2007 HONDA CRF70F 4-STROKE Motorcycle Factory Service & Work Shop Manual

A Few Words About Safety Service Information The serviCe and repair information contai ned in thIS manual is mtended for use by qualified, profeSSIOnal techniCIans. Attempting sel'VlCe or repairs wlthOullhe proper traming, 1000s, and eq uipment could cause injury to you or others. II could also damage the vehicle or create an unsafe condition This manual deSCribes the proper methods and procedures for performing service, mamtenance, and repai rs. Some procedures require the use 01 specially designed loois and dedicated eqUIpment. Any person who intends to use a replacement part, service procedure or a tool that is not recommended by Honda, must determine the riSks to thelf personal safety and the safe operation 01 the vehICle. II you need to replace a part. use genuine Hooda parts with the correct pari number or an equIValent part. We strongly recommend that you do not use replacement parts of Inferior quality. Fo r Your Customer's Safety Proper service and maintenance are essenlJal to the customer's safety and the reliability of the vehICle. Any error or oversight while servicing a vehicle can result in faulty operation. damage to the vehicle, or Injury to others. For Your Safety Because thiS manual is intended for the professional service techniCian, we do not provide warnings about many basIC shop safety praclJces (e.g., Hot parts-wear gloves). If you ha-ve nat received shop safety training or do not leel confidem about your knowledge of sale serviCing practICe, we recommended that you do not anempt to perform the procedures deSCribed in thiS manual Some of the most important general service safety precautions are given below However, we cannot warn you of every concei'llable hazard that can anse in performing service and repair procedures. Only you can decide whether or not you should perform a given lask. Important Safety Precautions AWARNING Improper service or repairs can create an unsafe cor)(lillon thaI can cause your customer or others to be seriously hurt or killed. Follow the procedures and precautIOns In this manual and other service matenals carefully AWARNING Failure to properly follow inslflJctlOOs and precautions can cause you to be seriously hurt or killed. Follow the procedures and precaultons In this manual carefully. Make sure you have a clear understanding of all baSIC shop safety practICeS and that you are wearing appropriate clothing and USing safety equipment. When performing any service task, be especially careful of the loIlowing o Read all of the Instructions before you begIn, and make sure you have the toots, the replacement or repair parts, and the skl "s required to perform the tasks safely and com~tely. o Protect your eyes by USing proper safety glasses. goggles or face shields any time you hammer . drill, gnnd, pry or 'NOrk around pressurized air or liqUIds. and springs or other stored·energy components. 11 there is any doubt. put on eye protection. o Use other protective wear when necessary. for example gloves or safety shoes. Handling hot or sharp parts can cause severe burns or cuts. Before you grab something that looks like (I can hurt you , stop and put on gloves. o Protect yourself and others whenever you have the vehiCle up in the air Any 1In"16 you lift the vehicle. either with a hoist or a }8ck. make sure thai it is always sectJrely supported Use l ack stands. Make sure the engine IS off belore you begin any servICing procedures. unless the Instruction tells you to do otherwise This will help eliminate severat potential hazards: o Carbon monoxide poiSOning from engine exhaust. Be sure there is adequate ventilatIon whenever you run the engine. o Burns from hot parts or coolant. lei the engine and exhaust system cool before working in those areas. o InjUry Irom moving parts. If the instrvctlOn tells you to run the engine, be sure your hands. fingers and clothing are oul 01 the way Gaso~ne vapors and hydrogen gases from banenes are exploSIVe. To reduce the possibility of a fire or exploSIOn, be careful when working around gasoline or banenes. o Use only a nonflammable SOlvent , not gasoline, to dean parts o Never dram or store gasoline In an open container. o Keep aU cigarettes, spar1<s and Ilames away 'rom Ihe battery and allluet·related part s. ,

