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2001 Honda CR 80 hard to shift

Just done top end rebuild on this bike plus new mains having problems selecting gears any ideas thanks

Posted by Anonymous on

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  • Honda Master
  • 39,957 Answers

Hi, Anonymous and the usual suspects are:
1. Clutch not adjusted properly.
2. Primary chaincase overfilled with lubricant.
3. Corners wore off shifter clutch dogs.
4. Shifter return spring bent or broken.
5. Bent shifter rod.
6. A loose shift lever on shifter shaft.
7. Shifter forks sprung.
8. Shifter pawl needs adjusting.
9. Heel/toe shifter coming in contact with the floorboard.
10. Transmission oil too heavy.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
Cr80 won shift
Shifting Problems Honda Dirtbike XL100 XR100 ETC
DOWNLOAD CR80R CR80 84 02 Service Repair Manual Download Manuals Technical $15
http://www.partsfish.com/page/oem-parts-for-honda
http://mybikemanuals.com/honda/honda-crf-owners-manuals

Posted on Aug 06, 2017

6 Suggested Answers

6ya6ya
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Posted on Jan 02, 2017

  • 2 Answers

SOURCE: no problem just done top end rebuild

turn the tick over screw on the carb not to much and make sure the back wheel is off the floor and start the bike and let it tick over in forth gear for a while

Posted on Apr 03, 2009

goofduck
  • 490 Answers

SOURCE: kicking oil out exhaust

repack the silencer and what are you mixing ratios for fuel??

Posted on Apr 15, 2009

  • 6 Answers

SOURCE: 954 fireblade splutters at 7000 rpm

1ST of all i think you should take your bike to another dealer to get it fixed as they should be able / confident mechanics to repair any problem.
But anyway have you checked the throttle position sensor ? of the fuel injector connections ?
just that water could of coroded the connectors.

Posted on Jun 21, 2009

  • 139 Answers

SOURCE: honda cr 125 new top end rebuild started ok but

sounds like the float in the carb is stuck or set to the wrong hight give the carb a few taps with a screwdriver if that dont work take the carb off and check the float and needle.

Posted on Oct 08, 2009

ollie reece
  • 1167 Answers

SOURCE: i have a dt 125 field bike will not kick start

try squirting some fuel on the inlet and see if it firse get back to me with results

Posted on Oct 11, 2009

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Why does my cr 125cc 2001 smoke when i start it but then clear up and spit oil on to my swing arm and out the exhaust


Excessive oil in the exhaust could be worn out piston rings. Has the bike ever had a top end rebuild? If it's been ridden even moderately in the last 10 years, it's probably due for a new top end.

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My bike wont change out of secound gear


This usually means a bent shift fork. Quite likely the shift lever is hard as a rock. The engine will need to be torn down to get to the bent fork or forks. Bummer. Please rate my answer. Thanks.
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Aug 24, 2010 | 2002 Honda CR 250 R

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My bike will not **** into 4th!! it goes into all the others just not forth. Does anyone have instructions on how to fix it?


The bike has a bent shift fork. The engine comes out and the top end gets dismantled then the gearbox dismantles and then splits in half. Now the gear sets come out and you can get to the shift drum and shift forks. I don't recommend a complete engine tear-down be done if you don't have the special tools needed and some serious experience. The shop will fix it for $750 to $1250. Bummer. If you do try the repair, don't start without a factory service manual.

Nov 23, 2009 | 2002 Honda CR 125 R

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I put a new shifter on my honda 125cc motorcross and no it will not shift gears. the shifter moves up and down but does not feel like it is shifting gears. what could be happening?


Did your bike shift gears prior to installing the new shift lever? Why did you replace the lever? If the bike was dropped and the shift lever damaged, the shifting mechanism inside the engine may have been damaged as well. This mechanism will probably be on the primary drive side of the engine and you'll probably have to pull the clutch drum to get to it.

Oct 17, 2009 | 2002 Honda CR 125 R

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I have a Honda XR650R 2001, in nuatural it keeps tryin to lock up


You have a bent shift fork not positioning the slider gear fully into neutral. The engine will need to come out of the bike. Remove the top end, the flywheel and electrics, the clutch, shift mechanism and kick starter and a few other parts. THEN you are ready to split the gearbox to get to the crankshaft, gears and shift forks.


You will need an impact driver, flywheel puller, case splitter, torque wrench and factory service manual, plus the normal screwdriver, pliers, etc.. Alternate to the special tools is taking it to the dealer. I normally tell people to take it to the shop just so they don't get into such an involved project and they have a knowing eye working on the engine. The diagram below shows how a shift fork moves a slider gear left and right to change gears. A slightly bent shift fork is not letting the slider gear "dogs" fully dis-engage 1st gear.

A “very helpful” rating for this answer? Thanks!

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Jun 30, 2009 | 2001 Honda XR 650 R

1 Answer

Stuck in gear


The bike has a bent shift fork. This means the engine comes out and must be totally torn down to fix the bad fork. The top end comes apart, the flywheel, electrics, shift shaft, clutch, main drive gear, kick starter, shift drum index wheel assembly all come apart then the gearbox gets split open for access to the shift drum and forks. This is not a job for the home mechanic. You have a few more problems I had best mention.

Most bike shops will not repair a bike more than 10 years old. Your bike is almost 40 years old. At today's repair rates it would cost around $500 to $600 for a shop to do the repair. That is probably more than the bike is worth. I searched the web and found a source for the original Honda shift forks. In round numbers they are $40 each. You should only need one fork. There is so much that should be done, all new bearings and seals, piston and rings, valve guide seals, and valves re-seated. Getting a gasket set could be a problem also. If I personally had the bike and it was really clean and nice, I would fix it up. But bear in mind, I have the tools and know how to do it in just a few hours and all it would cost me is the cost of parts. Paying the shop charges is the killer here.
A “very helpful” rating for this answer? Thanks!

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Jun 23, 2009 | 1970 Honda CB 100

2 Answers

No problem just done top end rebuild


Just ride it normally. Avoid super high revs when the bike is not in gear and using the power.

Please rate this solution. Thanks bookerm!

Apr 02, 2009 | 2003 Yamaha YZ 125

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