Honda XR70R User Manual

Safety guidelines and warnings for operating the vehicle.

Warning about hot engine and exhaust system parts.

Health risks associated with handling used engine oil.

Guidelines for performing service and maintenance procedures.

Information on identifying the motorcycle model and its components.

Technical specifications and measurements for the motorcycle.

Details on the motorcycle's lubrication system and components.

Information regarding the fuel system, including components and operation.

Service procedures for the cylinder head and valve train.

Service procedures for cylinder and piston components.

Service for clutch and gearshift linkage mechanisms.

Service for crankshaft, transmission, and kickstarter mechanisms.

Maintenance and service for front wheel, brakes, suspension, and steering.

Specified torque values for various fasteners and components.

List of specialized tools required for maintenance and repair.

Locations and materials for lubrication and sealing.

Diagrams showing routing of cables and electrical harnesses.

Explanation of the emission control system for models after 1999.

Details about the emission control information label for later models.

Illustrates the location of various body panels on the motorcycle.

General service information related to the frame, body panels, and exhaust system.

Specified torque values for frame, body, and exhaust system fasteners.

Common problems and solutions for the frame, body, and exhaust system.

Procedures for removing and installing the seat and rear fender assembly.

Steps for removing and installing the fuel tank and its related components.

Procedure for removing and installing the tank shroud on models after 2000.

Instructions for removing and installing the side cover of the motorcycle.

Procedure for removing and installing the front number plate.

Steps for removing and installing the front fender of the motorcycle.

How to remove and install the front mud guard.

Procedures for removing and installing the muffler and exhaust pipe.

Steps for removing and installing the side stand assembly.

General information and guidelines for performing maintenance.

Technical specifications relevant to maintenance tasks.

Specified torque values for various maintenance fasteners.

Tools required for maintenance procedures.

Recommended maintenance intervals and tasks for the vehicle.

Inspection and replacement of fuel lines for proper operation.

Checking and adjusting throttle grip free play for smooth operation.

Cleaning and maintenance procedures for the air cleaner element.

Inspection, replacement, and gap adjustment of the spark plug.

Inspection and adjustment procedures for valve clearance.

Inspection and change procedures for engine oil.

Cleaning the engine oil strainer screen.

Cleaning the engine oil centrifugal filter.

Adjusting the engine idle speed to the specified RPM.

Checking and adjusting drive chain slack and lubrication.

Checking and adjusting the slack in the drive chain for proper tension.

How to clean, inspect, and lubricate the drive chain.

Inspecting and replacing the drive chain slider if worn or damaged.

Checking front and rear brake shoes for wear using indicator marks.

Checking the front brake lever free play.

Checking and adjusting the rear brake pedal free play.

Adjusting the clutch for proper operation and checking for slipping.

Inspecting the side stand spring and pivot for damage or wear.

Safety warning and inspection of suspension components for damage.

Checking rear wheel bearings, swingarm bushings, and shock absorbers.

Procedures for removing and installing the spark arrester.

Ensuring all chassis nuts and bolts are tightened to the correct torque.

Checking tire pressure, tread depth, and wheel trueness.

Checking steering head bearings for smooth operation and proper adjustment.

Diagram illustrating the flow and components of the lubrication system.

General information and guidelines for lubrication system service.

Technical specifications for the lubrication system.

Specified torque values for lubrication system components.

Common problems and solutions for the lubrication system.

Procedures for removing, disassembling, and inspecting the oil pump.

General information and guidelines for fuel system service.

Technical specifications for the fuel system components.

Specifies the tool required for float level adjustment.

Common problems and solutions for the fuel system.

Procedures for removing and installing the air cleaner housing.

Steps for removing the carburetor from the motorcycle.

Information on the carburetor body and its components.

Steps for taking apart the carburetor for cleaning or repair.

Procedures for reassembling the carburetor after service.

How to measure and check the float level in the carburetor.

Steps for installing the carburetor back onto the motorcycle.

Installing the jet needle and throttle valve components.