HOW TO USE THIS MANUAL This service manual describes !he service procedures lor the CRF70F. FoIow Ih8 Ma,nll!flanoe Schedule (Section 3) leoJfT1mendations to EtnWre thin tOe vehICle ill ,n peak operatIng condltlOll and the emlssoon levels ale W1lt1rn the standard set by the U.S. Enviroomootal ProtectlOl1 Agency (EPA) and Cahfornia AIr Resources Board (CARS). Performing the firsl scheduled marnlenanoe is Y9ry important 11 compensates for the lnitoal wear thai ocru~ during the break·in p&riod . S6ctions t aM 3 apply 10 tile wtde motOll,:'fcle Section 2 ~Iusllales procedures lor removalllnstaHation of components that may be required to p&rlo<m service described in the following sactions. Section 4 Ihf'OUl,lh 14 deSCfibe parts of the motorcycle. grouped aco:::orl:llng to location Fmd tOo section you .... ant on thIS page. then tum to the table 01 COOlants on the ~rst page 01 the section Most sections star! with an assembly or system illustration. service inlomlallon and troubleshooting lor the section The subseqoonl pages gIw detailed procedures. If you don' know the source at the trouble. go to Section 16 Trotbleshooting Your safety, and the safety 01 others, is very impol'tanl To help you make irllormed OOCISlOl'1S we havoe providOO safety messages and other information throughout this manual. 01 coorse, II Is not practical or possible to warn you aDooI all the huards associalec1 with servicing this ve~. You mUSI IJ88 your own good judgemen1. You will lind Importanl safety InformallOn in a varie1y 01 forms including • Safety Labels - on the vef1icle • Safety :~~~~~~~~~'~E,~"safety alert symbol .L and one ot , WARNING. Of CAUTION. "- You WILL be KILLED Of SERIOUSLY HURT K you don' tlollow Instructions. M'4jiW i NI You CAN be KILLED or SERIOUSLY HURT ~ you don' tlollow inslru<::lIOns. You CAN be HURT W you don'! lollow mslructioos. • Instruc1ions - how lD service this vehICle correclly and satety As you read Ihls manual, you will find w,lormaliOl'1lhatls preceded by a [ NODI:EJ symbol. The purpose ot this message Is 10 help prevent damage to your whlCle, other p<operty, or the environment z ~ ~ W > ii: Q Q Z " W z a z w CONTENTS GENERAL INFORMATION MAINTENANCE LUBRICATION SYSTEM FUEL SYSTEM ENGINE REMOVALlINSTAlLATION CYLINDER HEADNALVES CYLINDER/PISTON CLUTCH/GEARSHIFT LINKAGE ALTERNATOR/CAM CHAIN TENSIONER CRANKSHAFTITRANSMISSION/KICKSTARTER FRONT WHEEVBRAKE/SUSPENSIONISTEERING REAR WHEEUBRAKE/SUSPENSION IGNITION SYSTEM WIRING DIAGRAM TROUBLESHOOTING INDEX

SYMBOLS The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it will be explained specifically in the text without the use of t he symbols. tI Replace the part(s) with new one{s) before assembly. - -, Use recommended engine oil, unless otherwise specified . .. 7! Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1 : 1) .... f.ijDj,. Use mUlti-purpose grease (Lithium based multi-purpose grease NlGI #2 or equivalent ). Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or equivalent. ~ Example: Molykote® BR·2 plus manufactured by Dow Corning U.S.A. Multi·purpose M-2 manufactured by Mitsubishi Oil, Japan Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or equivalent) . Examp!e: Molykot e® G-n Paste manufactured by Dow Corning U.S.A. ~ Honda Moly 60 (U.S.A. only) Aocol ASP manufactured by Aocol Li mited , U.K. Aocol Paste manufactured by Sumico Lubricant, Japan ...--'iSiII Use silicone grease. c;. Apply a locking agent. Use a middle strength locking agent unless otherwise specified . .,(@lll Apply sealant I Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified . .. Use Fork or Suspension Fluid.

1. GENERAL INFORMATION SERVICE RULES .................. .......................... ' -2 MOOElIDENTIFICATION······························ ' -2 GENERAL SPECiFiCATIONS ························· ' -5 LUBRICATION S YSTEM SPECIFICATION S· ' -6 FUEL SYSTEM SPECiFiCATIONS ················· ' -6 CYLINDER HEADIVAlVES SPECiFiCATIONS········································ ... '-6 CYLINDER / PISTON SPECiFiCATIONS ········· ' -7 CLUTCH / GEARSHIFT LINKAGE SPECiFiCATIONS ········································ ... ' -7 ALTERNATOR / CAM CHAIN TENSIONER SPECiFiCATIONS········································ ... ' -7 CRANKSHAFT/TRANSMISSION/ KICKSTARTER SPECIFICATIONS ········· ·········'- 8 FRONT WHEEL/ SUSPENSION/ STEERING SPECiFiCATIONS············································' -8 REAR WHEEL / BRAKE /SUSPENSION SPECiFiCATIONS············································ ' -8 IGNITION SYSTEM SPECIFICATIONS ·········· ' -9 STANDARD TORQUE VALUES ··················· , -,O .. ENGINE & FRAME TORQUE VALUES ········,-,O LUBRICATION & SEAL POINTS ·················· ' -' 3 CABLE & HARNESS ROUTING ··················· '-'5 EMISSION CONTROL SYSTEMS ················ ' -17 1-1

GENERAL INFORMATION SERVICE RULES 1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that don 't meet Honda 's design specifications may cause damage to the motorcycle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing the motorcycle. Metric boilS, nuts and screws are not interchangeable with English fasteners. 4. Install new gaskets, O-rings, cotter pins. and lock plates when reassembling. 5. When tightening bolts or nuls, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified. 6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. 7. After reassembly, check all parts for proper installation and operation. S. Route all electrical wires as shown on page 1-15, Cable and Harness Routing. MODEL IDENTIFICATION 1·2

The vehicle identification number (VIN) is stamped on the left side of the steering head. The engine serial number is stamped on the lower left of the crankcase. The model identification label (U.S.A.) or safety certification information label (Canada) is located on right side of the steering head. The carburetor identification number is stamped on the left side of the 1'::';':;;: carburetor body as shown . GENERAL INFORMATION ENGINE SERIAL NUMB , 1-3

GENERAL INFORMATION The Vehicle Emission Control Infor mation Label is attached on the left tank shroud back side. VEHICLE EMISSION CONTROL INFOR'MT"lC1 '.N LABEL The color label is attached as shown. When ordering color-coded parts, alwavs specify the designated color code. 1-4

GENERAL SPECIFICATIONS DIMENSIONS FRAME ITEM~-- Overall length Overall width Overall height Wheelbase Seat height Footpeg height Ground clearance Dry weight Curb weight Frame type Front suspension front wheellravel Rear suspension Rear wheel travel Rear damper Front tire size Rear tire size Tire brand Front brake Rear brake Caster angle Trail length ~ uellank capacity Fuel tank reserve ca"p~,~,~;Iy,-__ ENGINE Bore and stroke Displacement Compression ratio Valve train I CARBURETOR I DRIVE TRAIN Intake valve Exhaust valve lubrication system Oil pump type Cooling system Air filtration Crankshaft type Engine dry weight Cylinder arrangement Carburetor type opens closes opens closes Throttle bore=-___ _ Clutch system Clutch operation system Transmission Primary reductIOn Final reduction Gea r ratio Gearshift pattern ELECTRICAL Ignition system _____ Starting system GENERAL INFORMATION SPECIACATION --+' I Ci,5S"'9 mm \61.8 in) 694 mm (27.3 in) 885 mm (34.8 in) 1,063 mm (41.9 in) 655 mm (25.8 in) 240 mm (9.4 in) 178 mm (7.0 in) 58 kg ( 128Ibs) 63 kg (139 Ibs) Ba ck bone Telescopic fork 90 mm (3.5 in) Swingarm 88 mm (3.5 in) Conventional type oil damper 2.50- 144PR 3.oo·124PR CHENG SHIN Front: C803lRear: C803 Internal expanding shoe Internal expanding shoe 26~12' 61.5 mm (2.42 inJ 5.5 titer \1.45 US gal. 1.2 1 Imp gal) 1.1 liter (0.29 US gal. 0.24 Imp gal) 47.0 x 41 .4 mm (1.85 x 1.63 in) 71.8 em' (4.38 cu-in) 9.0 : 1 Silent multi-link chain drive and OHC with at 1 mm (0.04 in) "" rocker arm 7.5 0 BTDC 12.5 ABDC 1St 20" 3," 22.5 BBDC 2.5 BTOC Forced pressure and wet sump Trochoid Air cooled Oiled polyurethane foam Assembled type 17.7 kg (39.0 Ibs) __ __ +-~S~i.ngle cylinder inclined 80 u from vertical Piston valve type 13 mm (0.5 in) Multi-plate, wet Automatic centrifugal 3 speeds 3.722 (67/18) 2.400 (36115) 3.272 (36111) 1.667 (25115) 1.190 (25/21) Left foot operated return system, N -1-2-3 CDI ___ ~ K ~ ;':::kslarter 1-5

GENERAL INFORMATION LUBRICATION SYSTEM SPECIFICATIONS FUEL SYSTEM SPECIFICATIONS CYLINDER HEADIVALVES SPECIFICATIONS valve guide I. shaft to 0.08 (0.003) 1-6

2007 HONDA CRF70F 4-STROKE Motorcycle Factory Service & Work Shop Manual

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