Procedure for adjusting the air screw for optimal engine performance.

Adjusting idle speed and air screw for models after 1999.

Procedure for draining deposits from the crankcase breather tube.

General information and guidelines for engine removal and installation.

Technical specifications related to engine removal and installation.

Specified torque values for engine mounting bolts.

Step-by-step instructions for removing the engine from the motorcycle frame.

Steps for installing the engine back into the motorcycle frame.

General information and guidelines for cylinder head and valve service.

Technical specifications for cylinder head and valve components.

Specified torque values for cylinder head and valve fasteners.

Common problems and solutions related to the cylinder head and valves.

How to perform a cylinder compression test to diagnose engine issues.

Procedures for removing the camshaft from the cylinder head.

How to inspect the camshaft for wear and damage.

Steps for removing the cylinder head from the engine.

Procedures for disassembling the cylinder head and associated parts.

Inspecting the cylinder head for carbon deposits, cracks, and warpage.

Inspecting rocker arms and shafts for wear or damage.

Measuring the free length of valve springs.

Inspecting valves for bending, burning, or stem wear.

Procedures for replacing valve guides in the cylinder head.

Inspecting and refacing valve seats for proper sealing.

Using specialized cutters for refacing valve seats.

Reassembling the cylinder head components after service.

Installing rocker arms and rocker arm shafts.

Installing the cylinder head and cylinder head cover.

Procedures for installing the camshaft into the cylinder head.

Adjusting valve clearance after reassembly.

General information and guidelines for cylinder/piston service.

Technical specifications for cylinder and piston components.

Specified torque values for cylinder mounting bolts.

Common problems and solutions related to cylinder and piston issues.

Procedures for removing the cylinder from the engine.

Steps for removing the piston from the cylinder.

Inspecting the cylinder bore, taper, out-of-round, and warpage.

Wear limits for piston rings, piston diameter, and piston pin bore.

Proper method for installing piston rings into the grooves.

Installing the piston into the cylinder with correct orientation.

Installing the cylinder onto the crankcase.

General information and guidelines for clutch and gearshift service.

Common problems and solutions for the clutch and gearshift linkage.

Procedures for removing the right crankcase cover.

Procedures for removing and inspecting clutch components.

Steps for disassembling the clutch components.

Inspecting clutch lifter bearing, clutch spring, and clutch discs.

Measuring the free length of the clutch spring.

Replacing clutch discs based on thickness and condition.

Checking clutch plates for warpage.

Inspecting primary drive gear and clutch center guide for wear.

Measuring the crankshaft outside diameter.

Checking drive gear outer and clutch center for wear.

Reassembling the clutch components.

Installing the crankshaft collar, primary driven gear, clutch center guide, and primary drive gear.

Installing and tightening the clutch outer cover.

Procedures for removing and disassembling the gearshift linkage.

Checking the gearshift spindle for bending or damage.

Installing gearshift drum pins, dowel pins, and stopper plate.

Procedures for installing the right crankcase cover.

General information and guidelines for alternator and cam chain tensioner service.

Common problems and solutions for the alternator and cam chain tensioner.

Specified torque values for alternator and tensioner components.

Tools required for alternator and tensioner service.

Procedures for removing the flywheel and stator.

Procedures for removing the cam chain tensioner.

Measuring tensioner spring free length and push rod diameter.

Installing the cam chain tensioner components.

Procedures for installing the stator base and flywheel.

General information and guidelines for crankshaft, transmission, and kickstarter service.

Common problems and solutions for the crankshaft, transmission, and kickstarter.

Tools required for transmission and kickstarter service.

Common problems and solutions for transmission and kickstarter issues.

Procedures for separating the crankcase halves.

Steps for removing the crankshaft from the crankcase.

Inspecting crankshaft bearings, timing sprocket, and connecting rod clearance.

Installing the guide sprocket, guide spindle, and crankshaft.

Procedures for removing the transmission components.

Steps for disassembling the transmission gears.

Inspecting transmission gears, bushings, and shift fork grooves.

Reassembling the transmission gears and shafts.

Disassembling the gearshift drum and shift forks.

Measuring shift fork inner diameter and claw thickness.

Procedures for replacing transmission bearings and oil seals.

Installing the transmission assembly into the crankcase.

Procedures for removing the kickstarter spindle and its components.

Disassembling the kickstarter mechanism.

Reassembling the kickstarter components.

Procedures for assembling the crankcase halves.

General information and guidelines for front wheel, brake, suspension, and steering service.

Technical specifications for front wheel, brake, suspension, and steering components.

Specified torque values for front end components.

Tools required for front wheel, brake, suspension, and steering service.

Common problems and solutions for front end steering, wheel, and suspension.

Procedures for removing the handlebar and its controls.

Installing the handlebar and handlebar holders.

Steps for removing the front wheel, axle, and brake components.

Inspecting the axle, wheel bearings, and rim runout.

Removing the dust seal from the wheel hub.

Installing new wheel bearings and distance collars.

Proper method for installing new wheel bearings.

Installing the side collar, brake panel, and rear wheel.

Removing the brake panel from the front wheel for inspection.

Measuring front brake drum ID and lining thickness.

Removing brake shoes and springs from the brake panel.

Reassembling the front brake components.

Procedures for removing the front fork from the motorcycle.

Disassembling the front fork components.

Inspecting fork spring, tube, slider, and piston for wear or damage.

Assembling the fork components.

Installing the fork tubes into the steering stem.

Procedures for removing the steering stem assembly.

Procedures for replacing steering head bearing races.

Installing the steering stem, bearings, and races.

General information and guidelines for rear wheel, brake, and suspension service.

Common problems and solutions for the rear wheel, brake, and suspension.

Procedures for removing and inspecting the rear wheel.

Procedures for removing, inspecting, and disassembling the rear brake.

Common problems and solutions for rear suspension and wheel wobbling.

Steps for removing the rear wheel, axle, and brake components.

Inspecting the axle, wheel bearings, rim runout, and driven sprocket.

Removing wheel bearings and driven sprocket.

Installing wheel bearings and driven sprocket.

Proper method for installing new wheel bearings.

Installing the side collar, brake panel, and rear wheel.

Removing the brake panel from the rear wheel for inspection.

Measuring rear brake drum ID and lining thickness.

Removing rear brake shoes and springs.

Reassembling the rear brake components.

Procedures for removing the rear shock absorber.

Visually inspecting the shock absorber for damage.

Installing the shock absorber into the frame.

Procedures for removing the swingarm.

Inspecting the swingarm and pivot bushings for wear.

Installing the drive chain slider, swingarm, and shock absorber.

Procedures for removing and disassembling the rear brake pedal.

Installing the brake rod and adjusting brake pedal free play.

Electrical schematic of the ignition system.

General information and guidelines for ignition system service.

Common problems and solutions for the ignition system.

Procedures for inspecting ignition system components.

Information about the ignition coil.

General safety and caution notes for ignition system service.

Technical specifications for spark plugs and ignition timing.

Specified torque value for the ignition coil mounting bolt.

Tools required for ignition system testing.

Diagnosing ignition system issues based on symptoms.

Measuring the peak voltage output of the ignition coil.

Measuring the peak voltage output of the ignition pulse generator.

Measuring the peak voltage output of the alternator exciter coil.

Procedures for removing and installing the ignition coil.

Procedures for removing and installing the ignition control module.

Checking the continuity of the engine stop switch.

Checking the continuity of the ignition switch for models after 1999.

Checking and adjusting the ignition timing using a timing light.

Electrical wiring schematic for the motorcycle ignition system.

Diagnostic flowchart for engine starting problems.

Diagnostic flowchart for engine power loss.

Diagnostic flowchart for low speed and idle performance issues.

Diagnostic flowchart for high speed performance issues.

Diagnostic flowchart for issues affecting motorcycle handling.

Index entry for valve clearance procedures.

Index entry for wheel and tire maintenance.

Index entry for the electrical wiring diagram.